Airflow shut-off mechanism for vacuum cleaner

[0002] This application is a continuation-in-part of U.S. patent application Ser. No. 09/759,409, filed Jan. 12, 2001.

[0003] This invention relates to vacuum cleaners. More particularly, it relates to an airflow shut-off mechanism for a vacuum cleaner that is convertible for on-the-floor and above-the-floor vacuuming operations.

[0004] One way of increasing the amount of suction power available at a distal end of a suction airflow pathway (such as at a floor nozzle, or at an above-the-floor cleaning tool) for a given source of suction power is to reduce the length of the suction airflow pathway.

[0005] In the case of vacuum cleaners having a single source of suction power and multiple (e.g. two) suction airflow pathways (such as vacuum cleaners that are convertible between on-the-floor and above-the-floor cleaning operations), a further way of increasing the amount of suction power available at the distal end of an airflow pathway being used (e.g. from an above-the-floor cleaning tool) is to shut-off the suction airflow through the unused pathway (e.g. from the floor nozzle).

[0006] It is known to pivot a dirt passage door around a horizontal axis extending generally lateral across a vacuum cleaner floor nozzle to shut-off suction airflow through a floor nozzle airflow passage. However, such a pivoting arrangement limits the ability to reduce the length of the suction airflow pathway.

[0007] Accordingly, it is considered desirable to develop a new and improved vacuum cleaner having a airflow shut-off mechanism that meets the above-stated needs and overcomes the foregoing difficulties and others while providing better and more advantageous results.

[0008] One aspect of the present invention relates to a floor nozzle for a vacuum cleaner including a brushroll chamber having an outlet aperture; and an airflow shut-off mechanism including an airflow passage that communicates with the outlet aperture and that extends away from the brushroll chamber at an angle in the range of about 50° to about 75° relative to a surface to be vacuumed.

[0009] Another floor nozzle arrangement according to the present invention includes a housing, a nozzle inlet defined in the housing, and an airflow passage extending from the nozzle inlet through a wall of the housing, wherein the airflow passage has an axis oriented at an angle of about 50°-75° in relation to a plane of the nozzle inlet.

[0010] Still another floor nozzle arrangement of the present invention includes a brushroll chamber having an outlet aperture, and includes an airflow shut-off mechanism having a housing with a airflow passage therethrough. A first end of the airflow passage communicates with the outlet aperture and a second end of the airflow passage communicates with an associated discharge duct. A door is connected to the housing for pivotal movement within the airflow passage. The door has an arcuate surface that conforms substantially to a contour of the airflow passage in a door open position, and the door substantially blocks the airflow passage in a door closed position.

[0011] Another aspect of the present invention relates to a vacuum cleaner including a floor nozzle having an inlet opening, a first airflow passage extending in the floor nozzle from a first end communicating with the inlet opening to a second end located at a periphery of the floor nozzle; an upper assembly mounted on said floor nozzle; and a second airflow passage extending in said upper assembly and communicating with the second end of the first airflow passage, wherein the second airflow passage is positioned along a leading edge of upper assembly.

[0012] Yet another vacuum cleaner arrangement according to the present invention includes an upper assembly, and a floor nozzle pivotally connected to the upper assembly. The floor nozzle includes a brushroll chamber and a dirty airflow shutoff mechanism. The brushroll chamber includes an outlet aperture, and the dirty air shut-off mechanism includes a housing with a airflow passage therethrough wherein a first end of the airflow passage communicates with the outlet aperture and a second end of the airflow passage communicates with a discharge duct leading to the upper assembly. The dirty air shut-off mechanism further includes a door connected to the housing for pivotal movement within the airflow passage wherein the door has an arcuate surface that conforms substantially to a contour of the airflow passage in a door open position and the door substantially blocks airflow through the passage in a door closed position.

