DUST COLLECTOR

A dust collector includes a main-body housing and a motor assembly disposed in the main-body housing. The motor assembly includes a blower fan, which is disposed in the interior of the main-body housing; and a suction motor, which rotates the blower fan. The motor assembly generates suction force at a suction port, which fluidly communicates with the interior of the main-body housing. At least first and second air-exhaust passageways are respectively in the up-down direction in the interior of the main-body housing and through which air exhausted from the motor assembly flows.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese patent application nos. 2022-160529 and 2022-160530, both filed on Oct. 4, 2022, the contents of both of which are fully incorporated herein by reference.

TECHNICAL FIELD

The techniques disclosed in the present specification generally relate to a dust collector (dust extractor).

BACKGROUND ART

German Laid-open Patent Publication No. 10 2020 113 525 discloses a dust collector (dust extractor) related to the present teachings.

SUMMARY OF THE INVENTION

When noise is generated by a dust collector, it causes discomfort to the user of the dust collector and to people in the vicinity.

It is therefore one non-limiting object of the present teachings to disclose techniques for curtailing or attenuating noise generated by a dust collector (dust extractor).

In one aspect of the present teachings, a dust collector or dust extractor may comprise: a main-body housing; a motor assembly that (i) comprises: a blower fan, which is disposed in the interior of the main-body housing; and a suction motor, which rotates the blower fan; and (ii) generates suction force at a suction port, which communicates (is in fluid communication) with the interior of the main-body housing; and a plurality of air-exhaust passageways provided (e.g., superposed and/or in parallel) in the up-down direction in the interior of the main-body housing and through which gas (air) exhausted from the motor assembly flows.

Noise generated by a dust collector or dust extractor can be curtailed by utilizing techniques disclosed in the present specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an oblique view, viewed from the upper-left side, that shows a dust collector (dust collector) according to one representative embodiment of the present teachings.

FIG. 2 is an oblique view, viewed from the lower-left side, that shows the dust collector according to the embodiment.

FIG. 3 is an oblique view, viewed from the right-upper side, that shows the dust collector according to the embodiment.

FIG. 4 is a left view that shows the dust collector according to the embodiment.

FIG. 5 is a front view that shows the dust collector according to the embodiment.

FIG. 6 is a rear view that shows the dust collector according to the embodiment.

FIG. 7 is a cross-sectional view that shows the dust collector according to the embodiment.

FIG. 8 is a cross-sectional view that shows the dust collector according to the embodiment.

FIG. 9 is an exploded, oblique view, viewed from the upper-left side, that shows a tank cover, an inner cover, and a filter unit according to the embodiment.

FIG. 10 is an exploded, oblique view, viewed from the right-upper side, that shows the tank cover, the inner cover, and the filter unit according to the embodiment.

FIG. 11 is an exploded, oblique view, viewed from the right-lower side, that shows the tank cover, the inner cover, and the filter unit according to the embodiment.

FIG. 12 is an oblique view that shows the state in which a cowling and a separator have been removed from the dust collector according to the embodiment.

FIG. 13 is an oblique view that shows the state in which the cowling has been removed from the dust collector according to the embodiment.

FIG. 14 shows the gas-flow-through state in a first air-exhaust passageway according to the embodiment.

FIG. 15 shows the gas-flow-through state in a second air-exhaust passageway according to the embodiment.

FIG. 16 is an oblique view, viewed from the left-front side, that shows the dust collector, in the state in which a cap has been mounted into a suction tube, according to the embodiment.

FIG. 17 is an oblique view, viewed from the left-front side, that shows the cap according to the embodiment.

FIG. 18 is an oblique view, viewed from the right-rear side, that shows the cap according to the embodiment.

FIG. 19 is an oblique view, viewed from the right-rear side, that shows a portion of the cap according to the embodiment.

FIG. 20 is a partial, enlarged view of the cap, which is mounted into the suction tube, according to the embodiment.

FIG. 21 shows a portion of a cleaning apparatus according to the embodiment.

FIG. 22 shows the state of a filter when a first valve is in a second state and a second valve is in a third state according to the embodiment.

FIG. 23 shows the state of the filter when the first valve is in a first state and the second valve is in a fourth state according to the embodiment.

FIG. 24 is an oblique view that shows the dust collector, which is connected to a power tool, according to the embodiment.

FIG. 25 is a block diagram that shows the power tool and the dust collector according to the embodiment.

FIG. 26 is a flow chart that shows the operation of the power tool and the dust collector according to the embodiment.

FIG. 27 is a flow chart that shows the operation of the dust collector according to the embodiment.

 DETAILED DESCRIPTION OF THE INVENTION

As was noted above, a dust collector or dust extractor according to the present teachings may comprise: a main-body housing; a motor assembly that (i) comprises: a blower fan, which is disposed in the interior of the main-body housing; and a suction motor, which rotates the blower fan; and (ii) generates suction force at a suction port, which communicates (is in fluid communication) with the interior of the main-body housing; and a plurality of air-exhaust passageways provided (e.g., superposed and/or in parallel) in the up-down direction in the interior of the main-body housing and through which gas (air) exhausted from the motor assembly flows.

According to the above-mentioned configuration, the air-exhaust passageways can be designed to be relatively long, whereby air-exhaust noise generated by, for example, the motor assembly can be attenuated in the air-exhaust passageways. Consequently, noise generated by the dust collector is curtailed. In addition, because multiple air-exhaust passageways are provided (e.g., superposed and/or in parallel) in the up-down direction, even though relatively long air-exhaust passageways can be provided in this configuration, the overall size of the dust collector need not be enlarged. For example, the dust collector can be designed without enlarging the dust collector in the horizontal direction due to the fact that the multiple air exhaust passageways may overlap each other in the up-down direction.

In one or more embodiments, the air-exhaust passageways may include: a first air-exhaust passageway; and a second air-exhaust passageway, which is provided (disposed) more upward than the first air-exhaust passageway and overlaps at least a portion of the first air-exhaust passageway within a horizontal plane (e.g., in a vertical cross-section).

According to the above-mentioned configuration, even if the air-exhaust passageways are relatively long, the overall size of the dust collector need not be enlarged, in particular in the horizontal direction.

In one or more embodiments, the dust collector may have a communication-path opening, which (fluidly) connects the first air-exhaust passageway and the second air-exhaust passageway to each other. The communication-path opening may extend vertically in the main-body housing to fluidly connect the (lower) first air-exhaust passageway with the (upper) second air-exhaust passageway.

According to the above-mentioned configuration, air can flow from the first air-exhaust passageway to the second air-exhaust passageway via the communication-path opening.

In one or more embodiments, the communication-path opening may connect one-end portion of the first air-exhaust passageway with one-end portion of the second air-exhaust passageway.

According to the above-mentioned configuration, even if the air-exhaust passageways are relatively long, the overall size of the dust collector need not be enlarged, in particular in the horizontal direction.

In one or more embodiments, the communication-path opening may have a quadrangular shape in horizontal cross-section.

According to the above-mentioned configuration, the creation of dead space in the dust collector can be avoided.

In one or more embodiments, the surface area (e.g., horizontal cross-sectional area) of the communication-path opening may be ½ or less of the maximum cross-sectional area of the first air-exhaust passageway.

According to the above-mentioned configuration, the noise-reducing effect can be increased.

In one or more embodiments, the direction in which the gas (air) flows through the first air-exhaust passageway may be the reverse or opposite direction of the direction in which gas (air) flows through the second air-exhaust passageway.

According to the above-mentioned configuration, even if the air-exhaust passageways are relatively long, the overall size of the dust collector need not be enlarged, in particular in the horizontal direction.

In one or more embodiments, the dust collector may have an air-exhaust port or air-exhaust ports, which is/are (fluidly) connected to the second air-exhaust passageway and communicate(s) (is/are in fluid communication) with the exterior of the main-body housing.

According to the above-mentioned configuration, the air that has flowed through the first air-exhaust passageway and the second air-exhaust passageway is exhausted from (through) the air-exhaust port(s) to the exterior of the main-body housing.

In one or more embodiments, the gas (air) exhausted from the motor assembly may flow through the first air-exhaust passageway, then flow into the second air-exhaust passageway via the communication-path opening and thereafter flow through the second air-exhaust passageway, and then be exhausted from the air-exhaust port(s).

According to the above-mentioned configuration, because the gas (air) exhausted from the motor assembly flows through the relatively long air-exhaust passageways, air-exhaust noise generated by the motor assembly can be effectively attenuated in the air-exhaust passageways.

In one or more embodiments, the dust collector may comprise: a tank, on (in) which the suction port is provided. The main-body housing may comprise: a tank cover, which is disposed on the upper side of the tank; a separator, which is disposed on the upper side of the tank cover; and a cowling, which is disposed on the upper side of the separator. The first air-exhaust passageway may be defined by (between) the tank cover and the separator; and the second air-exhaust passageway may be defined by (between) the separator and the cowling.

According to the above-mentioned configuration, by combining (assembling) the tank cover, the separator, and the cowling, the first air-exhaust passageway and the second air-exhaust passageway are formed smoothly.

