SOUND DAMPENING PASSAGE AND SURFACE CLEANING APPARATUS WITH SAME
A surface cleaning apparatus is disclosed. The surface cleaning apparatus comprises a fluid flow path extending from a dirty fluid inlet to a clean air outlet and including a suction motor. At least one cleaning stage is positioned in the fluid flow path. The suction motor is positioned in a housing of the surface cleaning apparatus and upstream of the clean air outlet. A sound dampening passage is provided downstream from the suction motor and in fluid flow communication with the clean air outlet. At least a portion of the sound dampening passage comprises a first layer of a sound reflecting material and an inner layer of sound absorbing material. Such a passage is useable in other household apparatus that have an air exit.
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The application claims priority from U.S. Provisional Patent Application 60/869,586 (filed on Dec. 12, 2006), which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTIONThe invention relates to a surface cleaning apparatus and to sound dampening passages downstream from fluid flow motors. In a particularly preferred embodiment, the invention relates to a surface cleaning apparatus that has a sound dampening passage that comprises an outer sound reflecting material and an inner sound absorbing material.
BACKGROUND OF THE INVENTIONVarious types of surface cleaning apparatuses are known in the art. Such apparatuses include vacuum cleaners such as upright vacuum cleaners, hand or strap carryable vacuum cleaners, wet-dry vacuum cleaners, and carpet extractors, amongst others. These apparatuses typically include at least one suction or fluid flow motor. Generally, the motor produces a significant amount of noise, which can be uncomfortable to a user. For example, many full size vacuum cleaner use a 10A-13A motor.
In some vacuum cleaner, it is known to place a filter, such as a HEPA filter downstream from the suction motor. The filter is provided to collect fine particulate matter that is in the air stream that exits the vacuum cleaner, such as carbon dust. More recently, plastic housings of varying design have been suggested to surround a suction motor of a vacuum cleaner, so as to function as a sound shield. These designs add weight to the vacuum cleaner and provide an additional wall between the suction motor and the exterior of the vacuum cleaner.
SUMMARY OF THE INVENTIONIn one broad aspect, a surface cleaning apparatus is provided. The surface cleaning apparatus comprises a fluid flow path extending from a dirty fluid inlet to a clean air outlet and including a suction motor. At least one cleaning stage is positioned in the fluid flow path. The suction motor is positioned in a housing of the surface cleaning apparatus and upstream of the clean air outlet. A sound dampening passage is provided downstream from the suction motor and in fluid flow communication with the clean air outlet. At least a portion of the sound dampening passage comprises a first layer of a sound reflecting material and an inner layer of sound absorbing material.
Embodiments in accordance with this broad aspect are advantageous because the sound dampening passage may reduce the amount of sound exiting the clean air outlet. Accordingly, a user may perceive the surface cleaning apparatus to be less noisy, and therefore the surface cleaning apparatus may be more comfortable and acceptable.
In some embodiments, the passage comprises at least a pair of opposed walls wherein each wall comprises a first layer of a sound reflecting material and an inner layer of sound absorbing material.
In some embodiments, the sound reflecting material is selected from plastic and metal. In some embodiments, the sound absorbing material is selected from foam, rubber, silicone, a member having pockets filled will one of air or fluid and combinations thereof.
In some embodiments, the sound dampening passage comprises a longitudinally extending conduit interior of the housing having continuous sidewalls.
In some embodiments, the sound dampening passage is positioned exterior to the housing downstream of the clean air outlet. In further embodiments, the sound dampening passage extends between an outer wall of the surface cleaning apparatus and a sound dampening panel mounted to the surface cleaning apparatus and the sound dampening panel comprises a first outer layer of a sound reflecting material and the inner layer of sound absorbing material. In some embodiments, the sound dampening panel is removably mounted to the surface cleaning apparatus. Such embodiments may be advantageous because a user may remove the sound dampening panel in order to clean out the clean air outlet or a post motor filter provided therein.