[0013] The invention may take physical form in certain parts and arrangements of parts, preferred embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:

[0014] FIG. 1 is a perspective view from the left front of a vacuum cleaner according to the present invention;

[0015] FIG. 2 is a perspective view from the left rear of the vacuum cleaner of FIG. 1;

[0016] FIG. 3 is a perspective view from the right front of a floor nozzle base of the vacuum cleaner of FIG. 1;

[0017] FIG. 4 is a perspective view from the right rear of the floor nozzle base of FIG. 3 showing a airflow shut-off mechanism (and a floor nozzle cover in phantom);

[0018] FIG. 5 is perspective view from the rear right of the floor nozzle base of FIG. 3 with a door passage cover of the airflow shut-off mechanism removed;

[0019] FIG. 6 is an enlarged exploded view, partially broken away, of the airflow mechanism of FIG. 4;

[0020] FIG. 7 is an enlarged perspective view, partially broken away, of the airflow shut-off mechanism of FIG. 5 with a dirt passage door thereof partially closed;

[0021] FIG. 8 is a cross-section view taken along the line 8—8 of the airflow shut-off mechanism of FIG. 7;

[0022] FIG. 9 is a front elevation view of a vacuum cleaner according to a second embodiment of the present invention;

[0023] FIG. 10 is a central section view of a wheeled floor nozzle and a lower portion of an upper assembly taken along the line 10—10 of FIG. 9;

[0024] FIG. 11 is an enlarged central section view of the wheeled floor nozzle of FIG. 10 with a dirt passage door in a closed position;

[0025] FIG. 12 is a perspective view of a dirt passage housing;

[0026] FIG. 13 is an enlarged central section view of the wheeled floor nozzle of FIG. 10 with the dirt passage door in an open position; and

[0027] FIG. 14 is a longitudinal section view of the vacuum cleaner taken along the line 14—14 of FIG. 10.

[0028] Referring now to the drawings, wherein the showings are for purposes of illustrating preferred embodiments of the invention only and not for purposes of limiting same, there is shown a particular type of upright vacuum cleaner in which the subject airflow motor shut-off mechanism is embodied. While the airflow motor shut-off mechanism can be employed in this type of vacuum cleaner, it should be appreciated that it can be used in other types of vacuum cleaners as well.

[0029] More particularly, FIGS. 1 and 2 illustrate an upright vacuum cleaner A including a wheeled floor nozzle 2 and an upper assembly 4. The nozzle base 2 and the upper assembly 4 are preferably formed from conventional materials such as molded plastics and the like. As described further below, the upper assembly 4 is hingedly or pivotally secured to the floor nozzle 2 through opposing trunnions 7 (FIG. 8) extending from a motor housing 40 associated with the upper assembly 4.

[0030] The upper assembly 4 includes a lower handle portion 6, an upper handle portion 8 and a hand grip 10. The lower handle portion 6 is generally wishbone or U-shaped, and includes a pair of legs which define between them an opening 12. A motor/final filter assembly 14 is positioned within the opening 12, and is secured to the lower handle portion 6. A dirt cup assembly 18 is also positioned within the opening 12 above the motor/final filter assembly 14, and is removable from the upper assembly 4.

[0031] A cap 20 is pivotally mounted to the lower handle portion 6 above the dirt cup assembly 18. The cap 20 defines a portion of a latch assembly that cooperates with a catch frame (not shown) to secure the dirt cup assembly 18 to the upper assembly 4, as described and illustrated in the Assignee's copending U.S. patent application Ser. No. 09/758,725, the disclosure of which is hereby incorporated by reference. Further, the cap 20 includes at least one indentation on an upper surface thereof, which indentation is shaped to accommodate an associated cleaning tool of the vacuum cleaner.

[0032] The dirt cup assembly 18 includes i) a dirt cup 22, ii) a tubular or cylindrical primary filter assembly (not shown) removably positioned within the dirt cup 22, and iii) a lid 24 removably covering an open upper end of the dirt cup 22, as described and illustrated in the Assignee's copending U.S. patent application Ser. No. 09/758,834, the disclosure of which is hereby incorporated by reference. The primary filter assembly can be formed from any washable (e.g. reusable) or disposable filter medium such as a polytetrafluoroethylene (PTFE) material, a high-density polyethylene-based, open-celled, porous material, etc.

