Vacuum cleaner with reusable filter

[0001] 1. Field of the Invention

[0002] The present invention relates to a vacuum cleaner, and more particularly, to a vacuum cleaner having a cyclone dust collecting apparatus for separating and collecting contaminants from contaminant-laden air with a centrifugal force that is formed by generating an air vortex and a secondary filter that is removably positioned in the cleaner and can be cleaned and reused.

[0003] 2. Description of the Prior Art

[0004] U.S. Pat. No. 6,195,835 assigned to the same assignee as the present application discloses a vacuum cleaner having a cyclone dust collecting apparatus.

[0005] FIGS. 1 and 2 schematically show the structure of the vacuum cleaner having the cyclone dust collecting apparatus of U.S. Pat. No. 6,195,835.

[0006] As shown in FIG. 1, generally, a vacuum cleaner having a cyclone dust collecting apparatus includes a cleaner body 1, a suction port 2 and a cyclone dust collecting apparatus 10 disposed between the cleaner body 1 and an extension pipe 3 that is connected to the suction port 2.

[0007] The cleaner body 1 has a dust collecting chamber 5, in which a paper filter 4 is generally disposed, and a motor chamber (not shown). A lid 6 is movably disposed on the upper portion of the dust collecting chamber 5 to be pivoted open and closed. The extension pipe 3 is connected to a handle grip 7 and a flexible hose 8. One end of the flexible hose 8 is connected to lid 6.

[0008] As shown in FIG. 2, a cyclone dust collecting apparatus 10 includes a cyclone body 20, a dust receptacle 30 and a grill assembly 40. The cyclone body 20 includes a first connection pipe 21 connected to a suction port extension pipe 3a, a second connection pipe 22 connected to the cleaner body extension pipe 3b, an air inflow port 23 interconnected with the first connection pipe 21, and an air outflow port 24 interconnected with the second connection pipe 22. In the cyclone body 20, the contaminant-laden air is drawn in through the air inflow port 23, forming a whirling current.

[0009] The dust receptacle 30 is removably connected to the cyclone body 20, and receives the contaminants separated from the air by the centrifugal force of the whirling air current or airstream in the cyclone body 20.

[0010] The grill assembly 40 is disposed at the air outflow port 24 of the cyclone body 20, to prevent a reverse flow of the collected contaminants through the air outflow port 24. The grill assembly 40 includes a grill body 41, a plurality of fine holes 42 formed in an outer circumference of the grill body 41 to form a passage to the air outflow port 24, and a contaminant reversal preventing plate 43 of conical shape formed at the lower end of the grill body 41.

[0011] In the general vacuum cleaner having the cyclone dust collecting apparatus constructed as described above, the contaminant-laden air is drawn in by a suction force that is generated at the suction port 2 of the vacuum cleaner, into the cyclone body 20 in a tangential direction through the first connection pipe 21 and the air inflow port 23. The drawn air flows downward in the cyclone body 20, forming a vortex air current (indicated by solid-lined arrows of FIG. 2). In this process, contaminants are separated from the air by the centrifugal force of the vortex air hitting the grill, and collected in the dust receptacle 30.

[0012] As the air current reaches the bottom of the dust receptacle 30, the air flows in a reverse direction, i.e., it flows upward in the cyclone body 20. The air then flows through the fine holes 42 of the grill assembly 40, the air outflow port 24 and the second connection pipe 22, and then is discharged into the cleaner body 1 (indicated by a dot-lined arrow of FIG. 2). Some contaminants, floating in the upwardly moving air current, will be redirected by the contaminant reversal preventing plate 43 and thus reflected into the vortex air current. And some contaminants, which are still entrained in the upwardly moving air current after the contaminant reversal preventing plate 43, are filtered out at the fine holes 42 of the grill assembly 40 as the air flows through the fine holes 42, and the filtered contaminants are flown into the vortex air current.

[0013] Any remaining contaminants, which have not been removed even after the fine holes 42, are discharged through the fine holes 42 and the air outflow port 24. These remaining contaminants are then filtered out by a secondary filter, paper filter 4 of the cleaner body 1, while the clean air is discharged outside the vacuum cleaner via the motor chamber (not shown).