In one or more embodiments, the tank cover may comprise a first cover-plate part, which covers the tank, and a first guide-plate part, which protrudes upward from the upper surface of the first cover-plate part. The separator may comprise a second cover-plate part, which covers the tank cover, and a second guide-plate part, which protrudes upward from the upper surface of the second cover-plate part. The first air-exhaust passageway may be defined by the upper surface of the first cover-plate part, the first guide-plate part, and the lower surface of the second cover-plate part. The second air-exhaust passageway may be defined by the upper surface of the second cover-plate part, the second guide-plate part, and the lower surface of the cowling.

According to the above-mentioned configuration, by combining (assembling) the tank cover, the separator, and the cowling, the first air-exhaust passageway and the second air-exhaust passageway are formed smoothly.

Embodiments according to the present disclosure are explained below, with reference to the drawings, but the present disclosure is not limited to the embodiments. The structural elements of the embodiments explained below can be combined where appropriate. In addition, there are also situations in which some of the structural elements are not used.

In the embodiments, positional relationships among parts will be explained using the terms “front,” “rear,” “left,” “right,” “up,” and “down.” Each of these terms indicates a relative position or a direction, using the center of a dust collector 1 as a reference.

Dust Collector

FIG. 1 is an oblique view, viewed from the upper-left side, that shows the dust collector 1 according to a representative non-limiting embodiment of the present teachings. FIG. 2 is an oblique view, viewed from the lower-left side, that shows the dust collector 1 according to the embodiment. FIG. 3 is an oblique view, viewed from the right-upper side, that shows the dust collector 1 according to the embodiment. FIG. 4 is a left view that shows the dust collector 1 according to the embodiment. FIG. 5 is a front view that shows the dust collector 1 according to the embodiment. FIG. 6 is a rear view that shows the dust collector 1 according to the embodiment. FIG. 7 is a cross-sectional view that shows the dust collector 1 according to the embodiment and corresponds to a cross-sectional auxiliary view taken along line A-A in FIG. 5. FIG. 8 is a cross-sectional view that shows the dust collector 1 according to the embodiment and corresponds to a cross-sectional auxiliary view taken along line B-B in FIG. 4.

In the embodiment, the dust collector 1 is a wet/dry dust collector (dust extractor) that can suction not only gas but liquid as well. Air is given as an example of a gas. Water is given as an example of a liquid. It is noted that the dust collector 1 may instead be designed as a dry (only) dust collector.

As shown in FIGS. 1-8, the dust collector 1 comprises a suction tube 2, a tank 3, an inlet cover 4, a cap 5, wheels 6, a main-body housing 7, hooks 8, a motor assembly 9, an inner cover 10, a filter unit 11, a switch base 12, a switch button 13, a handle 14, and a controller 15.

The suction tube 2 suctions at least one of gas and liquid, e.g., both. The suction tube 2 has a suction port 16. The suction port 16 is disposed at a front-end portion of the suction tube 2. The suction tube 2, which includes the suction port 16, is disposed at a front portion of the tank 3. The suction port 16 faces forward. A dust-collecting hose 17 can be connected to the suction tube 2. The suction port 16 communicates (is in fluid communication) with the interior of the main-body housing 7 via the tank 3.

The tank 3 has an interior space, which houses (holds) dust, etc. suctioned from the suction port 16. The suction tube 2, which includes the suction port 16, is provided on (in) the tank 3. After dust, together with one or both of gas and liquid, has been suctioned from the suction port 16, it flows into the interior space of the tank 3. When liquid is suctioned from the suction port 16, the tank 3 also stores (holds) the liquid suctioned from the suction port 16. The liquid is stored in the interior space of the tank 3.

The inlet cover 4 is disposed around the suction tube 2. The inlet cover 4 is disposed so as to cover a front portion of the tank 3. A handle part (first handle) 18 is provided at a lower portion of the inlet cover 4. A space 19 is formed between the handle part 18 and the tank 3. The user can hold, with their hand, the handle part 18 by inserting one or more of their fingertips into the space 19. The user can lift up or drag the dust collector 1 by manually grasping and pulling/lifting the handle part 18.

The cap 5 is disposed so as to cover the suction port 16. In the state in which the dust-collecting hose 17 has been removed from the suction tube 2, leakage of the dust, etc. housed in the interior space of the tank 3 out to the exterior of the tank 3 via the suction port 16 can be curtailed (blocked) by covering the suction port 16 with the cap 5.

The wheels 6 are mounted at lower portions of the tank 3. The wheels 6 support the tank 3 in a movable manner. The wheels 6 include two casters 6F, which are mounted at lower-front portions of the tank 3, and two fixed wheels 6R, which are mounted at lower-rear portions of the tank 3. The tank 3 moves, via the wheels 6, across a surface to be cleaned. By dragging the dust collector 1 forward via the dust-collecting hose 17, the user can move the dust collector 1 forward on the surface to be cleaned.

The main-body housing 7 is supported on the tank 3. The main-body housing 7 is disposed on the upper side of the tank 3. The main-body housing 7 comprises a tank cover 20, a separator 21, a cowling 22, and a battery cover 23.

The tank cover 20 is disposed on the upper side of the tank 3. The tank cover 20 is disposed so as to cover an opening provided at an upper-end portion of the tank 3. The separator 21 is disposed on the upper side of the tank cover 20. The tank cover 20 and the separator 21 are fixed to each other by a screw. The cowling 22 is disposed on the upper side of the separator 21. The separator 21 and the cowling 22 are fixed to each other by a screw. The battery cover 23 is disposed at a front portion of the cowling 22.

The hooks 8 fix the tank 3 and the main-body housing 7 to each other. The hooks 8 are provided respectively at a left portion and a right portion of the tank 3.

The tank 3 comprises hose hooks 24, which support (hold) the dust-collecting hose 17. The hose hooks 24 are provided respectively at a right, rear-end portion and a left, rear-end portion of the tank 3. The dust-collecting hose 17 is a flexible hose and can bend. When not connected to the suction port 16, the dust-collecting hose 17 can be stored in a wound state on the tank 3. The hose hooks 24 support (hold), from below, the dust-collecting hose 17 wound on the tank 3. In addition, dust-collecting pipes 25 may be connected to the dust-collecting hose 17. The separator 21 comprises pipe-support parts 26, which respectively support (hold, e.g., elastically pinch) the dust-collecting pipes 25. The pipe-support parts 26 are provided respectively at a right, rear-end portion and a left, rear-end portion of the separator 21. Each of the pipe-support parts 26 comprises: a protruding part 26A, into which the corresponding dust-collecting pipe 25 is inserted; and a support surface 26B, which supports an outer-circumferential surface of the corresponding dust-collecting pipe 25. In addition, the separator 21 comprises a cap holder 27, which holds the cap 5. The cap holder 27 is provided on a rear surface of the separator 21. The cap holder 27 comprises a pair of clamp parts 27A, which sandwiches the cap 5 from the left and right directions. In addition, a support part 28 is provided at a rear portion of the tank 3. For example, when dust, etc. housed (contained) in the interior of the tank 3 is to be taken out of the tank 3 or a garbage bag is to be taken out of the tank 3, the user may optionally tip the tank 3 over such that the rear surface of the tank 3 faces downward. The support part 28 will support the tank 3, e.g., on a floor, when the tank 3 has been tipped over. In other words, the support part 28 can support the tipped-over tank 3 from below by contacting a prescribed support surface (e.g., the surface to be cleaned, such as a floor). In addition, as shown in FIG. 2, a handle part (second handle) 3A is provided at a lower-rear portion of the tank 3. The user can insert their hand into the handle part 3A to lift up or drag the dust collector 1.

The motor assembly 9 is disposed in the interior of the main-body housing 7. The motor assembly 9 generates suction force at the suction port 16, which communicates (is in fluid communication) with the interior of the main-body housing 7. The motor assembly 9 comprises: a blower fan 29 and a cooling fan 30, which are disposed in the interior of the main-body housing 7; a suction motor 31, which rotates the blower fan 29 and the cooling fan 30; a motor housing 32; a base 33A; a fan base 33B; and a fan cover 34. In the embodiment, the motor assembly 9 is supported by both the tank cover 20 and the separator 21. The tank cover 20 supports the motor assembly 9 from below. The separator 21 supports the motor assembly 9 from above.

The suction motor 31 is an inner-rotor-type brushless motor. The suction motor 31 generates motive (rotational) power for rotating both the blower fan 29 and the cooling fan 30. The suction motor 31 comprises a stator 31A, a rotor 31B, which is disposed in the interior of the stator 31A, and a rotor shaft 31C, which is fixed to the rotor 31B. The rotor shaft 31C extends in the up-down direction. The rotational axis of the rotor shaft 31C extends in the up-down direction. The rotor shaft 31C is rotatably supported by a first bearing 31D and a second bearing 31E. More specifically, the first bearing 31D rotatably supports an upper portion of the rotor shaft 31C. The second bearing 31E rotatably supports a lower portion of the rotor shaft 31C.

The blower fan 29 and the cooling fan 30 are both fixed to the rotor shaft 31C. Thus, the blower fan 29 and the cooling fan 30 are both rotated by the suction motor 31. When the rotor shaft 31C of the suction motor 31 rotates, the blower fan 29 and the cooling fan 30 both rotate. The blower fan 29 generates suction force at the suction port 16. The cooling fan 30 generates an airflow for cooling the suction motor 31. The blower fan 29 is fixed to a lower-end portion of the rotor shaft 31C. The cooling fan 30 is fixed to a portion of the rotor shaft 31C between a lower-end portion of the stator 31A and the blower fan 29. The blower fan 29 is a centrifugal fan. The cooling fan 30 is a centrifugal fan. The outer diameter of the blower fan 29 is larger than the outer diameter of the cooling fan 30.