In some embodiments, the sound dampening passage extends at an angle to a direction of airflow entering the sound dampening passage. In further embodiments, the angle is greater than 15°. In further embodiments, the angle is about 90°.
In some embodiments, the sound dampening passage extends linearly. In some embodiments, the sound dampening passage has at least a curved section. For example, it may be helical, e.g., extending around part or all of the outer circumference of the surface cleaning apparatus.
In some embodiments, the sound dampening passage has a cross sectional area transverse to its longitudinal extent that decreases in a downstream direction. In other embodiments, the sound dampening passage has a cross sectional area transverse to its longitudinal extent that increases in a downstream direction. For example, if the passage is circular in cross section, the diameter may increase or decrease in the downstream direction. Alternately, in some embodiments, the cross section may remain generally constant.
In another broad aspect, a sound dampening passage positionable downstream from a fluid flow motor is provided. The sound dampening passage comprises at least a pair of opposed walls. Each wall comprises a first layer of a sound reflecting material and at least one, and preferably each opposed wall, is provided with an inner layer of sound absorbing material.
In some embodiments, the sound reflecting material is selected from plastic and metal. In some embodiments, the sound absorbing material is selected from foam, rubber, silicone, a member having pockets filled will one of air or fluid and combinations thereof.
In some embodiments, the sound dampening passage comprises a longitudinally extending conduit interior of a housing of the fluid flow motor having continuous sidewalls.
In some embodiments, the sound dampening passage is positioned exterior to a housing of the fluid flow motor and downstream of an air outlet of the housing.
In some embodiments, the sound dampening passage extends between an outer wall of the housing and a sound dampening panel spaced from the housing and the sound dampening panel comprises the first layer of a sound reflecting material and the inner layer of sound absorbing material.
In some embodiments, the sound dampening panel is removably mounted.
In some embodiments, the sound dampening passage extends at an angle to a direction of airflow entering the sound dampening passage. In some embodiments, the angle is greater than 15°. In further embodiments, the angle is about 90°.
In some embodiments, the sound dampening passage extends linearly. In some embodiments, the sound dampening passage has at least a curved section.
In some embodiments, the sound dampening passage has a cross sectional area transverse to its longitudinal extent that decreases in a downstream direction. In other embodiments, the sound dampening passage has a cross sectional area transverse to its longitudinal extent that increases in a downstream direction.
These and other advantages of the present invention will be more fully and particularly understood in connection with the following description of the preferred embodiments of the invention in which:
The sound dampening passage is useable in various household appliances and tools wherein air is expelled from the apparatus. In accordance with the resent invention, the air is drawn past a fluid flow motor and then travels through a passage to the ambient. Part, and preferably all, of the passage is constructed as disclosed herein. The passage of the air through the passage reduces the noise level perceived by a user of the apparatus. Preferably, the passage is used in a surface cleaning apparatus. Any surface cleaning apparatus or any configuration may be used. The upright vacuum cleaners shown in
As shown in
The fluid flow path comprises a suction motor 20, and at least one cleaning stage 22. Fluid from dirty fluid inlet 12 is directed to the at least one cleaning stage 22. In the exemplified embodiments, an upflow duct 24 is mounted between surface cleaning head 16 and cleaning stage 22 for providing fluid communication therebetween. In alternate embodiments, wherein surface cleaning apparatus 10 is, e.g., a hand-carryable vacuum cleaner, an upflow duct may not be provided, and the dirty fluid inlet may be in direct fluid communication with the cleaning stage. In the embodiment shown, fluid passes directly from dirty fluid inlet 12 to cleaning stage 22 via upflow duct 24. In alternate embodiments, other components may be positioned between dirty fluid inlet 12 and cleaning stage 22; for example one or more filter assemblies.