[0014] According to the general vacuum cleaner having the cyclone dust collecting apparatus, since the contaminants of the contaminant-laden air drawn in through the suction port 2 are filtered by the cyclone dust collecting apparatus 10 disposed at the extension pipe 3, the amount of contaminants that the paper filter 4 at the dust collecting chamber 5 is reduced. Accordingly, the useful life of the paper filter 4 is extended. Even so, paper filter 4 is a consumable item in that the user still has to pay for replacement paper filters which are discarded after use.

[0015] Further, the general vacuum cleaner having the cyclone dust collecting apparatus has a dust collecting chamber which takes a considerable space of the cleaner body. Accordingly, the cleaner body becomes bulky and heavy, causing inconvenience to the user.

[0016] The present invention has been made to overcome the above-mentioned problems of the related art. Accordingly, it is an object of the present invention to provide a vacuum cleaner having a reusable dust collecting filter, that is, a washable dust collecting filter, and therefore is capable of reducing costs for a repair or maintenance of the cleaner.

[0017] Another object of the present invention is to provide a vacuum cleaner that achieves a compact size and light weight, by employing a compact-sized cassette type dust collecting filter, and thus reducing a space occupied by a dust collecting chamber.

[0018] The above objects are accomplished by a vacuum cleaner according to the present invention, including: a compact cleaner body having a relatively small dust collecting chamber and a motor chamber interconnected with the dust collecting chamber; a suction port connected to the cleaner body via an extension pipe; and a cyclone dust collecting apparatus connected to the extension pipe for separating and collecting contaminants from contaminant-laden air by a centrifugal force, and for generating a vortex of air from which the centrifugal force is generated. The inventive vacuum cleaner includes an integrated a dust collecting filter cassette removably disposed in the dust collecting chamber of the cleaner body for separating and collecting contaminants which pass through the cyclone dust collecting apparatus. The dust collecting filter is constructed to be reusable by removing the filter and then cleaning it of collected contaminants. The dust collecting filter cassette includes a locking mechanism for locking the dust collecting filter in a mounting position in the dust collecting chamber of the cleaner body. The locking mechanism includes guide grooves formed downward along two opposing sidewalls of the dust collecting chamber; semi-cylindrical key recesses formed on respective ends of the guiding grooves; and semi-cylindrical keys formed on two opposing sides of the handle, for being inserted along the guide grooves and connected to the semi-cylindrical key recesses.

[0019] The dust collecting filter also includes a filter housing having a filter screen and a dust collecting space; a filter cover movably dispose on the filter housing to pivot open and close the dust collecting space of the filter housing; and a handle pivotally supported on two opposing sides of the filter cover. The filter cover comprises an observation window through which a user can check the state of collection of the contaminants.

[0020] The above-mentioned objects and the feature of the present invention will be more apparent by describing the-preferred embodiment of the present invention by referring to the appended drawings, in which:

[0021] FIG. 1 is a perspective view of a conventional vacuum cleaner;

[0022] FIG. 2 is a sectional view showing the cyclone dust collecting apparatus of the vacuum cleaner of FIG. 1;

[0023] FIG. 3 is a perspective view of a vacuum cleaner according to a preferred embodiment of the present invention;

[0024] FIG. 4 is a sectional view showing a dust collecting filter being mounted in the body of the vacuum cleaner of FIG. 3;

[0025] FIG. 5 is a perspective view showing the dust collecting filter shown with the cover in an is opened position;

[0026] FIG. 6 is a perspective view showing the locking mechanism for mounting and locking the dust collecting filter into an operative position; and

[0027] FIG. 7 is a detailed view of the key and recess structure of the locking mechanism of FIG. 6.

[0028] As shown in FIGS. 3 and 4, a vacuum cleaner according to the present invention includes a cleaner body 1, a suction port 2, a cyclone dust collecting apparatus 10 and a dust collecting filter 300.

[0029] The cleaner body 1 includes a dust collecting chamber 100 at an upstream end and a motor chamber 200 at a downstream end. For convenience of description, the location of elements will be described with respect to the one-directional airstream or suction force. For example, the dust collecting chamber 100 is upstream of the motor chamber 200 so chamber 100 could be referred to as being in front of motor chamber 200. Dust collecting chamber 100 is defined by a front wall 110 and a rear wall 120 which have apertures 111 and 121 provided therein respectively. Dust collecting filter 300 is removably disposed in the dust collecting chamber 100, and a motor 400 is disposed in the motor chamber 200. The structure of the cleaner body 1 is similar to the structure of the conventional vacuum cleaner, however, as shown in FIG. 3, the cleaner body 1 according to the present invention is much smaller than the conventional cleaner (see FIG. 1) due to the reduced size of dust collecting chamber 100. Due to the compact-sized dust collecting chamber 100, the cleaner body 1 is also compact and light-weight, and accordingly, the use and handling of the cleaner is more convenient, particularly for tasks that require lifting and moving body 1.

