Upright vacuum cleaner

Abstract

A vacuum cleaner is disclosed. The vacuum cleaner comprises a cleaner body, a cyclonic chamber comprising a primary cyclone and at least one secondary cyclone disposed around the primary cyclone, a flow passage guide for guiding the airflow discharged from the primary cyclone to a secondary airflow inlet of the secondary cyclone, a first conduit for fludically connecting a nozzle section defining a suction opening to a primary airflow inlet of the primary cyclone, a suction source having an suction source inlet and an suction source outlet, and a second conduit for fludically connecting a secondary airflow outlet to the suction source inlet of the suction source. Accordingly, it is possible to achieve a low flow resistance by virtue of the flow passage guide and an enhanced dust collecting performance by virtue of a sealing effect of the sealing member.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to vacuum cleaners. More particularly, the present invention relates to upright vacuum cleaners used for suctioning dirt and dust from carpets and floors.

2. Discussion of the Related Art

Upright vacuum cleaners are known to include a cleaner body having a handle, by which an operator of the vacuum cleaner may grasp and maneuver the cleaner, and a nozzle section which travels across a floor, carpet, or other surfaces being cleaned.

The cleaner body often formed as a rigid plastic housing which encloses a dirt and dust collecting filter bag. The underside of the nozzle section includes a suction opening formed therein which is in fluid communication with the filter bag.

A suction source such as a motor and fan assembly is enclosed within the cleaner body. The suction source generates the suction force required to pull dirt from the carpet or floor through the suction opening and into the filter bag.

To avoid the need for vacuum filter bags, and the associated expense and inconvenience of replacing the bag, another type of upright vacuum cleaner utilizes cyclonic airflow, rather than a filter bag, to separate a majority of the dirt and other particulates from the suction airflow. The air is then filtered to remove residual particulates, returned to the motor, and exhausted.

Such cyclonic airflow upright vacuum cleaners have not been found to be entirely effective and convenient to use. For example, with these cyclonic airflow vacuum cleaners, the coupling structure of the dust collector is complex, thereby causing an inconvenience in use of the vacuum cleaner.

Also, in the vacuum cleaner having the above-mentioned configuration, there is a problem in that the vacuum cleaner has a low dust collecting performance by virtue of the leakage in the dust collector.

Also, in the vacuum cleaner having the above-mentioned configuration, there is a problem in that a flow resistance is high because the air within the dust collector does not flow smoothly due to the structure of the dust collector.

Accordingly, it has been deemed desirable to develop a new and improved upright vacuum cleaner which would overcome the foregoing difficulties and others while providing better and more advantageous overall results.

SUMMARY OF THE INVENTION

According to the present invention, a new and improved upright vacuum cleaner is provided.

An object of the present invention is to provide a vacuum cleaner which has a simple coupling structure, and is convenient in use.

Another object of the present invention is to provide a vacuum cleaner which has a high dust collecting performance.

Another object of the present invention is to reduce the flow resistance during the operation mode.

Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein.

In accordance with the first aspect of this invention, a vacuum cleaner comprises a cleaner body, a cyclonic chamber including a primary cyclone and at least one secondary cyclone, a flow passage guide for guiding the airflow discharged from the primary cyclone to a secondary airflow inlet of the secondary cyclone, a first conduit for fludically connecting a nozzle section defining a suction opening to a primary airflow inlet of the primary cyclone, a suction source having a suction source inlet and a suction source outlet, and a second conduit for fludically connecting a secondary airflow outlet to the suction source inlet of the suction source.

The primary cyclone being in fluid communication with the cleaner body separates contaminants from the airflow. The secondary cyclone is integrated with the primary cyclone and disposed around the primary cyclone for separating contaminants entrained in the airflow discharged from the primary cyclone.

The suction source generates and maintains the airflow flowing from the suction source inlet to the suction source outlet.

The flow passage guide is formed at an underside of a chamber cover mounted to the upper end of the cyclonic chamber. The flow passage guide has a conical shape and one end of the flow passage guide extends to the secondary airflow inlet.

The vacuum cleaner may further comprise a third conduit for fludically connecting the suction source outlet to the atmosphere.

Upon activation of the suction source, contaminants from a surface being cleaned are entrained in the airflow. The airflow travels (a) from the cleaner body into the primary cyclone through the primary airflow inlet, (b) downwardly from the primary airflow inlet and in a cyclonic fashion within the primary cyclone so that the entrained contaminants are separated from the suction airflow, (c) from the primary cyclone into the secondary cyclone with passing through the flow passage guide, (d) downwardly from the secondary airflow inlet and in a cyclonic fashion within the secondary cyclone so that contaminants are separated from the airflow flowing into the secondary cyclone, and (e) from the secondary cyclone into the suction source with passing through the second conduit.