The motor housing 32 houses the suction motor 31 and the cooling fan 30 in the interior of the main-body housing 7. The motor housing 32 supports the suction motor 31. The motor housing 32 supports (fixedly holds) both the first bearing 31D and the second bearing 31E. The motor housing 32 has a tubular shape. The motor housing 32 has at least one motor air-intake port 32A and at least one motor air-exhaust port 32B. The motor air-intake port(s) 32A is (are) provided at an upper-end portion of the motor housing 32. The motor air-exhaust port(s) 32B is (are) provided at a lower portion of the side surface of the motor housing 32. Gas (air) at (surrounding) the periphery of the motor housing 32 can flow into the interior space of the motor housing 32 via the motor air-intake port(s) 32A. Gas (air) in the interior space of the motor housing 32 can flow out to the periphery of the motor housing 32 via the motor air-exhaust port(s) 32B.

The base 33A is disposed around the suction motor 31 and the motor housing 32. The base 33A supports the motor housing 32. The base 33A guides the gas (air) exhausted from the motor air-exhaust port 32B. The fan base 33B is disposed around the base 33A. The fan base 33B supports the base 33A. The fan base 33B is made of a synthetic resin (polymer) such as a polycarbonate resin.

The fan cover 34 is disposed so as to cover at least a portion of the blower fan 29. The fan cover 34 is connected to the fan base 33B. At least a portion of the fan cover 34 is disposed around the blower fan 29. At least a portion of the fan cover 34 is disposed more downward than (below) the blower fan 29. The fan cover 34 has at least one fan air-intake port 34A and at least one fan air-exhaust port 34B. The fan air-intake port(s) 34A is (are) provided at (in) a lower portion of the fan cover 34. The fan air-exhaust port(s) 34B is (are) provided in a side surface of the fan cover 34.

The inner cover 10 is supported by the tank cover 20. The inner cover 10 is disposed on the lower side of the tank cover 20. The inner cover 10 is fixed to the tank cover 20. The inner cover 10 is disposed between the tank 3 and the tank cover 20. The inner cover 10 has (fluid, e.g., air) communication openings 35. Mesh parts 36 are provided on (in) the inner cover 10. The (fluid, e.g., air) communication openings 35 are provided in the mesh parts 36. The mesh parts 36 include a first mesh part 36L and a second mesh part 36R. The first mesh part 36L and the second mesh part 36R are disposed in the left-right direction. The (fluid, e.g., air) communication openings 35 include first (fluid, e.g., air) communication openings 35L, which are provided in the first mesh part 36L, and second (fluid, e.g., air) communication openings 35R, which are provided in the second mesh part 36R.

The filter unit 11 comprises filters 37 and a filter holder 38, which holds the filters 37. The filters 37 are disposed between the suction port 16 and the blower fan 29. The filters 37 are disposed between the tank 3 and the motor assembly 9. The communication openings 35 are disposed between the tank 3 and the blower fan 29. The filters 37 are disposed between the communication openings 35 and the blower fan 29. The filters 37 recover (catch, remove, trap) foreign matter from the air that flows from the interior space of the tank 3 into the motor assembly 9. In the embodiment, the filter holder 38 of the filter unit 11 is detachable from the inner cover 10.

FIG. 9 is an exploded, oblique view, viewed from the upper-left side, that shows the tank cover 20, the inner cover 10, and the filter unit 11 according to the embodiment. FIG. 10 is an exploded, oblique view, viewed from the right-upper side, that shows the tank cover 20, the inner cover 10, and the filter unit 11 according to the embodiment. FIG. 11 is an exploded, oblique view, viewed from the right-lower side, that shows the tank cover 20, the inner cover 10, and the filter unit 11 according to the embodiment.

The filter unit 11 comprises the filters 37 and the filter holder 38, which holds the filters 37. The communication openings 35 are disposed between the tank 3 and the filters 37. The filters 37 are disposed between the communication openings 35 and the blower fan 29. The filters 37 include a first filter 37L, which is disposed between the blower fan 29 and the first communication openings 35L, and a second filter 37R, which is disposed between the blower fan 29 and the second communication openings 35R. The first filter 37L and the second filter 37R each comprise a prefilter 37A, an intermediate filter 37B, and a main filter 37C. The prefilters 37A face the interior space of the tank 3. The prefilters 37A recover (catch, remove, trap) foreign matter from the air supplied from the tank 3. The intermediate filters 37B recover (catch, remove, trap) foreign matter from the air that has passed through the prefilters 37A. The main filters 37C recover (catch, remove, trap) foreign matter from the air that has passed through the intermediate filters 37B.

The filter holder 38 is detachable from the inner cover 10. The filter holder 38 has: a retaining part 38H which retains the filters 37; a latch lever 38A, which is provided at a front-end portion of the retaining part 38H; recessed portions 38B, which are provided respectively on the left side and the right side of the latch lever 38A; a pair of hook parts 38C, which is provided at a rear-end portion of the retaining part 38H; and a handle part (third handle) 38D, which is provided at a rear-end portion of the retaining part 38H.

The inner cover 10 comprises an engaging part 10A, to which the latch lever 38A latches, protruding parts 10B, which are inserted into the recessed portions 38B; and tab parts 10C, to which the hook parts 38C latch. When the protruding parts 10B have been inserted into the recessed portions 38B, and then the hook parts 38C are latched to the tab parts 10C, the latch lever 38A engages with the engaging part 10A. Thereby, the filter unit 11 is connected to the inner cover 10. By manipulating (manually operating) the latch lever 38A, the engagement between the latch lever 38A and the engaging part 10A can be released, and then the filter unit 11 can be removed from the inner cover 10.

The lower surfaces of the filters 37 face the interior space of the tank 3. The upper surfaces of the filters 37 oppose the communication openings 35 of the mesh parts 36. The tank cover 20 has a recessed portion 20B, in which the fan cover 34 is disposed. A vent 20A is provided in a bottom surface of the recessed portion 20B. The fan air-intake port(s) 34A of the fan cover 34 and the vent 20A overlap. In addition, the tank cover 20 comprises a tube part 20C, which protrudes downward from the circumference (periphery) of the vent 20A. The inner cover 10 has a recessed portion 10D, in which the tube part 20C is disposed.

Ventilation paths 71, through which air that proceeds from the communication openings 35 to the vent 20A passes, are provided in the tank cover 20. The ventilation paths 71 include a first ventilation path 71L, which is provided between the first filter 37L and the blower fan 29, and a second ventilation path 71R, which is provided between the second filter 37R and the blower fan 29. Air that proceeds from the first communication openings 35L to the vent 20A passes through the first ventilation path 71L. Air that proceeds from the second communication openings 35R to the vent 20A passes through the second ventilation path 71R.

By rotating the blower fan 29, suction force is generated at the suction port 16. After gas (air) that has been suctioned from the suction port 16 into the interior space of the tank 3 has passed through the filters 37, it flows into the communication openings 35. As shown in FIG. 10, a passageway 10E, which connects the communication openings 35 and the recessed portion 10D to each other, is provided on the upper surface of the inner cover 10. After the air that has passed through the communication openings 35 passes through the ventilation paths 71 and flows through the passageway 10E, it flows into the fan air-intake port(s) 34A via the vent 20A. The gas (air) that has passed through the fan air-intake port(s) 34A flows into the blower fan 29. The air that has flowed into the blower fan 29 is exhausted to the periphery of the fan cover 34 via the fan air-exhaust port(s) 34B provided in the fan cover 34.

By rotating the cooling fan 30, the gas (air) at (surrounding) the periphery of the motor housing 32 flows into the interior space of the motor housing 32 via the motor air-intake port(s) 32A. The gas (air) that has flowed into the interior space of the motor housing 32 cools the suction motor 31. After it has cooled the suction motor 31, the gas (air) is exhausted to the periphery of the motor housing 32 via the motor air-exhaust port(s) 32B.

The switch base 12 is disposed at a front portion of the main-body housing 7. The switch base 12 has a plate shape. The switch base 12 is long (oblong, elongated) in the up-down direction. The switch base 12 comprises a main-power-supply switch 39.

The switch button 13 is disposed more upward than the switch base 12 at a front portion of the main-body housing 7. The switch button 13 is supported on the main-body housing 7 in a pivotable manner. When the main-power-supply switch 39 is switched ON, the suction motor 31 becomes switchable between a drive state (mode) and a stop state (mode) by manually operating (pressing) the switch button 13.

The handle 14 is supported at an upper portion of the main-body housing 7 in a pivotable manner. The handle 14 is disposed more rearward than the switch button 13. The user of the dust collector 1 can carry the dust collector 1 by grasping the handle 14.