[0033] Briefly, the dirt cup 22 includes a central dust/debris collection or separation chamber 26, a forward dirty-air conduit or inlet duct 28, and a rear dirty-air conduit or inlet duct 30 circumferentially spaced from the forward inlet duct 28 by about 120°. A side wall defining the dirt cup 22 cooperates with the centrally-positioned primary filter assembly to define an annular, cyclonic airflow passage within separation chamber 26. A handle 32 extends from the dirt cup 22 at a position substantially opposite (i.e. about 180°) from the forward inlet duct 28.

[0034] The motor/final filter assembly 14 includes i) a motor housing 40 having a suction motor/fan assembly mounted approximately upright within the housing 40 such that a motor output shaft extends generally parallel to a central longitudinal axis of the upper assembly 4, ii) a final filter housing 42 positioned above and mounted to the motor housing 40, iii) a final or exhaust filter (e.g. HEPA) (not shown) removably positioned within the filter housing 42, and iv) a filter housing lid (not shown) removably covering the filter housing 42, as described and illustrated in the Assignee's copending U.S. patent application Ser. No. 09/759,437, the disclosure of which is hereby incorporated by reference.

[0035] With continued reference to FIGS. 1 and 2, and particular reference to FIG. 3, the floor nozzle 2 includes a base 50 and a cover 52. The floor nozzle further includes a brushroll chamber or cavity 54 that extends laterally along a front portion of the nozzle base and opens downwardly to form a nozzle inlet 56. The brushroll chamber 54 is adapted to receive and support a rotatable agitator or brushroll 58. The brushroll 58 is driven by a dedicated brushroll motor/drive belt assembly 59.

[0036] An aperture 60 extends through a rear wall 62 of the brushroll chamber 54. The aperture 60 is substantially centered between two side walls 64, 66 that define the lateral extent of brushroll chamber 54. Thus, the aperture 60 is substantially centered on a center line 68 of the floor nozzle 2. It should be appreciated that, with the aperture 60 substantially centered along the floor nozzle center line 68, a substantially even (i.e. symmetrical) amount of suction air flow can be drawn from each side of the nozzle inlet 56.

[0037] Referring now to FIG. 4, a airflow shut-off mechanism 70 is positioned rearward of the brushroll chamber rear wall 62 and aperture 60. A discharge duct 72, such as a conventional flexible, expandable, helical wire-type hose, communicates with and extends from the airflow shut-off mechanism 70 to an upper extent of a forward passageway 74 (FIG. 1) associated with the final filter housing 42. Thus, when the dirt cup assembly 18 is mounted to the vacuum cleaner, the forward inlet duct 28 is in fluid communication with the brushroll chamber 54 through the flexible hose 72 to establish a dirty airflow pathway for suction air that is drawn by a source of suction power (e.g. fan/motor assembly within motor housing 40) through the brushroll chamber 54 from the nozzle inlet 56.

[0038] Likewise, as shown in FIG. 2, when the dirt cup assembly 18 is mounted to the vacuum cleaner, the dirt cup rear inlet duct 30 is in fluid communication with an above-the-floor cleaning wand 76 through a connector 78 associated with the final filter housing 42 and a depending flexible hose 80 connected thereto.

[0039] A distal end of the wand 76 is retained in a storage cup 82 associated with the upper assembly 4. The storage cup 82 has a generally closed end (i.e. bottom) wall. Thus, when the vacuum cleaner is energized and the wand 76 is positioned within the storage cup 82, the suction airflow through the hose 80 causes the wand 76 to be drawn against the storage cup end wall to, in effect, block or otherwise prevent a substantial suction airstream from flowing through the above-the-floor dirty airflow pathway during on-the-floor cleaning operations. Of course, the wand 76 can be removed from the storage cup 82 during operation of the vacuum cleaner against the suction force generated by the motor/fan assembly to perform above-the-floor cleaning operations.

[0040] It should be appreciated that, with the dirt cup assembly 18 mounted to the vacuum cleaner, the dirt cup inlet duct 28 is positioned forward of the lower handle portion 6, and the dirt cup inlet duct 30 is positioned rearward of the lower handle portion 6. This, in effect, minimizes the lengths of the dirty airflow pathways between the dust collection chamber 26 and the brushroll chamber 54, and between the dust collection chamber 26 and an above-the-floor cleaning tool secured to the wand 76, respectively.