The vacuum cleaner may further include a main filter assembly for filtering contaminants from the airflow discharged form the secondary cyclone.

The main filter assembly comprises a selectively permeable material, and the main filter assembly is located on an upper portion of the secondary cyclone.

The vacuum cleaner may further comprise a final filter assembly connected in fluid communication with the suction source outlet and adapted for filtering the airflow exhausted by the suction source prior to the airflow being dispersed into the atmosphere, wherein the final filter assembly comprises a high efficiency particulate arrest (HEPA) filter medium.

In accordance with another aspect of the present invention, a vacuum cleaner comprises a dust collector including a primary cyclone for separating contaminants from an airflow and at least one secondary cyclone for separating contaminants entrained in the airflow discharged from the primary cyclone, a cleaner body comprising a socket for holding selectively the dust collector, a suction source located in the cleaner body for generating a cyclonic flow of the airflow in the dust collector, and a selectively removable main filter assembly located in the dust collector for filtering contaminant from the airflow prior to the airflow flowing into the suction source.

It is preferred that the primary cyclone is integrated with the secondary cyclone.

It is preferred that the dust collector is at least partially transparent.

In accordance with a further aspect of the invention, an upright vacuum cleaner comprises a dust collector comprising a primary cyclone and at least one secondary cyclone for separating contaminants from an airflow, a cleaner body including a socket for holding selectively the dust collector, a nozzle section pivotably connected the cleaner body and including a suction opening, an agitator positioned in the nozzle section for contacting and scrubbing the surface being cleaned, a suction source located below the dust collector for generating a cyclonic flow of the airflow in the dust collector, the suction source include an suction source inlet and an suction source outlet, a belt for transferring the rotational force of the suction source to the agitator, a first conduit for fludically connecting the suction opening to a primary airflow inlet of the primary cyclone, and a second conduit for fludically connecting a secondary airflow outlet to the suction source inlet.

The upright vacuum cleaner may further comprise a flow passage guide for guiding the airflow discharged from the primary cyclone to a secondary airflow inlet of the secondary cyclone.

Upon activation of the suction source, contaminants from a surface being cleaned are entrained in the airflow. The airflow travels (a) from the cleaner body into the primary cyclone through the primary airflow inlet (b) downwardly from the primary airflow inlet and in a cyclonic fashion within the primary cyclone so that the entrained contaminants are separated from the suction airflow, (c) from the primary cyclone into the secondary cyclone with passing through the flow passage guide (d) downwardly from the secondary airflow inlet and in a cyclonic fashion within the secondary cyclone so that contaminants are separated from the airflow flowing into the secondary cyclone, and (e) from the secondary cyclone into the suction source with passing through the second conduit.

The secondary cyclone is disposed around the primary cyclone.

The primary airflow inlet is horizontally oriented and arranged so that the airflow entering the primary cyclone through the primary airflow inlet moves cyclonically within the primary cyclone.

The upright vacuum cleaner further comprises an agitator brush provided at an outer circumference of the agitator.

In accordance with a further aspect of the invention, an upright vacuum cleaner comprises a nozzle section, a rotating brush assembly disposed in the nozzle section, a primary cyclone being in fluid communication with the nozzle section for separating contaminants from an airflow, at least one secondary cyclone for separating contaminants entrained in the airflow discharged from the primary cyclone, a dust collecting container comprises a primary dust storing part for storing contaminants separated in the primary cyclone and a secondary dust storing part for storing contaminants separated in the secondary cyclone, a sealing member for sealing airtightly the primary dust storing part and the secondary dust storing part, a suction source for generating the airflow, and a selectively removable main filter assembly located on upper portion of the secondary cyclone for filtering contaminants from the airflow prior to the airflow flowing into the suction source.

The upright vacuum cleaner further comprises a conduit interconnecting the secondary cyclone with the suction source.

The upright vacuum cleaner further comprises a final filter assembly connected in fluid communication with the suction source and adapted for filtering the airflow exhausted by the suction source prior to the airflow being dispersed into the atmosphere, wherein the final filter assembly comprises a high efficiency particulate arrest (HEPA) filter medium.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take form in certain components and structures, preferred embodiments of which will be illustrated in the accompanying drawings wherein:

FIG. 1 is a perspective view illustrating a cyclonic airflow upright vacuum cleaner in accordance with the present invention;

FIG. 2 is a partial perspective view illustrating a state of an operative mode of the upright vacuum cleaner in FIG. 1.