The controller 15 comprises a computer system. The controller 15 outputs control signals for controlling the electronic devices installed in the dust collector 1. Such electronic devices include the suction motor 31. The controller 15 outputs a control signal for controlling the suction motor 31. The controller 15 comprises a control circuit board (e.g., a PCB), on which a plurality of electronic parts is mounted. Illustrative examples of the electronic parts mounted on the control circuit board include: a processor, such as a CPU (central processing unit); nonvolatile memory, such as ROM (read-only memory) and storage; volatile memory, such as RAM (random-access memory); transistors; capacitors; and resistors.

FIG. 12 is an oblique view that shows the state in which the cowling 22 and the separator 21 have been removed from the dust collector 1. FIG. 13 is an oblique view that shows the state in which the cowling 22 has been removed from the dust collector 1.

As shown in FIG. 12 and FIG. 13, the tank cover 20 comprises battery chambers 41, in which battery packs 40 are respectively disposed. Battery-mounting parts, on which the battery packs 40 are respectively mounted, are provided on bottom surfaces of the battery chambers 41.

Air-exhaust passageways 50, through which gas (air) exhausted from the fan air-exhaust port(s) 34B of the motor assembly 9 flows, are provided in the interior of the main-body housing 7. A plurality of the air-exhaust passageways 50 is provided in the interior of the main-body housing 7 in the up-down direction. More specifically, in the embodiment, the air-exhaust passageways 50 include a first air-exhaust passageway 51 and a second air-exhaust passageway 52, which is provided more upward than (above) the first air-exhaust passageway 51. At least a portion of the first air-exhaust passageway 51 and the second air-exhaust passageway 52 overlap at (along) a horizontal plane. In other words, at least one vertical extending line will intersect both the first air-exhaust passageway 51 and the second air-exhaust passageway 52 due to the second air-exhaust passageway 52 being superposed on (above) the first air-exhaust passageway 51. The vertically extending line may be perpendicular to a bottom surface of each of the first air-exhaust passageway 51 and the second air-exhaust passageway 52. Thus, the first air-exhaust passageway 51 preferably extends, at least partially, in parallel with the second air-exhaust passageway 52 in the up-down (vertical) direction.

In addition, a communication-path opening 53, which (fluidly) connects the first air-exhaust passageway 51 and the second air-exhaust passageway 52 to each other, is provided in the interior of the main-body housing 7. The communication-path opening 53 is provided so as to (fluidly) connect a left-end portion of the first air-exhaust passageway 51 with a left-end portion of the second air-exhaust passageway 52. In the embodiment, the communication-path opening 53 has a quadrangular shape in horizontal cross-section.

The first air-exhaust passageway 51 is defined by (between) the tank cover 20 and the separator 21. The second air-exhaust passageway 52 is defined by (between) the separator 21 and the cowling 22.

The tank cover 20 comprises: a first cover-plate part 43, which covers the tank 3; and a first guide-plate part 44, which protrudes upward from an upper surface of the first cover-plate part 43. The separator 21 comprises: a second cover-plate part 45, which covers the tank cover 20; and second guide-plate parts 46, which protrude upward from an upper surface of the second cover-plate part 45.

The first air-exhaust passageway 51 is defined by the upper surface of the first cover-plate part 43, a guide surface of the first guide-plate part 44, and a lower surface of the second cover-plate part 45. The guide surface of the first guide-plate part 44 faces the first air-exhaust passageway 51. In the embodiment, sound-absorbing members 44A are disposed on the guide surface of the first guide-plate part 44. The second air-exhaust passageway 52 is defined by the upper surface of the second cover-plate part 45, guide surfaces of the second guide-plate parts 46, and a lower surface of the cowling 22. The guide surfaces of the second guide-plate parts 46 face the second air-exhaust passageway 52. The communication-path opening 53 includes a through opening, which goes through (penetrates) the lower surface and the upper surface of the second cover-plate part 45 of the separator 21.

In the embodiment, in the state in which the wheels 6 are set on the surface to be cleaned, which is parallel to the horizontal plane, the upper surface of the first cover-plate part 43 and the upper surface of the second cover-plate part 45 are at least substantially parallel to each other, i.e. either parallel or at an angle of 5° or less to each other. The guide surface of the first guide-plate part 44 and the guide surfaces of the second guide-plate parts 46 each are at least substantially orthogonal to the horizontal plane, i.e. either perpendicular or at an angle of 85-95° to the horizontal plane.

The second air-exhaust passageway 52 is connected to air-exhaust ports 42, which (fluidly) communicate with the exterior of the main-body housing 7. The air-exhaust ports 42 are provided in the rear surface of the separator 21. Sound-absorbing members 42A are provided in the air-exhaust ports 42.

FIG. 14 shows the gas-flow-through state (direction) in the first air-exhaust passageway 51 according to the embodiment. FIG. 15 shows the gas-flow-through state (direction) in the second air-exhaust passageway 52 according to the embodiment. As shown in FIG. 14, the gas (air) exhausted from the fan air-exhaust port(s) 34B of the motor assembly 9 flows through the first air-exhaust passageway 51. In at least a portion of the first air-exhaust passageway 51, the gas flows through from the right side toward the left side. The gas that has flowed through the first air-exhaust passageway 51 rises through the (vertically-extending) communication-path opening 53 and flows into the second air-exhaust passageway 52. As shown in FIG. 15, the air that has flowed from the first air-exhaust passageway 51 into the second air-exhaust passageway 52 via the communication-path opening 53 flows through the second air-exhaust passageway 52 and then is exhausted from the air-exhaust ports 42. In at least a portion of the second air-exhaust passageway 52, the gas (air) flows through from the left side toward the right side. The direction in which gas flows through the first air-exhaust passageway 51 is the reverse or opposite direction of the direction in which gas flows through the second air-exhaust passageway 52.

The surface area (horizontal cross-sectional area) of the communication-path opening 53 is ½ or less of the maximum cross-sectional area of the first air-exhaust passageway 51. The surface area of the communication-path opening 53 refers to the surface area of the communication-path opening 53 in a direction parallel to the horizontal plane in the state in which the wheels 6 are set on the surface to be cleaned, which is parallel to the horizontal plane. The cross-sectional area of the first air-exhaust passageway 51 refers to the surface area of the first air-exhaust passageway 51 within a plane orthogonal to both the upper surface of the first cover-plate part 43 and the guide surface of the first guide-plate part 44 in the state in which the wheels 6 are set on the surface to be cleaned, which is parallel to the horizontal plane. The maximum cross-sectional area of the first air-exhaust passageway 51 refers to the maximum cross-sectional area from among the cross-sectional areas of every region in the direction in which air flows through the first air-exhaust passageway 51. In the embodiment, because the sound-absorbing members 44A are disposed on the guide surface of the first guide-plate part 44, the cross-sectional area of the first air-exhaust passageway 51 includes the surface area of the first air-exhaust passageway 51 within a plane orthogonal to both the upper surface of the first cover-plate part 43 and the guide surfaces of the sound-absorbing members 44A in the state in which the wheels 6 are set on the surface to be cleaned, which is parallel to the horizontal plane. The guide surfaces of the sound-absorbing members 44A face the first air-exhaust passageway 51.

Cap

FIG. 16 is an oblique view, viewed from the left-front side, that shows the dust collector 1 according to the embodiment in the state in which the cap 5 is mounted in the suction tube 2. FIG. 17 is an oblique view, viewed from the left-front side, that shows the cap according to the embodiment. FIG. 18 is an oblique view, viewed from the right-rear side, that shows the cap 5 according to the embodiment. FIG. 19 is an oblique view, viewed from the right-rear side, that shows a portion of the cap 5 according to the embodiment. FIG. 20 is a partial, enlarged view of the cap 5 mounted in the suction tube 2 according to the embodiment.

The cap 5 comprises a flange part (flange) 60, a tubular part (tube) 61, and a handle part (fourth handle) 62. The outer shape of the flange part 60 is substantially a circular shape. The tubular part 61 is provided so as to protrude rearward from a center portion of the flange part 60. The tubular part 61 is disposed more radially inward of the flange part 60 than the outer-circumferential surface of the flange part 60. Rear portions of the tubular part 61 are insertion portions 63, which are inserted into the suction port 16. Front portions of the tubular part 61 are non-insertion (non-inserted) portions 64, which are not inserted into the suction port 16 when the insertion portions 63 are inserted into the suction port 16; i.e. the non-insertion portions 16 are adjacent to, but not within, the suction port 16 when the cap 5 is disposed on/in the suction port 16. The handle part 62 protrudes radially outward of the flange part 60 from a portion of the outer-circumferential surface of the flange part 60.

The flange part 60 has an opposing surface 65, which opposes a front-end surface 2A of the suction tube 2. The cap 5 comprises ribs 66, which protrude rearward from the opposing surface 65. The amount by which the ribs 66 protrude from the opposing surface 65 is, for example, 1 mm. The opposing surface 65 has a ring shape. The ribs 66 are provided so as to extend in the radial direction of the opposing surface 65. The ribs 66 are provided spaced apart in the circumferential direction of the opposing surface 65. At least three of the ribs 66 are provided. In the embodiment, twelve (12) of the ribs 66 are provided spaced apart in the circumferential direction. In the embodiment, the twelve ribs 66 are preferably provided (disposed) equispaced from each other.