[0041] Referring now to FIGS. 5 and 6, the airflow shut-off mechanism 70 includes a dirt passage cover 90, a dirt passage door 92, a link arm 94, a generally L-shaped lever arm 96, a coiled spring 98, and a normally-on, micro-switch assembly 100.

[0042] The dirt passage cover 90 includes an approximately upright opening 102 adapted to engage (e.g. threadably, frictionally, adhesively) with a forward end of the discharge hose 72. The dirt passage cover 90 is secured, such as by screws, etc., to a corresponding upright wall or rib 104 formed integral with the nozzle base 50. The dirt passage cover 90 and wall 104 cooperate to define a dirt passage cavity 105. An elastomeric gasket or seal can be positioned between the cover 90 and the upright wall 104 to insure a fluid-tight seal therebetween. The brushroll chamber aperture 60 defines an inlet of the dirt passage cavity 105, and the upright opening 102 of the cover 90 defines an outlet of the dirt passage cavity 105.

[0043] The upright wall 104 includes an arcuate wall portion 106 that cooperates with an upstanding rib 108 projecting from the nozzle base 50 within the cavity 105, and with a recess 110 of the dirt passage cover 90 to pivotally support the dirt passage door 92 in an approximately upright orientation within the dirt passage cavity 105. A notch 111 is formed in the upstanding rib 108.

[0044] The dirt passage door 92 extends from an upright pin 112, which pin pivots about an approximately vertical or upright axis 113. A control arm 114 extends from an upper extent of the pivot pin 112 in a direction generally opposite to that of the dirt passage door 92. A U-shaped notch or hook member 116 is formed integral with the pivot pin 112 proximate the control arm 114. A reduced diameter, notched portion 118 forms a lower extent of the upright pivot pin 112.

[0045] The coil spring 98 includes a intermediate coiled portion 120, a first arm 122 projecting radially outward from the coiled portion 120, and a second arm 124 projecting radially inward from the coiled portion 120. The spring coiled portion 120 surrounds the pivot pin reduced diameter portion 118 with the spring second arm 124 positioned within the notch of the pin reduced diameter portion 118 so that the spring second arm 124 moves (i.e. rotates) along with the pivot pin 112. The spring first arm 122 is positioned within the notch 111 of rib 108 to anchor or otherwise prevent movement of the spring first arm 122 relative to the pivot pin 112. As a result, the coil spring 98 biases the dirt passage door 92 in an open position within the dirt passage cavity 105 as shown in FIG. 5.

[0046] The lever 96 includes a shorter arm 130 and a longer arm 132 extending at an obtuse angle (e.g. about 120°) from the shorter arm 130. A pair of trunnions 134 project in opposing directions from a juncture of the arms 130, 132. A free end of the longer arm 132 includes a notch or hook 136 therein. The lever 96 is pivotally secured to the nozzle base 50. More particularly, the lever 96 is pivotally supported by a clip arrangement 140 formed integral with the nozzle base 50. The clip arrangement 140 includes a cantilevered center clip 142 and opposing L-shaped flanges 144, 146 positioned on either side of the center clip 142. When the lever trunnions 134 are positioned under the L-shaped flanges 144, 146, the clip 142 urges the lever 96 and trunnions 134 upward into abutting contact with the flanges 144, 146.

[0047] The control link 94 includes a first hook-shaped end portion 150 that engages with the notch 136 associated with the longer lever arm 132. Likewise, a second hook-shaped end portion 152 of the control link 94 engages with the notch 116 associated with the upright pivot pin 112 of the dirt passage door 92.

[0048] The normally-on micro-switch assembly 100 electrically controls the operation of the brushroll motor 59. The switch assembly 100 includes a spring-biased contact element, plunger, button, or switch 154. The switch assembly 100 is positioned in a manner that permits the pivot pin control arm 114 to operatively engage the element 154 to shut-off the brushroll motor 59.