FIG. 3 is a side elevational view of the vacuum cleaner shown in FIG. 1;

FIG. 4 is a rear elevational view of the vacuum cleaner of FIG. 1;

FIG. 5 is a bottom plan view of the vacuum cleaner of FIG. 1;

FIG. 6 is a side view in cross-section of the vacuum cleaner illustrated in FIG. 1;

FIG. 7 is an exploded perspective view of the dust collector illustrated in FIG. 1;

FIG. 8 is a perspective view illustrating an upper part of the dust collector illustrated in FIG. 7;

FIG. 9 is a partial side view in cross-section of the dust collector illustrated in FIG. 7

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

FIGS. 1-6 illustrate an upright vacuum cleaner including a cleaner body 100, a nozzle section 200 connected to the cleaner body 100, and conduits for guiding the suction airflow from the nozzle section 200 to the atmosphere with passing through the cleaner body 100.

The cleaner body 100 and the nozzle section 200 are pivotally or hingedly connected through the use of suitable hinge assembly so that the cleaner body 100 pivots between a generally vertical storage position (as shown) and an inclined operative position.

The hinge assembly includes a rotation shaft 150 and rotating shaft holes 151 corresponding to the rotation shaft 150. The rotation shaft 150 protrudes from two lower opposing sides of the cleaner body 100 and the rotating shaft holes are provided at nozzle section 200 for retaining the rotation shaft 150.

The cleaner body 100 and nozzle section 200 are connected to each other as the rotation shaft 150 is inserted into the rotating shaft hole 151, allowing the cleaner body and the nozzle section to rotate freely with respect to each other.

The nozzle section 200 includes a nozzle case 210, a suction opening 211 which formed at the underside of the nozzle case 210, and a rotating brush assembly which provided in the nozzle case 210. Front wheels 121 and rear wheels 120 are rotatably mounted to underside of the nozzle case 210, respectively, to enable the nozzle section 200 to smoothly move on a floor.

The suction opening 211 extends substantially across the width of the nozzle case 210 at the front end thereof. And, the suction opening 211 is in fluid communication with the cleaner body 100 through a first conduit 410.

The rotating brush assembly includes an agitator 220, an agitator brush 230 which provided at the outer circumference of the agitator 220, and a belt 240 for transferring the rotational force of a suction source 180 to the agitator 220.

The agitator 220 and the agitator brush 230 are positioned in the region of the suction opening 211 for contacting and scrubbing the surface being vacuumed to loosen embedded dirt and dust. That is, when the rotational force of the suction source 180 is transferred to the agitator 220, the agitator rotates and brushes up contaminants from the surface being cleaned. The rotating brush assembly may further include an agitator motor (not shown) for driving the agitator.

A height adjustment knob 110 is rotatably mounted in the nozzle section 200. The user rotates the height adjustment knob 110 with his/her hand to lift up and down a shaft supporting front wheels (not shown) of the vacuum cleaner and thus adjust the height of the nozzle section 200. It is preferred that the height adjustment knob 110 is capable of adjusting the height of the nozzle section step by step and in accordance with the state of the surface to be cleaned.

The cleaner body 100 includes a control part (not shown) for controlling the vacuum cleaner, the suction source 180 for generating the required suction airflow for cleaning operations, and a dust collector 300 for separating contaminants entrained in the suction airflow passed through the suction opening 211.

The cleaner body may further comprise a coupling device including a latch 327 and a coupling protrusion 190 for coupling the dust collector 300 to the cleaner body 100. Also, the cleaner body further comprises a socket 195 for holding selectively the dust collector 300. The socket has a shape of a recess and several grooves corresponding to the surface of the dust collector.

The suction source 180 including an electronic motor and a fan generates a suction force in a suction source inlet 181 and an exhaust force in a suction source outlet 183.

The suction source outlet 183 is in fluid communication with a final filter assembly 600 for filtering the exhaust airflow of any contaminants immediately prior to its discharge into the atmosphere. The suction source inlet 181 is in fluid communication with the dust collector 300 of the cleaner body 100. Of course, the suction source could be disposed in the nozzle section 200.