Inner-end portions in the radial direction of the ribs 66 are disposed more radially inward than the opposing surface 65. That is, the ribs 66 protrude radially inward from radially inward end portions of the opposing surface 65. The non-insertion portions 64 of the tubular part 61 are disposed more radially inward than the opposing surface 65. The non-insertion portions 64 are disposed outward of the suction port 16 in the state in which the insertion portions 63 are inserted into the suction port 16. A radially outer-end portion 63A of each of the insertion portions 63 protrudes more radially outward than the outer-circumferential surface of the corresponding non-insertion portion 64. The radially outer-end portions 63A of the insertion portions 63 make contact with an inner-circumferential surface of the suction tube 2. The radially inner-end portions of the ribs 66 are connected to the non-insertion portions 64.

The tubular part 61 has slits 67. The slits 67 are formed so as to extend in the axial direction of the tubular part 61. That is, the slits 67 are formed so as to extend in the front-rear direction. The slits 67 are formed so as to span from tip portions (rear-end portions) of the insertion portions 63 to base-end portions (front-end portions) of the non-insertion portions 64. Each of the slits 67 is formed between two ribs 66 that are adjacent to each other in the circumferential direction. One slit 67 is formed between each two adjacent ribs 66.

The tubular part 61 is divided by the plurality of slits 67 into a plurality of small-piece parts 68 in the circumferential direction of the tubular part 61. Reinforcing ribs 69 are connected to radially-inward-facing inner surfaces of the small-piece parts 68. The reinforcing ribs 69 are provided so as to extend in the radial direction from the center of the tubular part 61.

As shown in FIG. 20, gaps 70 are formed between the front-end surface 2A of the suction tube 2 and the opposing surface 65 in the state in which the front-end surface 2A of the suction tube 2 and rear-end surfaces of the ribs 66 are in contact with each other. In the circumferential direction of the cap 5, dimension Wa of each of the gaps 70 is larger than dimension Wb of the ribs 66.

The gaps 70 and the slits 67 are set such that the maximum degree of vacuum becomes 90% or more and 97% or less in case the maximum degree of vacuum is set to 100% while the suction motor 31 is being driven in the state in which the suction port 16 is closed up by the cap 5. The gaps 70 are set based on the amount by which the ribs 66 protrude from the opposing surface 65.

Cleaning Apparatus

In the embodiment, the dust collector 1 comprises a (filter) cleaning apparatus 80, which cleans the filters 37. FIG. 21 shows a portion of the cleaning apparatus 80 according to the embodiment. FIG. 21 shows, as viewed from below, a portion of the tank cover 20. As was shown in FIG. 11, the tank cover 20 comprises the first ventilation path 71L, which is provided between the first filter 37L and the blower fan 29, and the second ventilation path 71R, which is provided between the second filter 37R and the blower fan 29. In addition, the tank cover 20 has a first connection opening 72L, which (fluidly) connects the first ventilation path 71L and the first air-exhaust passageway 51 to each other, and a second connection opening 72R, which (fluidly) connects the second ventilation path 71R and the first air-exhaust passageway 51 to each other. The first connection opening 72L and the second connection opening 72R are each provided so as to pass through (penetrate) an upper surface and a lower surface of the first cover-plate part 43.

The dust collector 1 comprises a first valve 83L, which opens and closes the first ventilation path 71L, and a second valve 83R, which opens and closes the second ventilation path 71R. The first valve 83L and the second valve 83R are respectively supported on the first cover-plate part 43 of the tank cover 20 in a pivotable manner. The first valve 83L operates so as to change between a first state, in which the first ventilation path 71L is open and the first connection opening 72L is closed, and a second state, in which the first ventilation path 71L is closed and the first connection opening 72L is open. The second valve 83R operates so as to change between a third state, in which the second ventilation path 71R is open and the second connection opening 72R is closed, and a fourth state, in which the second ventilation path 71R is closed and the second connection opening 72R is open.

A torsion spring is provided at the pivot axis of both the first valve 83L and the second valve 83R. When an external force is not acting on the first valve 83L, the first valve 83L operates, owing to the elastic force of the torsion spring, so as to enter the first state, in which the first ventilation path 71L is open and the first connection opening 72L is closed. The second valve 83R operates, owing to the elastic force of the torsion spring, so as to enter the third state, in which the second ventilation path 71R is open and the second connection opening 72R is closed. In the first state and the third state, when the suction motor 31 is driven, air in the interior space of the tank 3 passes through the filters 37, the communication openings 35, and the ventilation paths 71, and then flows into the blower fan 29 via the vent 20A. In addition, in the first state and the third state, the air exhausted from the fan air-exhaust port 34B of the motor assembly 9 flows through the first air-exhaust passageway 51 and is then supplied to the second air-exhaust passageway 52 via the fan air-exhaust port 34B.

As shown in FIG. 7 and FIG. 21, the cleaning apparatus 80 comprises a cleaning motor 81 and an actuation member 82, which is pivoted by the cleaning motor 81. The actuation member 82 actuates the first valve 83L and the second valve 83R. When the cleaning motor 81 is actuated to generate motive power, the actuation member 82 pivots between the direction indicated by arrow YL and the direction indicated by arrow YR shown in FIG. 21. When the actuation member 82 moves in the arrow YL direction, the first valve 83L is pressed by the actuation member 82 and operates so as to enter the second state, in which the first ventilation path 71L is closed and the first connection opening 72L is open. On the other hand, when the actuation member 82 moves in the arrow YR direction, the second valve 83R is pressed by the actuation member 82 and operates so as to enter the fourth state, in which the second ventilation path 71R is closed and the second connection opening 72R is open.

FIG. 22 shows the state of the filters 37 when the first valve 83L is in the second state and the second valve 83R is in the third state, according to the embodiment. FIG. 23 shows the state of the filters 37 when the first valve 83L is in the first state and the second valve 83R is in the fourth state, according to the embodiment.

In the embodiment, the cleaning of the filters 37 includes separating (dislodging) the dust that has adhered to the lower surfaces of the filters 37 from the lower surfaces of the filters 37. The lower surfaces of the filters 37 include the lower surfaces of the prefilters 37A. In the embodiment, the cleaning of the filters 37 includes separating the dust that has adhered to the lower surfaces of the prefilters 37A from the lower surfaces of the prefilters 37A. In the embodiment, the cleaning of the filters 37 includes the cleaning of the first filter 37L and the cleaning of the second filter 37R.

While the suction motor 31 is being driven and the first valve 83L is operated (actuated) so as to change from the first state to the second state, the first ventilation path 71L closes and air no longer flows from the tank 3 into the first filter 37L. Because the second ventilation path 71R is open, air flows from the tank 3 into the second filter 37R. The air that has flowed into the second filter 37R flows into the motor assembly 9 and then is exhausted from the motor assembly 9 to the first air-exhaust passageway 51. Because the first connection opening 72L is open, at least a portion of the air that has exhausted from the motor assembly 9 to the first air-exhaust passageway 51 is supplied to the upper surface of the first filter 37L via the first connection opening 72L and the first communication openings 35L. Owing to the (pressurized) air being supplied to the upper surface of the first filter 37L, gas (pressurized air) is jetted (forcibly exhausted) from (through) the lower surface of the first filter 37L, as shown by an arrow in FIG. 22. Thereby, foreign matter that is adhered to the lower surface of the first filter 37L will be separated (dislodged) from the lower surface of the first filter 37L, and thereby the first filter 37L is cleaned. The foreign matter (dust, debris, liquid, etc.) removed from the first filter 37L is thereby stored in the interior space of the tank 3.

Similarly, while the suction motor 31 is being driven and the second valve 83R is operated (actuated) so as to change from the third state to the fourth state, the second ventilation path 71R closes and therefore air no longer flows from the tank 3 into the second filter 37R. Because the first ventilation path 71L is open, air flows from the tank 3 into the first filter 37L. The air that has flowed into the first filter 37L flows into the motor assembly 9, and then is exhausted from the motor assembly 9 to the first air-exhaust passageway 51. Because the second connection opening 72R is open, at least a portion of the air exhausted from the motor assembly 9 to the first air-exhaust passageway 51 is supplied to the upper surface of the second filter 37R via the second connection opening 72R and the second communication openings 35R. Owing to the (pressurized) air being supplied to the upper surface of the second filter 37R, gas (pressurized air) is jetted from (through) the lower surface of the second filter 37R, as shown by the arrow in FIG. 23. Thereby, foreign matter that is adhered to the lower surface of the second filter 37R will be separated from the lower surface of the second filter 37R, and thereby the second filter 37R is cleaned. Thus, the foreign matter (dust, debris, liquid, etc.) removed from the second filter 37R is thereby also stored in the interior space of the tank 3.

Linking with a Power Tool

FIG. 24 is an oblique view that shows the dust collector 1 (fluidly) connected to a power tool 90 according to the embodiment. In general, dust collectors 1 according to the present teachings are connectable to a variety of power tools 90. A circular saw, which is one type of portable cutting machine, is given as a representative, non-limiting example of a type of power tool 90 that can be connected to the dust collector 1. When the power tool 90 is cutting a workpiece, dust from the workpiece is generated by the power tool 90. The power tool 90 and the suction port 16 of the dust collector 1 are (fluidly) connected to each other via the dust-collecting hose 17. In the embodiment, the dust collector 1 is operably (e.g., wirelessly) linked (e.g., “paired”) with the power tool 90. That is, when the power tool 90 starts operating, the suction motor 31 will also start, and the suction operation of the dust collector 1 begins. In the embodiment, the power tool 90 and the dust collector 1 communicate with each other wirelessly. The power tool 90 and the dust collector 1 may communicate with each other wirelessly based on, for example, a Bluetooth® standard.