[0049] As best shown in FIGS. 1 and 8, the upper assembly 4, and more particularly, the motor housing 40 includes a forwardly projecting nub 160 that is positioned to contact an upper surface of the shorter lever arm 130 when the upper assembly 4 is pivoted into a fully forward position relative to the floor nozzle 2. In addition, the nozzle base 50 includes upright bearing surfaces 162 that mutually conform to and rotatably support the upper assembly trunnions 7 so that the upper assembly 4 can pivot about a generally horizontal axis 164 relative to the floor nozzle 2.

[0050] During on-the-floor cleaning operations utilizing the nozzle base 2, the upper assembly 4 is pivoted rearward relative to the nozzle base 2. As a result, i) the motor housing nub 160 does not contact the shorter lever arm 130, ii) a spring force generated by the spring 98 urges the dirt passage door 92 to pivot rearward around the upright axis 113 into an open position with the dirt passage cavity 105 as shown in FIG. 5, and iii) the control arm 114 does not engage the micro-switch element 154, thus the normally-on micro-switch 100 permits the brushroll motor 59 to operate.

[0051] Accordingly, dirty airflow is drawn by the motor/fan assembly within motor housing 40 along a generally straight, and hence, short, path from the brushroll chamber 54 through aperture 60, dirt passage cavity 105, opening 102, discharge duct 72, upper portion of passageway 74, dirt cup inlet duct 28, and into the cyclonic airflow passage within the dirt cup separation chamber 26.

[0052] It should also be appreciated that, by positioning the dirt cup inlet duct 28 along the vacuum cleaner center line 68 and forward of the lower handle portion 16, the length of the dirty airflow path from the brushroll chamber 54 to the dirt cup dust collection chamber 26 can be minimized, thus providing increased suction power in the brushroll chamber 54. In other words, the length of the dirty airflow pathway from the brushroll chamber 54 to the dirt cup dust collection chamber 26 can be minimized by completely positioning the dirty airflow pathway forward of the pivot axis 164 of the upper assembly 4. In addition, when the dirt passage door 92 is pivoted into the open position about upright axis 113, the door enables a free flow of suction air through the discharge duct 72, rather than block the duct 72 as would occur if the door was to pivot upward about a horizontal axis as in the prior art.

[0053] The dirty air flow drawn from the inlet duct 28 is diverted to a tangential path within the separation chamber 26 resulting in a cyclonic or vortex-type flow that spirals downward within the separation chamber 26. The cyclonic action separates a substantial portion of the entrained dust and dirt when the suction airstream is drawn radially inward through the primary filter assembly. The dust and dirt is deposited in the dirt cup 22. Thereafter, the suction airstream is drawn axially downward through a central suction duct of the final filter housing 42 and a motor/fan assembly within the motor housing 40, before being redirected back up through an annular exhaust flow passageway surrounding the motor/fan assembly and into an exhaust plenum of the final filter housing 42. Thereafter, the suction airstream is discharged radially outwardly through the final filter assembly, as described and illustrated more fully in the Assignee's copending U.S. patent application Ser. No. 09/759,437.

[0054] Referring now to FIGS. 7 and 8, during above-the-floor cleaning operations utilizing the wand 76 and depending hose 80, the upper assembly 4 is pivoted fully forward relative to the nozzle base 2. As a result, i) the motor housing nub 160 contacts the shorter lever arm 130 and drives it downward, ii) the longer lever arm 132 and depending control link 94 are driven rearward, iii) the dirt passage door 92 is rotated forward about upright axis 113 into abutting contact with the aperture 60 against the biasing force of the spring 98, and iv) the pivot pin control arm 114 is rotated into operative engagement with the micro-switch element 154, thus shutting off the brushroll motor 59.

[0055] It should be appreciated that stopping or otherwise blocking the flow of suction air through the discharge duct 72 during above-the-floor cleaning operations results in diverting more suction air to the above-the-floor cleaning tool. Thus, dirty air flows from the cleaning tool/wand arrangement 76 and depending hose 80, through the dirt cup inlet duct 30, and into the dirt cup separation chamber 26. As mentioned above, positioning the dirt cup inlet duct 30 slightly rearward of the lower handle portion 6 minimizes the length of the dirty airflow path from an above-the-floor cleaning tool to the dirt cup separation chamber 26 to provide increased suction power at the cleaning tool. As with an on-the-floor cleaning operation, dirty air flow from the inlet duct 30 is diverted to a tangential path within the separation chamber to cause a cyclonic or vortex-type airflow that follows the same pathway through the dirt cup 22, filter housing 42, and motor housing 40 as described above.