The cleaner body 100 further includes a handle 700 extending upward therefrom by which a user of the vacuum cleaner is able to grasp and maneuver the vacuum cleaner. The handle 700 includes a telescopic release lever 710 for adjusting the height of the handle according to a height of the user.

The cleaner body 100 further includes a cord hook provided at rear side of the cleaner body 100. The cord hook includes an upper cord hook 141 and a lower cord hook 140 corresponding to the upper cord hook. The space between the upper cord hook 141 and the lower cord hook 140 is sufficient to accommodate the number of turns necessary to store the entire length of the cord. A cord holder (not shown) adjacent to the cord hook prevents the cord releasing from its stored position.

The conduits include a first conduit 410 connecting the suction opening 211 to dust collector 300, a second conduit 420 connecting the dust collector 300 to the suction source inlet 181, and a third conduit 430 connecting the suction source outlet 183 to the atmosphere.

The first conduit 410 including hoses is supported and connected by fitting members. One side of a first fitting member 171 is connected to a first hose 411 and the other side of the first fitting member 171 is connected to a passage 170 which is in fluid communication with the suction opening 211.

A second fitting member 173 connects the first hose 411 to a second hose 412 and a third fitting member 175 connects the second hose 412 to the cleaner body. Each of first and second hose (411, 412) is connected detachably to the second fitting member 173.

The vacuum cleaner further includes body release lever13O for an inclined operative position of the vacuum cleaner. The body release lever13O is pivotably mounted on a mounting portion 131 which is provided at the nozzle section. The body release lever13O has a locking protrusion 132 protruding from a side thereof. The locking protrusion 132 is sequentially locked in the one or more locking recess 135 provided at lower side of cleaner body.

When the vacuum cleaner is in use, with cleaner body 100 being rotated at a predetermined angle with respect to a surface to be cleaned, a locking protrusion 132 is locked in one of the inclined position recesses 135.

Hereinafter, the structures of the dust collector will be described in detail with reference to FIGS. 7-9.

Referring to the FIGS. 7-9, the dust collector 300 comprises a cyclonic chamber 320, a dust collecting container 330, a bottom panel 340 which is positioned at lower end of the dust collecting container 330 and a top cover 310 which is positioned at upper end of the cyclonic chamber 320.

According to the present invention, the dust collecting container and the cyclonic chamber are formed as one body.

The dust collector 300 further includes a dust collector handle 350 which is provided on the exterior of the dust collecting container 330 for handling the container. For coupling the dust collector to the cleaner body, the latch 327 is positioned at the upper end of the dust collector handle 350 and the coupling protrusion (190, as shown FIG. 6) is formed at the front portion of the cleaner body.

The cyclonic chamber 320 includes a primary cyclone 321 and at least one secondary cyclone 323. The primary cyclone 321 separates dust and dirt from the suction airflow passed through the suction opening 211. The secondary cyclone 323 separates dust and dirt entrained in the airflow discharged form the primary cyclone 321.

The primary cyclone 321 has a downwardly-opened cylindrical container shape. A primary airflow inlet 321a is formed through an upper portion of the primary cyclone 321 at one side of the primary cyclone 321. A primary airflow outlet 321b is formed through the top of the primary cyclone 321 such that the primary airflow outlet 321b extends vertically.

The primary airflow inlet 321a is tangentially oriented and arranged so that the airflow entering the primary cyclone 321 through the primary airflow inlet 321a moves cyclonically within the primary cyclone 321. That is, the primary airflow inlet 321a guides dirt-laden air into the cyclonic chamber 320 in a tangential direction of the primary cyclone 321 so that the air flows spirally along an inner wall surface of the primary cyclone 321.

The secondary cyclones 323 have peripheral walls formed integrally with a peripheral wall of the cyclonic chamber 320, respectively. The secondary cyclones 323 are partitioned each other by peripheral walls of the secondary cyclones 323. The cyclonic chamber 320 may be constructed as one body with the dust collecting container 330 and define the dust collecting container 330 at least partially.

In particular, the secondary cyclones 323 are circumferentially arranged around the primary cyclone 321. Each secondary cyclone 323 has an upper end upwardly protruded to a level higher than that of the upper end of the primary cyclone 321.

The peripheral wall of each secondary cyclone 323 is vertically cut out at a region where the peripheral wall is upwardly protruded above the upper end of the primary cyclone 321, thereby forming a secondary airflow inlet 323a communicating with the primary airflow outlet 321b.

Each secondary cyclone 323 also has a cone shape in partial. That is, the secondary cyclone 323 has a conical portion 323d formed at a lower portion of the secondary cyclone 323 such that the conical portion 323d has a diameter reduced gradually as the conical portion extends toward the bottom of the dust collecting container 330.