It will be appreciated that any filtration or cleaning stage or stages known in the art may be used. Preferably, the surface cleaning apparatus includes at least one cyclonic cleaning stage. For example, referring to
A dirt chamber 34 is positioned below cleaning stage 22. Dirt chamber 34 is in fluid communication with dirt outlet 30, and collects dirt and/or fluid removed from air in cyclone chamber 26. Preferably, dirt chamber 34 is openable such that dirt collected therein may be emptied. For example, in the embodiment shown in
Referring back to
In the embodiment shown, air exits air outlet 32 and is directed into optional filter assembly 42. Filter assembly 42 may comprise a filter 44 housed in a filter housing 46 (see
It will be appreciated that more than one cyclonic cleaning stage may be used. For example two cyclonic cleaning stages wherein each stage comprises a single cyclone or two or more cyclones in parallel may be used.
Referring to
As shown by arrows A1, air that enters motor housing 48, is directed past or through motor 20, and out of motor housing outlet 50. A sound dampening passage 52 is provided downstream from motor 20. Sound dampening passage 52 serves to reduce the amount of noise that is generated by motor 20 that exits clean air outlet 14 and is perceived by a user. Sound dampening passage 52 is constructed such that, as sound waves pass through the passage, they bounce or reflect between walls of the passage, and are dampened by the walls, thereby reducing the decibel level of the sound produced by the surface cleaning apparatus. Accordingly, at least a portion of passage 52 comprises a first layer of sound reflecting material 54, and an inner layer of sound absorbing material 56.
In the embodiments shown, passage 52 is provided downstream of clean air outlet 14. As exemplified, clean air outlet comprises a grill 50 on the outer surface of motor housing 48 and provides fluid communication between motor housing outlet 50 and outlet 15 of the sound dampening passage 52. In other embodiments, passage 52 may be provided within the surface cleaning apparatus, such as within motor housing 48, downstream from motor 20 and upstream from clean air outlet 14. For example, the air may travel past motor 20 and then be directed in a passage internal of the surface cleaning apparatus towards a clean air outlet that may be located distal to motor 20. In further embodiments, more than one passage 52 may be provided. For example, as shown in
In the embodiments shown, clean air outlet 14 is directly adjacent to passage 52 and may optionally comprise part or all of motor housing 48. In alternate embodiments, another member may be provided between motor housing outlet 50 and passage 52. For example, a post-motor filter housed in a housing may be provided adjacent or as part of clean air outlet 14, and passage 52 may be downstream from the post motor filter.
In the embodiment of
In the embodiments shown, wall 58a is provided as a sound dampening panel 59 which is mounted to motor housing 48 via one or more posts 61 that are received in a mount 61a (see
In use, sound, exemplified by stippled arrows A2, exits motor housing outlet 50, and enters passage 52. Some of the sound will contact sound absorbing material 56 of wall 58a, and be absorbed. Some of the sound will pass through sound absorbing material 56, contact sound reflecting material 54 of wall 58a, and be reflected back into passage 52. This portion of the sound will contact wall 58b, and again be reflected back into passage 52, and into sound absorbing material 56 of wall 58a. Accordingly, while the sound passes through passage 52, it will reflect back and forth between walls 58a and 58b, and will be absorbed. Accordingly, the sound exiting outlet 15 will be dampened. Accordingly, as the sound passes though passage 52, sound that is not absorbed by sound absorbing material 56 will be reflected back into passage 52 by the sound reflecting material 54. This process will continue until the air exits passage 52. Passage 52 may be of any desired length. Preferably, the length is selected to reduce the sound to a desired decibel level. It will be appreciated that some of the sound may pass through the sound reflecting material 54 (e.g., if it is plastic having standard wall thicknesses used for vacuum cleaners). The sound reflecting material may be honeycombed to assist is further reducing sound transmission through the sound reflecting material.
It will be appreciated that if the inner wall 58b of the passage 52 is provided with sound absorbing material. It may be the same as the sound absorbing material on panel 59 or different. Preferably the layer of sound absorbing material extends continuously across each of walls 58a, 58b. It will be appreciated that a layer of sound absorbing material may also be provided on the outer surface of panel 59.