FIG. 25 is a block diagram that shows electronic components of the power tool 90 and the dust collector 1 according to the embodiment. The power tool 90 comprises a trigger switch 91, a tool motor 92, a controller 93, and a wireless transmitter 94. The controller 93 comprises the following functional units: a tool-start-signal generating part 93A, a tool-stop-signal generating part 93B, and a signal-transmitting part 93C. The dust collector 1 comprises the controller 15, the suction motor 31, the cleaning motor 81, and a wireless receiver 47. The controller 15 comprises the following functional units: a signal-receiving part 15A, a motor-control part 15B, and a cleaning-control part 15C. For example, the above-noted “parts” of the controllers 15, 93 may simply be different sets of instructions (code, programs) stored in storage or memory of the controller 15, 93 and executed by one or microprocessors.

The tool motor 92 serves as a motive power supply. That is, when the tool motor 92 is driven (energized), an output part of the power tool 90 rotates. In an embodiment in which the power tool 90 is a circular saw, the tool motor 92 causes the rotary cutting tool (circular saw blade), which serves as the output portion of the power tool 90, to rotate. The trigger switch 91 is manipulated (manually operable) by the user. When the trigger switch 91 is manually operated (e.g., pressed), a manipulation signal is generated at the trigger switch 91, and thereby the tool motor 92 starts. By releasing the manipulation of the trigger switch 91, the tool motor 92 stops.

When the trigger switch 91 is manually operated (pressed), the tool-start-signal generating part 93A outputs a tool-start signal, based on the generated manipulation signal, to start the tool motor 92. The tool motor 92 starts based on the tool-start signal output from the tool-start-signal generating part 93A.

When the manipulation (pressing) of the trigger switch 91 is released, the tool-stop-signal generating part 93B outputs a tool-stop signal to stop the tool motor 92. The tool motor 92 stops based on the tool-stop signal output from the tool-stop-signal generating part 93B.

The signal-transmitting part 93C transmits the tool-start signal and the tool-stop signal to the dust collector 1. More specifically, the signal-transmitting part 93C transmits the tool-start signal to the dust collector 1 via the wireless transmitter 94 synchronized to the output of the tool-start signal from the tool-start-signal generating part 93A to the tool motor 92. Similarly, the signal-transmitting part 93C transmits the tool-stop signal to the dust collector 1 via the wireless transmitter 94 synchronized to the output of the tool-stop signal from the tool-stop-signal generating part 93B to the tool motor 92.

The wireless receiver 47 receives the tool-start signal and the tool-stop signal transmitted from the wireless transmitter 94, which is provided on (in) the power tool 90. The signal-receiving part 15A receives, via the wireless transmitter 94, the tool-start signal and the tool-stop signal transmitted from the power tool 90.

The motor-control part 15B controls the operation (actuation, energization) of the suction motor 31. The motor-control part 15B controls the suction motor 31 so as to be linked with the power tool 90. The motor-control part 15B controls the suction motor 31 based on the tool-start signal and the tool-stop signal transmitted from the power tool 90. The motor-control part 15B starts the power tool 90 and starts the suction motor 31 based on the tool-start signal transmitted from the power tool 90. After the power tool 90 stops based on the tool-stop signal transmitted from the power tool 90, the motor-control part 15B stops the suction motor 31 while continuing the drive of the suction motor 31 for a prescribed (time) interval Ta (e.g., 3 sec). The tool-stop signal functions as a motor-stop signal that stops the suction motor 31. After the motor-control part 15B wirelessly receives the tool-stop signal, which stops the power tool 90, via the wireless receiver 47 and the signal-receiving part 15A, the motor-control part 15B stops the suction motor 31 while continuing the drive of the suction motor 31 for prescribed interval Ta.

The cleaning-control part 15C is configured to selectively actuate the cleaning apparatus 80. More specifically, the cleaning-control part 15C controls the actuation of the cleaning motor 81 of the cleaning apparatus 80. Actuating the cleaning apparatus 80 includes driving the cleaning motor 81. The cleaning-control part 15C actuates the cleaning apparatus 80 after the power tool 90, which is connected to the suction port 16, stops. More specifically, the cleaning-control part 15C actuates the cleaning apparatus 80 after having wirelessly received, via the wireless receiver 47 and the signal-receiving part 15A, the tool-stop signal, which stops the power tool 90. The cleaning-control part 15C actuates the cleaning apparatus 80 in prescribed interval Ta described above.

FIG. 26 is a flow chart that shows a representative, non-limiting manner for operating of the power tool 90 and the dust collector 1 according to the embodiment. The power tool 90 is (fluidly) connected to the suction port 16 of the dust collector 1 via the dust-collecting hose 17. When the user manipulates (presses) the trigger switch 91 of the power tool 90, the tool-start-signal generating part 93A generates the tool-start signal (step SB1). The tool-start signal generated in the tool-start-signal generating part 93A is output to the tool motor 92. The tool motor 92 starts in response to the tool-start signal (step SB2). In addition, the tool-start signal generated in the tool-start-signal generating part 93A is transmitted to the dust collector 1 via the wireless transmitter 94.

The wireless receiver 47 receives the tool-start signal transmitted from the power tool 90 (step SA1). The motor-control part 15B starts the suction motor 31 in response to receiving the tool-start signal transmitted from the power tool 90 (step SA2). In the embodiment, the tool motor 92 and the suction motor 31 are started substantially at the same time. By starting the tool motor 92, the workpiece can be cut. By starting the suction motor 31, dust, etc. generated from the workpiece is suctioned into the dust collector 1 via the dust-collecting hose 17.

When the user releases the trigger switch 91, the tool-stop-signal generating part 93B generates the tool-stop signal (step SB3). The tool-stop signal generated in the tool-stop-signal generating part 93B is output to the tool motor 92. The tool motor 92 stops based on the tool-stop signal (step SB4). In addition, the tool-stop signal generated in the tool-stop-signal generating part 93B is transmitted to the dust collector 1 via the wireless transmitter 94.

The wireless receiver 47 receives the tool-stop signal transmitted from the power tool 90 (step SA3). Even though the motor-control part 15B receives the tool-stop signal transmitted from the power tool 90, the motor-control part 15B continues to drive the suction motor 31 for prescribed (time) interval Ta instead of immediately stopping the suction motor 31.

The cleaning-control part 15C starts the cleaning motor 81 in response to receiving the tool-stop signal transmitted from the power tool 90 (step SA4). Thus, as the suction motor 31 is continued to be driven, the actuation member 82 actuates by the starting of the cleaning motor 81, and thereby the filters 37 are cleaned, as was explained above with reference to FIG. 22 and FIG. 23. The time needed to clean the filters 37 is shorter than prescribed interval Ta (e.g., 3 sec).

After the filters 37 have been cleaned by driving (actuating) the cleaning motor 81, the cleaning-control part 15C stops the cleaning motor 81 (step SA5). After the motor-control part 15B ends the cleaning of the filters 37 and prescribed interval Ta has elapsed since the tool-stop signal was received, the motor-control part 15B stops the suction motor 31 (step SA6).

Effects

As explained above, in the embodiment, the dust collector 1 comprises: the main-body housing 7; the motor assembly 9 that (i) comprises: the blower fan 29, which is disposed in the interior of the main-body housing 7; and the suction motor 31, which rotates the blower fan 29; and (ii) generates suction force at the suction port 16, which (fluidly) communicates with the interior of the main-body housing 7; and the plurality of air-exhaust passageways 50 provided in the up-down direction in the interior of the main-body housing 7 and through which gas exhausted from the motor assembly 9 flows.

Because the air-exhaust passageways 50 can be made relatively long in this configuration (owing to the fact that at least two air-exhaust passageways 51, 52 can be provided one above the other and both extend in the horizontal direction), air-exhaust noise generated by, for example, the motor assembly 9 can be effectively attenuated in the air-exhaust passageways 50. Consequently, noise generated by the dust collector 1 is curtailed. In addition, because at least two of the air-exhaust passageways 50 are provided in the up-down direction (e.g., one above the other), even though the air-exhaust passageways 50 can be relatively long, the overall size of the dust collector 1 need not be enlarged. For example, the dust collector 1 need not be enlarged in the horizontal direction in order to implement this configuration.

In the embodiment, the air-exhaust passageways 50 include: the first air-exhaust passageway 51; and the second air-exhaust passageway 52, which is provided more upward than the first air-exhaust passageway 51 and overlaps (superposes) at least a portion of the first air-exhaust passageway 51 within a horizontal plane (e.g., in the up-down direction).

The above-mentioned configuration thus enables the air-exhaust passageways 50 to be relatively long without enlargement of the dust collector 1.

In the embodiment, the dust collector 1 has the communication-path opening 53, which (fluidly) connects the first air-exhaust passageway 51 and the second air-exhaust passageway 52 to each other.

According to the above-mentioned configuration, air can flow respectively through the first air-exhaust passageway 51 and the second air-exhaust passageway 52 via the communication-path opening 53.