A contaminants discharge port 323c is formed at a lower end of each secondary cyclone 323 to downwardly discharge contaminants such as dust.

The secondary cyclones 323 have an integrated structure such that adjacent ones of the secondary cyclones 323 are in contact with each other to prevent air from being leaked between the adjacent secondary cyclones 323.

The cyclonic chamber 320 may further include a chamber cover 325 mounted to the upper end of the cyclonic chamber 320 to open or close the upper ends of the cyclonic chamber 320.

A flow passage guide 326 is provided at the underside of the chamber cover 325. The flow passage guide 326 guides more smoothly air emerging from the primary airflow outlet 321b to the secondary cyclones 323. The flow passage guide 326 has a conical shape and one end of the flow passage guide extends to the secondary airflow inlet 323a.

The secondary airflow inlet 323a of each secondary cyclone 323 guides air discharged from the primary airflow outlet 321b to flow in a tangential direction of the secondary cyclone 323 so that the air entering the secondary airflow inlet 323a flows spirally along an inner wall surface of the secondary cyclone 323.

Secondary airflow outlets 323b are formed at the chamber cover 325 along the peripheral portion of the chamber cover 325 to discharge air from the secondary cyclones 323, respectively.

Dust separated in the primary cyclone 321 and second cyclones 323, which have the above-described configurations, respectively, is stored in a dust storing part formed at the dust collecting container 330. The stored dust is subsequently outwardly discharged by virtue of gravity when the bottom panel 340 is opened.

An opening/closing device 360 is mounted to the peripheral wall of the dust collecting container 330 to open or close the bottom panel 340. The opening/closing device 360 includes a locking hook 361 for locking the bottom panel 340. Also, the bottom panel 340 includes a bottom hook 341 corresponding to the locking hook 361.

The dust collecting container 330 is preferably at least partially transparent so that an operator of the vacuum cleaner is able to view the level of dirt and dust accumulated therein for purposes of determining when the dust collecting container should be emptied.

The dust storing part includes a primary dust storing part 331 for storing the dust separated by the primary cyclone 321, and a secondary dust storing part 333 for storing dust separated by the secondary cyclones 323.

The primary dust storing part 331 and secondary dust storing part 333 are partitioned by a substantially cylindrical boundary wall 335, which is connected to the secondary cyclones 323, and has a diameter smaller than that of the peripheral wall of the dust collecting container330.

The boundary wall 335 has a lower end extending downward to the bottom of the dust collecting container 330, that is, the upper surface of the bottom panel 340, beyond the lower end of the primary cyclone 321.

The boundary wall 335 may have a circumferentially corrugated shape, in order to prevent the dust stored in the primary dust storing part 331 from floating due to a spiral air flow formed in the primary cyclone 321.

A sealing member 342 is mounted between the boundary wall 335 and the bottom panel 340. The sealing member 342 having a cylindrical shape is a elastic material. The sealing member 342 prevents the primary dust storing part 331 from communicating with the secondary dust storing part 333. The sealing member seals airtightly the primary dust storing part and the secondary dust storing part and then the dust collecting performance is improved.

In addition to the above-described configuration, the dust collector 300 according to the illustrated embodiment of the present invention further includes a discharge member 370 mounted on the upper end of the primary cyclone 321. Plurality of holes 371 are formed at a peripheral wall of the discharge member 370, in order to allow the discharge member 370 to communicate with the primary airflow outlet 321b of the primary cyclone 321.

It is preferred that the discharge member 370 be centrally arranged in the primary cyclone 321, extend axially through the primary cyclone 321, and have a substantially conical structure having an opened upper end and a closed lower end while having a diameter gradually reduced as the discharge member 370 extends downward.

When the discharge member 370 has such a structure, the velocity of the spiral air flow in the primary cyclone 321 is gradually reduced toward the lower end of the primary cyclone 321. Therefore, it is possible to prevent dust from being influenced by a suction force exerted in the discharge member 370. Of course, the discharge member 370 may have a cylindrical shape.

The upper end of the discharge member 370 is coupled separably to the peripheral edge of the primary airflow outlet 321b. In detail, a coupling part 376 is coupled to a coupling protrusion 321c formed at the upper edge of the primary airflow outlet 321b.

An annular sealing member (not shown), which provides a sealing effect for the dust collector, is interposed between the upper end of the discharge member 370 and the primary airflow outlet 321b.