In the embodiment of
In some embodiments, rather than a pair of opposed walls, passage 52 may comprise a longitudinally extending conduit. The longitudinally extending conduit may be, for example, cylindrical or rectangular. Accordingly, passage 52 may have an inlet end in flow communication with motor 20 and a distal outlet 15. In such embodiments, passage 52 may be provided interior of motor housing 48, or exterior of motor housing 48 and internal of the surface cleaning apparatus or exterior of the surface cleaning apparatus. In some such embodiments, the passage 52 may comprise a single cylindrical layer of sound reflecting material, and a single cylindrical layer of sound absorbing material positioned inwardly thereof. In other such embodiments, the passage may comprise a single cylindrical layer of sound reflecting material, and a single layer of sound absorbing material extending along only half of the conduit, for example in a half-pipe shape. In this embodiment, the sound waves will reflect back and forth across the diameter of passage 52, and will be absorbed as they pass through passage 52. Accordingly, all walls of passage 52 may be lined with the sound absorbing material or only part of the walls may be so lined. For example, if the transverse cross section of passage 52 is square, there will be a pair of opposed walls, each of which may be so lined. If only part is so lined, it is preferred that the part that is lined is positioned on the outward side of the passage 52. For example, a portion of the passage 52 that faces in toward the appliance (e.g., wall 58b that has motor 20 on the other side thereof need not be so lined.
Preferably, in some of the above embodiments such as that exemplified in
For example, in the embodiments shown, passage 52 curves around a portion of the outer surface of the upright section of the vacuum cleaner and also defining a curved path extending horizontally, and extends vertically along axis 62 (
In some embodiments, passage 52 may be a linearly extending conduit having continuous sidewalls. In other embodiments, it may be a spiral or helically extending conduit having continuous sidewalls.
Alternately, or in addition, in some embodiments, the sound dampening passage has a cross sectional area transverse to its longitudinal extent that decreases in a downstream direction (see for example,
In some embodiments, as previously mentioned, more than one sound dampening passage may be associated with motor 20. For example, as shown in
In the above embodiments, the sound reflecting material may be selected from a variety of materials. For example, the sound reflecting material may be a plastic, such as ABS (acrylonitrile butadiene styrene), polycarbonate, or polyproplyene. Any hard plastic may be used. Alternatively or in addition, the sound reflecting material may be a metal, such as aluminum or steel. In some embodiments, more than one reflecting material may be selected. For example, the sound reflecting portion of wall 58a may be a metal, and the sound reflecting portion of wall 58b may be a plastic.
Additionally, the sound absorbing material 56 may be selected from a variety of materials. For example, the in some embodiments, the sound absorbing material 56 may be a foam, a rubber, or a silicone. In alternate embodiments, the sound reflecting material may comprise pockets filled with a gas or a fluid. For example, the sound reflecting material may be a bubble-wrap like material. Preferably, a soft material is used.
While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.
Claims
1. A surface cleaning apparatus comprising:
- (a) a fluid flow path extending from a dirty fluid inlet to a clean air outlet of including a suction motor;
- (b) at least one cleaning stage positioned in the fluid flow path;
- (c) the suction motor positioned in a housing of the surface cleaning apparatus and upstream of the clean air outlet; and,
- (d) a sound dampening passage downstream from the suction motor and in fluid flow communication with the clean air outlet wherein at least a portion of the sound dampening passage comprises a first layer of a sound reflecting material and an inner layer of sound absorbing material.
2. The surface cleaning apparatus of claim 1 wherein the passage comprises at least a pair of opposed walls wherein each wall comprises a first layer of a sound reflecting material and an inner layer of sound absorbing material.
3. The surface cleaning apparatus of claim 1 wherein the sound reflecting material is selected from plastic and metal.
4. The surface cleaning apparatus of claim 1 wherein the sound absorbing material is selected from foam, rubber, silicone, a member having pockets filled will one of air or fluid and combinations thereof.