In the embodiment, the communication-path opening 53 connects one-end portion of the first air-exhaust passageway 51 and one-end portion of the second air-exhaust passageway 52 to each other.

The above-mentioned configuration thus also enables the air-exhaust passageways 50 to be relatively long without enlargement of the dust collector 1.

In the embodiment, the communication-path opening 53 has a quadrangular shape in cross-section.

According to the above-mentioned configuration, the creation of dead space in the dust collector 1 is curtailed.

In the embodiment, the surface area (horizontal cross-sectional area) of the communication-path opening 53 is ½ or less of the maximum cross-sectional area of the first air-exhaust passageway 51.

The above-mentioned configuration increases the noise-reducing effect of the communication-path opening 53.

In the embodiment, the direction in which the gas (air) flows through the first air-exhaust passageway 51 is the reverse or opposite direction of the direction in which gas (air) flows through the second air-exhaust passageway 52. For example, as shown in FIGS. 14 and 15, the air may flow generally from right to left in the first air-exhaust passageway 51 (FIG. 14) and the air may flow generally from left to right in the second air-exhaust passageway 52.

The above-mentioned configuration thus also enables the air-exhaust passageways 50 to be relatively long without enlargement of the dust collector 1.

In the embodiment, the dust collector 1 has the air-exhaust ports 42, which are (fluidly) connected to the second air-exhaust passageway 52 and (fluidly) communicate with the exterior of the main-body housing 7.

According to the above-mentioned configuration, the air that has flowed through the first air-exhaust passageway 51 and the second air-exhaust passageway 52 is exhausted from the air-exhaust ports 42 to the exterior of the main-body housing 7.

In the embodiment, the gas (air) exhausted from the motor assembly 9 flows through the first air-exhaust passageway 51, then flows into the second air-exhaust passageway 52 via the communication-path opening 53 and then flows through the second air-exhaust passageway 52, and finally is exhausted from through the air-exhaust ports 42.

According to the above-mentioned configuration, because the gas exhausted from the motor assembly 9 flows through the long air-exhaust passageways 50, air-exhaust noise generated by the motor assembly 9 can be effectively attenuated in the air-exhaust passageways 50.

In the embodiment, the dust collector 1 comprises: the tank 3, on (in) which the suction port 16 is provided. The main-body housing 7 comprises: the tank cover 20, which is disposed on the upper side of the tank 3; the separator 21, which is disposed on the upper side of the tank cover 20; and the cowling 22, which is disposed on the upper side of the separator 21. The first air-exhaust passageway 51 is defined by the tank cover 20 and the separator 21; and the second air-exhaust passageway 52 is defined by the separator 21 and the cowling 22.

According to the above-mentioned configuration, by combining the tank cover 20, the separator 21, and the cowling 22, the first air-exhaust passageway 51 and the second air-exhaust passageway 52 are formed smoothly.

In the embodiment, the tank cover 20 comprises the first cover-plate part 43, which covers the tank 3, and the first guide-plate part 44, which protrudes upward from the upper surface of the first cover-plate part 43. The separator 21 comprises the second cover-plate part 45, which covers the tank cover 20, and the second guide-plate part 46, which protrudes upward from the upper surface of the second cover-plate part 45. The first air-exhaust passageway 51 is defined by the upper surface of the first cover-plate part 43, the first guide-plate part 44, and the lower surface of the second cover-plate part 45. The second air-exhaust passageway 52 is defined by the upper surface of the second cover-plate part 45, the second guide-plate part 46, and the lower surface of the cowling 22.

According to the above-mentioned configuration, by combining the tank cover 20, the separator 21, and the cowling 22, the first air-exhaust passageway 51 and the second air-exhaust passageway 52 are formed smoothly.

Other Embodiments

In the embodiment explained above with reference to FIG. 26, it was assumed that, after the motor-control part 15B receives the tool-stop signal (motor-stop signal) transmitted from the power tool 90, the motor-control part 15B stops the suction motor 31 while continuing the drive of the suction motor 31 for prescribed interval Ta, and that the cleaning-control part 15C actuates the cleaning apparatus 80 in prescribed interval Ta. However, in another embodiment of the present teachings, the cleaning apparatus 80 may clean the filters 37 without being linked (paired) with the power tool 90. Below, an example of the operation of the cleaning apparatus 80 in an alternate embodiment in which the cleaning apparatus 80 is not linked with the power tool 90 will be explained, with reference to FIG. 27.

FIG. 27 is a flow chart that shows the operation of the dust collector 1 according to the alternate embodiment. When the user of the dust collector 1 manipulates (presses) the switch button 13 to be ON, a motor-start signal, which serves as the manipulation signal and starts the suction motor 31, is generated in (by) the switch button 13. The motor-control part 15B receives the motor-start signal from the switch button 13 (step SC1). The suction motor 31 starts based on the motor-start signal (step SC2).

When the user manipulates (presses) the switch button 13 to be OFF, the motor-stop signal, which serves as the manipulation signal and stops the switch button 13, is generated in (by) the switch button 13. The motor-control part 15B receives the motor-stop signal from the switch button 13 (step SC3).

Even though the motor-control part 15B receives the motor-stop signal from the switch button 13, the motor-control part 15B continues the drive of the suction motor 31 for prescribed interval Ta instead of immediately stopping the suction motor 31.

The cleaning-control part 15C starts the cleaning motor 81 based on (in response to) the motor-stop signal from the switch button 13 (step SC4). While the suction motor 31 is continued to be driven, the actuation member 82 is actuated by the start of the cleaning motor 81, and thereby the filters 37 are cleaned, as was explained above with reference to FIG. 22 and FIG. 23. The time needed to clean the filters 37 is shorter than prescribed interval Ta (e.g., 3 sec).

After the filters 37 have been cleaned by the drive of the cleaning motor 81, the cleaning-control part 15C stops the cleaning motor 81 (step SC5). After the cleaning of the filters 37 ends and prescribed interval Ta has elapsed since the motor-stop signal was received, the motor-control part 15B stops the suction motor 31 (step SC6).

In the alternate example explained with reference to FIG. 27 as well, the drive of the suction motor 31 is continued until the elapse of prescribed interval Ta from the reception of the motor-stop signal. The cleaning apparatus 80 can clean the filters 37 using the suction generated by the suction motor 31 within prescribed interval Ta. After the foreign matter has been separated (dislodged) from the filters 37, the user can resume use of the dust collector 1.

Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved dust collectors or dust extractors and methods of making and using the same.

Moreover, combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.

All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.

Although some aspects of the present disclosure have been described in the context of a device, it is to be understood that these aspects also represent a description of a corresponding method, so that each block or component of a device, such as the controllers 15, 93, is also understood as a corresponding method step or as a feature of a method step. In an analogous manner, aspects which have been described in the context of or as a method step also represent a description of a corresponding block or detail or feature of a corresponding device, such as the controllers 15, 93.

Depending on certain implementation requirements, exemplary embodiments of the controllers 15, 93 of the present disclosure may be implemented in hardware and/or in software. The implementation can be configured using a digital storage medium, for example one or more of a ROM, a PROM, an EPROM, an EEPROM or a flash memory, on which electronically readable control signals (program code) are stored, which interact or can interact with a programmable hardware component such that the respective method is performed.

A programmable hardware component can be formed by a processor, a computer processor (CPU=central processing unit), an application-specific integrated circuit (ASIC), an integrated circuit (IC), a computer, a system-on-a-chip (SOC), a programmable logic element, or a field programmable gate array (FGPA) including a microprocessor.

The digital storage medium can therefore be machine- or computer readable. Some exemplary embodiments thus comprise a data carrier or non-transient computer readable medium which includes electronically readable control signals which are capable of interacting with a programmable computer system or a programmable hardware component such that one of the methods described herein is performed. An exemplary embodiment is thus a data carrier (or a digital storage medium or a non-transient computer-readable medium) on which the program for performing one of the methods described herein is recorded.

In general, exemplary embodiments of the present disclosure, in particular the control unit, are implemented as a program, firmware, computer program, or computer program product including a program, or as data, wherein the program code or the data is operative to perform one of the methods if the program runs on a processor or a programmable hardware component. The program code or the data can for example also be stored on a machine-readable carrier or data carrier. The program code or the data can be, among other things, source code, machine code, bytecode or another intermediate code.

A program according to an exemplary embodiment can implement one of the methods during its performing, for example, such that the program reads storage locations or writes one or more data elements into these storage locations, wherein switching operations or other operations are induced in transistor structures, in amplifier structures, or in other electrical, optical, magnetic components, or components based on another functional principle. Correspondingly, data, values, sensor values, or other program information can be captured, determined, or measured by reading a storage location. By reading one or more storage locations, a program can therefore capture, determine or measure sizes, values, variable, and other information, as well as cause, induce, or perform an action by writing in one or more storage locations, as well as control other apparatuses, machines, and components.

Therefore, although some aspects of the controllers 15, 93 have been identified as “parts” or “steps”, it is understood that such parts or steps need not be physically separate or distinct electrical components, but rather may be different blocks of program code that are executed by the same hardware component, e.g., one or more microprocessors, and/or may be implemented using discrete hardware components.