A floatation prevention member 373 may also be mounted to the lower end of the discharge member 370, in order to prevent the dust collected in the primary dust storing part 331 from rising due to the spiral air flow, and thus, from entering the secondary cyclones 323.

For such a function, it is preferred that the floatation prevention member 373 have an inclined portion formed integrally with the lower end of the discharge member 370. It is also preferred that the inclined portion has a radially-extending and downwardly-inclined upper surface. Specifically, the floatation prevention member 373 has a conical structure having a diameter gradually increased as the floatation prevention member 373 extends downward.

Also, it is preferred that a cross blade 375 is attached under the inclined portion for preventing swirling airflow in the primary dust storing part 331 additionally. If there is no cross blade 375, then the air turbulence will occur causing more dust to rise up. Of course, the structure of the floatation prevention member 373 does not be restricted in this embodiment.

The dust collector 300 also includes a guide rib 380 provided at the primary cyclone 321. The guide rib 380 guides air entering the primary airflow inlet 321a to flow in a direction tangential to the inner peripheral wall surface of the primary cyclone 321. That is, the guide rib 380 prevents the air entering the primary airflow inlet 321a from being directly introduced into the discharge member 370.

Meanwhile, a main filter assembly 500 located on the dust collector 300 for filtering contaminants from the airflow discharged form the secondary cyclone 323.

The main filter assembly 500 includes a filter housing 510 and a main filter element 520 mounted in the filter housing 510 and a filter housing knob 530 for handling the filter housing.

The filter housing 510 coupled detachably to the cleaner body receives and retains the main filter element 520. The filter housing 510 includes a plurality of apertures, slots, or other passages formed therethrough, preferably in the lower half thereof, so that the suction airflow flows freely from the cover discharge port 313 into the filter housing 510 and to the main filter element 520.

It is preferable that the main filter element 520 is made of permeable material. For cleaning the main filter element 520, the user is able to detach the filter housing 510 from the cleaner body by rotating and drawing out the filter housing knob 530.

The preferred main filter element 520 comprises Porex. RTM. brand high density polyethylene-based open-celled porous media available commercially from Porex Technologies Corp., Fairburn, Ga. 30213, or an equivalent foraminous filter member. This preferred main filter element 520 is a rigid open-celled foam that is moldable, machinable, and otherwise workable into any shape as deemed advantageous for a particular application.

The main filter assembly 500 may further include a filter supporter (not shown) for supporting and fixing the main filter element 520. The filter supporter is formed at the inner frame of the filter housing. Also, the main filter assembly 500 may be positioned in the top cover 310.

The cleaner body 100 also comprises a final filter assembly 600 for filtering the suction airflow immediately prior to its exhaustion into the atmosphere. The preferred final filter assembly 600 includes a final filter element 610 and a final filter housing 620 for retaining the final filter element.

The final filter element 610 is preferably a high efficiency particulate arrest (HEPA) filter element in a sheet or block form. The final filter housing 620 has protective grid or grate structure for securing the final filter element 610 in place.

The vacuum cleaner may further include an auxiliary filter assembly (not shown) disposed downstream from the main filter assembly. The auxiliary filter assembly includes an auxiliary filter element (not shown), a filter supporter for supporting and installing the auxiliary filter element, and an auxiliary filter housing (not shown) for retaining the auxiliary filter element.

Those skilled in the art will recognize that the final filter assembly 600 will remove the contaminant such that only contaminant-free air is discharged into the atmosphere.

Operation of the vacuum cleaner, in which the dust collector 300 according to the illustrated embodiment of the present invention is incorporated, will now be described referring to FIGS. 1-9.

When the vacuum cleaner operates, the suction source 180 establishes a suction force at its suction source inlet 181, in the elongated the first conduit, and thus in the primary cyclone 321.

This suction force or negative pressure in primary cyclone 321 is communicated to the suction opening 211 formed in the nozzle underside through the hoses and associated fitting members. This, then, in combination with the scrubbing action of the rotating brush assembly causes dust and dirt from the surface being cleaned to be entrained in the suction airflow and pulled into the primary cyclone 321 through the primary airflow inlet 321a.

The air introduced into the primary cyclone 321 is guided by the guide rib 380 to flow in a direction tangential to the inner peripheral surface of the primary cyclone 321 without being directly introduced into the discharge member 370, thereby forming a spiral flow.