5. The surface cleaning apparatus of claim 1 wherein the sound dampening passage comprises a longitudinally extending conduit interior of the housing, the longitudinally extending conduit having continuous sidewalls.
6. The surface cleaning apparatus of claim 1 wherein the sound dampening passage is positioned exterior to the housing downstream of the clean air outlet.
7. The surface cleaning apparatus of claim 6 wherein the sound dampening passage comprises an outer wall of the surface cleaning apparatus and a sound dampening panel mounted to the surface cleaning apparatus and the sound dampening panel comprises the first layer of the sound reflecting material and the inner layer of sound absorbing material.
8. The surface cleaning apparatus of claim 6 wherein the sound dampening panel is removably mounted to the surface cleaning apparatus.
9. The surface cleaning apparatus of claim 1 wherein the sound dampening passage extends at an angle to a direction of airflow entering the sound dampening passage.
10. The surface cleaning apparatus of claim 9 wherein the angle is greater than 15°.
11. The surface cleaning apparatus of claim 9 wherein the angle is about 90°.
12. The surface cleaning apparatus of claim 1 wherein the sound dampening passage extends linearly.
13. The surface cleaning apparatus of claim 1 wherein the sound dampening passage has at least a curved section.
14. The surface cleaning apparatus of claim 1 wherein the sound dampening passage has a cross sectional area transverse to its longitudinal extent that decreases in a downstream direction.
15. The surface cleaning apparatus of claim 1 wherein the sound dampening passage has a cross sectional area transverse to its longitudinal extent that increases in a downstream direction.
16. A sound dampening passage positionable downstream from a fluid flow motor comprising at least a pair of opposed walls wherein each wall comprises a first layer of a sound reflecting material and at least one wall has an inner layer of sound absorbing material.
17. The sound dampening passage of claim 16 wherein the sound reflecting material is selected from plastic and metal.
18. The sound dampening passage of claim 16 wherein the sound absorbing material is selected from foam, rubber, silicone, a member having pockets filled will one of air or fluid and combinations thereof.
19. The sound dampening passage of claim 16 wherein the sound dampening passage comprises a longitudinally extending conduit interior of a housing of the fluid flow motor having continuous sidewalls.
20. The sound dampening passage of claim 16 wherein the sound dampening passage is positioned exterior to a housing of the fluid flow motor and downstream of an air outlet of the housing.
21. The sound dampening passage of claim 20 wherein the sound dampening passage comprises an outer wall of the housing and a sound dampening panel spaced from the housing and the sound dampening panel comprises the first layer of a sound reflecting material and the inner layer of sound absorbing material.
22. The sound dampening passage of claim 21 wherein the sound dampening panel is removably mounted.
23. The sound dampening passage of claim 16 wherein the sound dampening passage extends at an angle to a direction of airflow entering the sound dampening passage.
24. The sound dampening passage of claim 23 wherein the angle is greater than 15°.
25. The sound dampening passage of claim 23 wherein the angle is about 90°.
26. The sound dampening passage of claim 16 wherein the sound dampening passage extends linearly.
27. The sound dampening passage of claim 16 wherein the sound dampening passage has at least a curved section.
28. The sound dampening passage of claim 16 wherein the sound dampening passage has a cross sectional area transverse to its longitudinal extent that decreases in a downstream direction.
29. The sound dampening passage of claim 16 wherein the sound dampening passage has a cross sectional area transverse to its longitudinal extent that increases in a downstream direction.
30. The sound dampening passage of claim 16 wherein each opposed wall is provided with the inner layer of sound absorbing material.
Type: Application
Filed: Dec 12, 2007
Publication Date: Jul 31, 2008
Applicant: G.B.D. CORP. (Nassau)
Inventor: Wayne Ernest Conrad (Hampton)
Application Number: 11/954,300
International Classification: F01N 1/08 (20060101);