EXPLANATION OF THE REFERENCE NUMBERS

    • 1 Dust collector
    • 2 Suction tube
    • 2A Front-end surface
    • 3 Tank
    • 3A Handle part
    • 4 Inlet cover
    • 5 Cap
    • 6 Wheel
    • 6F Caster
    • 6R Fixed wheel
    • 7 Main-body housing
    • 8 Hook
    • 9 Motor assembly
    • 10 Inner cover
    • 10A Engaging part
    • 10B Protruding part
    • 10C Tab part
    • 10D Recessed portion
    • 10E Passageway
    • 11 Filter unit
    • 12 Switch base
    • 13 Switch button
    • 14 Handle
    • 15 Controller
    • 15A Signal-receiving part
    • 15B Motor-control part
    • 15C Cleaning-control part
    • 16 Suction port
    • 17 Dust-collecting hose
    • 18 Handle part
    • 19 Space
    • 20 Tank cover
    • 20A Vent
    • 20B Recessed portion
    • 20C Tube part
    • 21 Separator
    • 22 Cowling
    • 23 Battery cover
    • 24 Hose hook
    • 25 Dust-collecting pipe
    • 26 Pipe-support part
    • 26A Protruding part
    • 26B Support surface
    • 27 Cap holder
    • 27A Clamp part
    • 28 Support part
    • 29 Blower fan
    • 30 Cooling fan
    • 31 Suction motor
    • 31A Stator
    • 31B Rotor
    • 31C Rotor shaft
    • 31D Bearing
    • 31E Bearing
    • 32 Motor housing
    • 32A Motor air-intake port
    • 32B Motor air-exhaust port
    • 33A Base
    • 33B Fan base
    • 34 Fan cover
    • 34A Fan air-intake port
    • 34B Fan air-exhaust port
    • 35 Communication opening
    • 35L First communication opening
    • 35R Second communication opening
    • 36 Mesh part
    • 36L First mesh part
    • 36R Second mesh part
    • 37 Filter
    • 37A Prefilter
    • 37B Intermediate filter
    • 37C Main filter
    • 37L First filter
    • 37R Second filter
    • 38 Filter holder
    • 38A Latch lever
    • 38B Recessed portion
    • 38C Hook part
    • 38D Handle part
    • 38H Retaining part
    • 39 Main-power-supply switch
    • 40 Battery pack
    • 41 Battery chamber
    • 42 Air-exhaust port
    • 42A Sound-absorbing member
    • 43 First cover-plate part
    • 44 First guide-plate part
    • 44A Sound-absorbing member
    • 45 Second cover-plate part
    • 46 Second guide-plate part
    • 47 Wireless receiver
    • 50 Air-exhaust passageway
    • 51 First air-exhaust passageway
    • 52 Second air-exhaust passageway
    • 53 Communication-path opening
    • 60 Flange part
    • 61 Tubular part
    • 62 Handle part
    • 63 Insertion portion
    • 63A Outer-end portion in the radial direction
    • 64 Non-insertion portion
    • 65 Opposing surface
    • 66 Rib
    • 67 Slit
    • 68 Small-piece part
    • 69 Reinforcing rib
    • 70 Gap
    • 71 Ventilation path
    • 71L First ventilation path
    • 71R Second ventilation path
    • 72L First connection opening
    • 72R Second connection opening
    • 80 Cleaning apparatus
    • 81 Cleaning motor
    • 82 Actuation member
    • 83L First valve
    • 83R Second valve
    • 90 Power tool
    • 91 Trigger switch
    • 92 Tool motor
    • 93 Controller
    • 93A Tool-start-signal generating part
    • 93B Tool-stop-signal generating part
    • 93C Signal-transmitting part
    • 94 Wireless transmitter
    • Ta Prescribed interval
    • Wa Dimension
    • Wb Dimension

Claims

1. A dust collector comprising:

a main-body housing having a suction port, which in fluid communication with an interior of the main-body housing;
a motor assembly that comprises: a blower fan, which is disposed in the interior of the main-body housing; and a suction motor, which is configured to rotate the blower fan, the motor assembly being configured to generate suction force at the suction port; and
at least first and second air-exhaust passageways provided in an up-down direction in the interior of the main-body housing and through which air exhausted from the motor assembly flows.

2. The dust collector according to claim 1, wherein the second air-exhaust passageway is disposed above the first air-exhaust passageway such that a vertically extending line intersects the first air-exhaust passageway and the second air-exhaust passageway.

3. The dust collector according to claim 1, wherein a communication-path opening fluidly connects the first air-exhaust passageway to the second air-exhaust passageway.

4. The dust collector according to claim 3, wherein the communication-path opening fluidly connects one-end portion of the first air-exhaust passageway to one-end portion of the second air-exhaust passageway.

5. The dust collector according to claim 3, wherein the communication-path opening has a quadrangular shape.

6. The dust collector according to claim 3, wherein a horizontal cross-sectional area of the communication-path opening is ½ or less of the maximum cross-sectional area of the first air-exhaust passageway.

7. The dust collector according to claim 1, wherein when the motor assembly is generating the suction force, the direction in which air flows through the first air-exhaust passageway is opposite of the direction in which air flows through the second air-exhaust passageway.

8. The dust collector according to claim 1, wherein an air-exhaust port is fluidly connected to the second air-exhaust passageway and fluidly communicates with the exterior of the main-body housing.

9. The dust collector according to claim 1, wherein air exhausted from the motor assembly flows through the first air-exhaust passageway, then flows into the second air-exhaust passageway via a communication-path opening and then flows through the second air-exhaust passageway, and finally is exhausted from an air-exhaust port.

10. The dust collector according to claim 1, further comprising:

a tank, on or in which the suction port is provided;
wherein:
the main-body housing comprises: a tank cover, which is disposed on the upper side of the tank; a separator, which is disposed on the upper side of the tank cover; and a cowling, which is disposed on the upper side of the separator;
the first air-exhaust passageway is defined by the tank cover and the separator; and
the second air-exhaust passageway is defined by the separator and the cowling.

11. The dust collector according to claim 10, wherein:

the tank cover comprises a first cover-plate part, which covers the tank, and a first guide-plate part, which protrudes upward from an upper surface of the first cover-plate part;
the separator comprises a second cover-plate part, which covers the tank cover, and a second guide-plate part, which protrudes upward from an upper surface of the second cover-plate part;
the first air-exhaust passageway is defined by the upper surface of the first cover-plate part, the first guide-plate part, and a lower surface of the second cover-plate part; and
the second air-exhaust passageway is defined by the upper surface of the second cover-plate part, the second guide-plate part, and a lower surface of the cowling.

12. The dust collector according to claim 2, wherein each of the first and second air-exhaust passageway has a longest dimension that extends in a horizontal direction perpendicular to the up-down direction.

13. The dust collector according to claim 12, wherein a communication-path opening fluidly connects the first air-exhaust passageway to the second air-exhaust passageway.

14. The dust collector according to claim 13, wherein when the motor assembly is generating the suction force, the direction in which air flows through the first air-exhaust passageway is opposite of the direction in which air flows through the second air-exhaust passageway.

15. The dust collector according to claim 14, wherein an air-exhaust port is fluidly connected to the second air-exhaust passageway and fluidly communicates with the exterior of the main-body housing.

16. The dust collector according to claim 15, wherein air exhausted from the motor assembly flows through the first air-exhaust passageway, then flows into the second air-exhaust passageway via the communication-path opening and then flows through the second air-exhaust passageway, and finally is exhausted from the air-exhaust port.

17. The dust collector according to claim 16, wherein:

the communication-path opening fluidly connects an end portion of the first air-exhaust passageway to an end portion of the second air-exhaust passageway;
the communication-path opening has a quadrangular shape in horizontal cross-section; and
a horizontal cross-sectional area of the communication-path opening is ½ or less of the maximum cross-sectional area of the first air-exhaust passageway.

18. The dust collector according to claim 17, further comprising:

a tank, on or in which the suction port is provided;
wherein:
the main-body housing comprises: a tank cover, which is disposed on the upper side of the tank; a separator, which is disposed on the upper side of the tank cover; and a cowling, which is disposed on the upper side of the separator;
the first air-exhaust passageway is defined by the tank cover and the separator; and
the second air-exhaust passageway is defined by the separator and the cowling.

19. The dust collector according to claim 18, wherein:

the tank cover comprises a first cover-plate part, which covers the tank, and a first guide-plate part, which protrudes upward from an upper surface of the first cover-plate part;
the separator comprises a second cover-plate part, which covers the tank cover, and a second guide-plate part, which protrudes upward from an upper surface of the second cover-plate part;
the first air-exhaust passageway is defined by the upper surface of the first cover-plate part, the first guide-plate part, and a lower surface of the second cover-plate part; and
the second air-exhaust passageway is defined by the upper surface of the second cover-plate part, the second guide-plate part, and a lower surface of the cowling.
Patent History
Publication number: 20240108184
Type: Application
Filed: Sep 6, 2023
Publication Date: Apr 4, 2024
Inventors: Takayuki TAHARA (Anjo-shi), Kosuke KOMIYA (Anjo-shi), Kenji SHIBATA (Anjo-Shi)
Application Number: 18/461,579
Classifications
International Classification: A47L 9/00 (20060101); A47L 5/36 (20060101);