In the instance, the air acquires a certain swirling force, and the swirling force separates heavy and large dust particles. As a result, relatively heavy and large dust is separated from the air in accordance with the cyclone principle, and is then stored in the primary dust storing part 331 after falling downward.

The dust stored in the primary dust storing part 331 is prevented from floating in accordance with the functions of the floatation prevention member 373 and corrugated boundary wall 335.

The air, from which relatively heavy and large dust has been separated, is discharged from the primary cyclone 321 through the primary airflow outlet 321b communicating with the holes 371 formed at the peripheral wall of the discharge member 370.

The finer dust is then filtered through the discharge member 370 placed between the primary cyclone 321 and the secondary cyclones 323. Also, the air is then introduced into the secondary cyclones 323 so that the air is again subjected to a dust separation process, in order to separate relatively light and fine dust from the air.

The air, from which relatively light and fine dust has been separated in the secondary cyclones 323, is introduced into the interior of the top cover 310 detachably connected to the dust collecting container 330.

The air introduced into the interior of the top cover 310 is discharged through a cover discharge port 313 formed at the center of the top cover 310. The air emerging from the cover discharge port 313 is introduced into the main filter assembly 500.

Then, the air passes through the apertures formed in the filter housing 510, passes through the main filter element 520 so that residual contaminants are removed, and exits the main filter assembly 500. The air discharging from the main filter assembly 500 is introduced into the suction source 180 through the second conduit 420. Then, the air emerging from the suction source outlet 183 is introduced into the final filter assembly 600 through the third conduit 430.

In the final filter assembly 600, the air is filtered again by the HEPA filter to remove any contaminants that passed through the dust collector 300 and the main filter assembly 500. The air passed through the final filter assembly 600 outwardly is discharged from the vacuum cleaner to atmosphere.

The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

The above-described vacuum cleaner according to the present invention has various effects.

First, in accordance with the present invention, there is advantage in that the vacuum cleaner has a low flow resistance by virtue of the flow passage guide guiding the airflow smoothly.

Second, in accordance with the present invention, there is further advantage in that it is possible to enhance the dust collecting performance of the dust collector by virtue of the provision of the sealing member adapted to provide a sealing effect between the primary and secondary dust storing parts.

Third, in accordance with the present invention, there is still further advantage in that the vacuum cleaner separates dust and dirt from the airflow and deposits the dust and dirt into the dust collecting container easily and conveniently.

Claims

1. A vacuum cleaner comprising:

a cleaner body;

a cyclonic chamber comprising; a primary cyclone for separating contaminants from an airflow, the primary cyclone being in fluid communication with the cleaner body; and at least one secondary cyclone integrated with the primary cyclone and disposed around the primary cyclone for separating contaminants entrained in the airflow discharged from the primary cyclone;

a flow passage guide for guiding the airflow discharged from the primary cyclone to a secondary airflow inlet of the secondary cyclone;

a first conduit for fludically connecting a nozzle section defining a suction opening to a primary airflow inlet of the primary cyclone;

a suction source having an suction source inlet and an suction source outlet, the suction source operative to generate and maintain an airflow flowing from the suction source inlet, to the suction source outlet; and

a second conduit for fludically connecting a secondary airflow outlet to the suction source inlet of the suction source.

2. The vacuum cleaner as set forth in claim 1, wherein the flow passage guide is formed at an underside of a chamber cover mounted to the upper end of the cyclonic chamber.

3. The vacuum cleaner as set forth in claim 2, wherein the flow passage guide has a conical shape and one end of the flow passage guide extends to the secondary airflow inlet.

4. The vacuum cleaner as set forth in claim 1 further comprising a third conduit for fludically connecting the suction source outlet to the atmosphere.

5. The vacuum cleaner as set forth in claim 4, whereby upon activation of the suction source, contaminants from a surface being cleaned are entrained in the airflow, the airflow travels:

(a) from the cleaner body into the primary cyclone through the primary airflow inlet;

(b) downwardly from the primary airflow inlet and in a cyclonic fashion within the primary cyclone so that the entrained contaminants are separated from the suction airflow;

(c) from the primary cyclone into the secondary cyclone with passing through the flow passage guide;

(d) downwardly from the secondary airflow inlet and in a cyclonic fashion within the secondary cyclone so that contaminants are separated from the airflow flowing into the secondary cyclone; and

(e) from the secondary cyclone into the suction source with passing through the second conduit.

6. The vacuum cleaner as set forth in claim 1 further comprising a main filter assembly for filtering contaminants from the airflow discharged form the secondary cyclone.