[0030] The suction port 2 is connected to the cleaner body 1. The extension pipe 3 is connected a handle grip 7 and a flexible hose 8. One end of the flexible hose 8 is connected to aperture 111 in a wall 110 of the cleaner body I. As the motor 400 is driven, a strong suction airstream is generated at the cleaning head or suction port 2 via flexible hose 8 and extension pipe 3.

[0031] As described earlier in the description of the related art, the cyclone dust collecting apparatus 10 is disposed adjacent extension pipe 3, and the contaminants in the contaminant-laden air drawn in through the suction port 2 are first filtered out at the cyclone dust collecting apparatus 10. The construction and operation of the cyclone dust collecting apparatus 10 is similar to conventional cyclone dust collecting apparatus.

[0032] In cleaner body 1, a removable dust collecting filter 300 is disposed in the dust collecting chamber 100 to separate and collect any contaminants which have not been separated and collected by the cyclone dust collecting apparatus 10. According to the present invention, a reusable cassette type dust collecting filter 300 is advantageous because after the collected contaminants are removed the filter 300 can be cleaned and returned to its position in the dust collecting chamber 100 for reuse.

[0033] As shown in FIGS. 4 through 7, the dust collecting cassette filter 300 includes a filter housing 310, a filter cover 320 and a handle 330. The filter housing 310 has a filter 311 at its downstream side and a dust collecting space 312 in front of filter 311. In other words, filter 311 is attached to the rear wall of the dust collecting space 312. A filter cover 320 is movably hinged to the filter housing 310 by a hinge 321 to pivot between an open or closed position relative to dust collecting space 312 of the filter housing 310. When closed, cover 320 covers space 312 and is substantially parallel to and upstream of filter 311. Cassette filter 300 is configured to be inserted into dust collecting chamber 100 with cover 320 in the closed position. Filter cover 320 has an intake aperture 322 aligned and in communication with aperture 111 in the front wall 110 of the dust collecting chamber 100 when cassette filter 300 is assembled into its operating position. Accordingly, after the air is discharged from the cyclone dust collecting apparatus 10, the air flows into the dust collecting space 312 of the dust collecting filter 300 via aperture 110 and intake aperture 322, where any remaining contaminants are filtered out by filter 311 and the resulting clean air is discharged outside of the cleaner body 1 via the motor chamber 200. Filter cover 320 can also have an observation window 323 through which the user can check the amount of collected contaminants in dust collecting space 312.

[0034] Cassette filter 300 has a handle 330 which is movably supported on both sides of the filter cover 320 in a pivotable manner. Handle 330 can be pivoted between an assembly position when dust collecting filter 300 is being mounted in or removed from dust collecting chamber 100, and a locked, operative position when the cassette filter 300 is mounted in dust collecting chamber 100.

[0035] To enable reuse of the cassette filter after washing, mounting and removing dust collecting filter 300 must be convenient, while ensuring that dust collecting filter 300 remain in place when it is mounted in dust collecting chamber 100 in its operative position. To accomplish this, the vacuum cleaner according to the present invention includes a locking mechanism 500 which not only enables easy removal of dust collecting filter 300, but also securely locks dust collecting filter 300 in the operative position in dust collecting chamber 100.

[0036] As best seen in FIGS. 6-7, the locking mechanism 500 includes guide grooves 510 formed along opposing sidewalls of dust collecting chamber 100, semi-cylindrical key recesses 520 formed at the distal ends of the guiding grooves 510, and mating semi-cylindrical keys 530 formed on opposing sides of handle 330. The keys 530 are configured to be matingly received in recesses 520 via grooves 510 when cassette filter 300 is inserted into place in body 1. To mount cassette filter 300, the handle 330 of the dust collecting filter 300 is positioned in an upright manner so that semi-cylindrical keys 530 of the handle 330 are inserted in guide grooves 510 of dust collecting chamber 100 with keys 530 positioned longitudinally in grooves 510. When cassette filter 300 is fully inserted, keys 530 would have reached key recesses 520 at the terminus of grooves 510. Key recesses 520 are configured to enable keys 530 to rotate 90 to a lateral position.