7. The vacuum cleaner as set forth in claim 6, the main filter assembly comprising a selectively permeable material, and the main filter assembly is located on an upper portion of the secondary cyclone.

8. The vacuum cleaner as set forth in claim 1 further comprising:

a final filter assembly connected in fluid communication with the suction source outlet and adapted for filtering the airflow exhausted by the suction source prior to the airflow being dispersed into the atmosphere, wherein the final filter assembly comprises a high efficiency particulate arrest (HEPA) filter medium.

9. A vacuum cleaner comprising:

a dust collector comprising, a primary cyclone for separating contaminants from an airflow; and at least one secondary cyclone for separating contaminants entrained in the airflow discharged from the primary cyclone;

a cleaner body comprising a socket for holding selectively the dust collector;

a suction source located in the cleaner body for generating a cyclonic flow of the airflow in the dust collector; and

a selectively removable main filter assembly located in the dust collector for filtering contaminant from the airflow prior to the airflow flowing into the suction source.

10. The vacuum cleaner as set forth in claim 9, wherein the primary cyclone is integrated with the secondary cyclone.

11. The vacuum cleaner as set forth in claim 10, wherein the dust collector is at least partially transparent.

12. An upright vacuum cleaner comprising:

a dust collector comprising a primary cyclone and at least one secondary cyclone for separating contaminants from an airflow;

a cleaner body including a socket for holding selectively the dust collector;

a nozzle section pivotably connected the cleaner body and including a suction opening;

an agitator positioned in the nozzle section for contacting and scrubbing the surface being cleaned;

a suction source located below the dust collector for generating a cyclonic flow of the airflow in the dust collector, the suction source include an suction source inlet and an suction source outlet;

a belt for transferring the rotational force of the suction source to the agitator;

a first conduit for fludically connecting the suction opening to a primary airflow inlet of the primary cyclone; and

a second conduit for fludically connecting a secondary airflow outlet to the suction source inlet.

13. The upright vacuum cleaner as set forth in claim 12 further comprising a flow passage guide for guiding the airflow discharged from the primary cyclone to a secondary airflow inlet of the secondary cyclone.

14. The upright vacuum cleaner as set forth in claim 13, whereby upon activation of the suction source, contaminants from a surface being cleaned are entrained in the airflow, the airflow travels:

(a) from the cleaner body into the primary cyclone through the primary airflow inlet;

(b) downwardly from the primary airflow inlet and in a cyclonic fashion within the primary cyclone so that the entrained contaminants are separated from the suction airflow;

(c) from the primary cyclone into the secondary cyclone with passing through the flow passage guide;

(d) downwardly from the secondary airflow inlet and in a cyclonic fashion within the secondary cyclone so that contaminants are separated from the airflow flowing into the secondary cyclone; and

(e) from the secondary cyclone into the suction source with passing through the second conduit.

15. The upright vacuum cleaner as set forth in claim 14, wherein the secondary cyclone is disposed around the primary cyclone.

16. The upright vacuum cleaner as set forth in claim 14, wherein the primary airflow inlet is horizontally oriented and arranged so that the airflow entering the primary cyclone through the primary airflow inlet moves cyclonically within the primary cyclone.

17. The upright vacuum cleaner as set forth in claim 12 further comprising an agitator brush provided at an outer circumference of the agitator.

18. An upright vacuum cleaner comprising:

a nozzle section;

a rotating brush assembly disposed in the nozzle section;

a primary cyclone for separating contaminants from an airflow, the primary cyclone being in fluid communication with the nozzle section;

at least one secondary cyclone for separating contaminants entrained in the airflow discharged from the primary cyclone;

a dust collecting container comprising: a primary dust storing part for storing contaminants separated in the primary cyclone; and a secondary dust storing part for storing contaminants separated in the secondary cyclone

a sealing member for sealing airtightly the primary dust storing part and the secondary dust storing part

a suction source for generating the airflow; and

a selectively removable main filter assembly located on upper portion of the secondary cyclone for filtering contaminants from the airflow prior to the airflow flowing into the suction source.

19. The upright vacuum cleaner as set forth in claim 18 further comprising a conduit interconnecting the secondary cyclone with the suction source.

20. The upright vacuum cleaner as set forth in claim 18 further comprising a final filter assembly connected in fluid communication with the suction source and adapted for filtering the airflow exhausted by the suction source prior to the airflow being dispersed into the atmosphere, wherein the final filter assembly comprises a high efficiency particulate arrest (HEPA) filter medium.