[0037] To lock the cassette filter in place, handle 330 is pivoted so as to rotate semi-cylindrical keys 530 90 so that at least a portion of the diametrical surfaces of keys 530 abut against at least a portion of the walls of the key recesses. To remove dust collecting filter 300 from the dust collecting chamber 100, as handle 330 is pivoted back to an upright position, the semi-cylindrical keys 530 rotate so as to clear any abutment walls of key recesses 520 to thereby unlock the keys and allow movement in grooves 510. Accordingly, dust collecting filter 300 can be removed from chamber 100.

[0038] It will be understood that the locking mechanism may be embodied in a variety of structures and configurations. Any structure which provides for mating elements which can be moved relative to one another to provide a releaseable configuration in a first position and a locked configuration in a second position may be used for the locking mechanism. Guide grooves or the like may be provided to facilitate the assembly and locking operation.

[0039] Although this invention has been described in the context of a canister type of vacuum cleaner with a cyclone dust collecting device, the filter cassette of the present invention is not limited to this environment. The inventive filter cassette could be used in a variety of cleaning apparatus including upright vacuum cleaners, wet vacuum cleaner, and the like. The filter cassette could also serve as the sole filter for a vacuum, and is not necessarily limited to functioning as a second filter that is downstream of a cyclone dust collecting device as presently described.

[0040] In operation, when motor 400 of the vacuum cleaner according to the present invention is driven, negative pressure produced in dust collecting chamber 100 causes a strong suction force at the suction port 2 of the vacuum cleaner via hose 8 and extension pipe 3. As a result, contaminant-laden air is drawn through the suction port 2 to cyclone dust collecting apparatus 10. First, the contaminant-laden air is drawn into the cyclone body 20 in a tangential direction through the first connection pipe 21 and the inflow port 23, forming a vortex air current moving downward the dust receptacle 30. The centrifugal force of the vortex air separates the contaminants from the air, and the separated contaminants are received in the dust receptacle 30.

[0041] When the air current reaches the bottom of dust receptacle 30, the contaminant-laden air is discharged to the cleaner body 1 through the fine holes 42 of the grill assembly 40, the outflow port 24 and the second connection pipe 22. At this time, some contaminants floating in the upwardly moving air in the dust receptacle 30 are reflected against the dust reversal preventing plate 43 into the vortex current. The contaminants, still remaining in the upwardly moving air after the dust reversal preventing plate 43, are entrained in the air and thus discharged through the fine holes 42 of the grill assembly 40 in the air. At this time, any contaminants larger than the fine holes 42 are filtered out at the fine holes 42, and accordingly, the filtered contaminants are returned to the vortex air.

[0042] Meanwhile, any contaminants still entrained in the air even after passing the fine holes 42, are discharged through the outflow port 24 through the fine holes 42 of the grill assembly 40, and filtered at a secondary filter in the cleaner body. A reusable dust collecting filter 300 is mounted in dust collecting chamber 100 of cleaner body 1 for this purpose. The resulting clean air after filtering through the secondary filter is discharged outside the cleaner, via the motor chamber 200.

[0043] When dust collecting filter 300 becomes full of contaminants, it can be removed from dust collecting chamber 100, the contaminants cleaned away by washing, agitation or other means, and back into dust collecting chamber 100. The user can also monitor the amount of collecting contaminants in dust collecting filter 300 through observation window 323.

[0044] As described above, according to the present invention, since the reusable cassette type dust collecting filter 300 is employed, there is no need for a consumable filter such as paper filters which must be discarded. As a result, costs for maintenance of the vacuum cleaner are greatly reduced. Moreover, since nothing is discarded, use of the inventive vacuum cleaner will have a positive environmental impact. In addition, according to the present invention, since the reusable dust collecting filter 300 can be made smaller than a paper filter or bag, the size of the dust collecting chamber 100 of the cleaner body 1 is reduced. As a result, the cleaner body can be more compactly-sized and light-weight making it more convenient to use and handle the vacuum cleaner.

[0045] Although the preferred embodiment of the present invention has been described, it will be understood by those skilled in the art that the present invention should not be limited to the described preferred embodiment, but various changes and modifications can be made within the spirit and scope of the present invention as defined by the appended claims.