[0056] An alternative airflow shut-off arrangement is shown in FIGS. 9-14, where reference numerals offset by a factor of 200 are used to denote the same or similar components of the vacuum cleaner described and illustrated in FIGS. 1-8. Referring now to FIG. 9, an upright vacuum cleaner B includes a wheeled floor nozzle 202 and an upper assembly 204 that is hingedly or pivotally secured to the floor nozzle 202 through opposing trunnions (e.g. trunnions 7, FIG. 8) extending from a motor housing 240 (FIG. 10) associated with the upper assembly 204.

[0057] The upper assembly 204 includes an upper handle portion 208 and a lower handle portion 206 that is generally wishbone or U-shaped and includes a pair of legs which define between them an opening 212. A motor/final filter assembly 214 is at least partially positioned within the opening 212. A dirt cup assembly 218 is also positioned at least partially within the opening 212 above the motor/final filter assembly 214, and is removable from the motor/final filter assembly 214 and upper assembly 204.

[0058] As best shown in FIG. 10, the dirt cup assembly 218 includes a central dust/debris collection or separation chamber 226, a forward dirty-air conduit or inlet duct 228, a rear dirty-air conduit or inlet duct (e.g. inlet duct 30, FIG. 2) circumferentially spaced from the forward inlet duct 228, and a tubular or cylindrical primary filter assembly 366 removably positioned within the chamber 226 such that an annular, cyclonic airflow passage 368 is defined within separation chamber 226.

[0059] The motor/final filter assembly 214 includes i) the motor housing 240 having a suction motor/fan assembly 370 mounted approximately upright within the housing 240 such that a motor output shaft extends generally parallel to a central longitudinal axis of the upper assembly 204, ii) a final filter housing 242 positioned above and mounted to the motor housing 240, iii) a final or exhaust filter (e.g. HEPA) 372 removably positioned within the filter housing 242, and iv) a filter housing lid 374 removably covering the filter housing 242.

[0060] With continued reference to FIG. 10, the floor nozzle 202 includes a base 250 and a cover 252. The floor nozzle further includes a brushroll chamber or cavity 254 that extends laterally along a front portion of the nozzle base and that opens downward to form a nozzle inlet 256. The brushroll chamber 254 is adapted to receive and support a rotatable agitator or brushroll 258. The brushroll 258 is driven by a dedicated brushroll motor/drive belt assembly (e.g. motor 59, FIG. 4) mounted within the floor nozzle 202. In the embodiment being described, a user-operated switch 375 (FIG. 9) is positioned on the upper handle assembly 208 and electrically controls the operation of the brushroll motor (e.g. motor 59).

[0061] Referring now to FIG. 11, the brushroll chamber 254 is further defined by a rear wall 262 and an upper arcuate wall 376 that joins to an upper end of the rear wall 262. An upper portion of the rear wall 262 and a rearward portion of the upper wall 376 are both notched, recessed, cut-out, relieved, etc. to define an aperture 260 that extends through portions of both the rear wall 262 and the upper wall 376. In contrast, the aperture 60 extends only through the rear wall 62 of the vacuum cleaner A as shown in, for example, FIG. 3.

[0062] Further, the aperture 260 is substantially centered between the two side walls that define the lateral extent of brushroll chamber 254. Thus, the aperture 260 is substantially centered on a center line 268 (FIG. 9) of the vacuum cleaner B. It should be appreciated that, with the aperture 260 substantially centered along the center line 268, a substantially even (i.e. symmetrical) amount of suction air flow can be drawn from each side of the nozzle inlet 256.

[0063] With continued reference to FIG. 11, a airflow shut-off mechanism 270 communicates with the brushroll chamber aperture 260 from a position generally rearward and above the brushroll chamber 254. A discharge duct 272, such as a conventional flexible, expandable, helical wire-type hose, communicates with and extends from the airflow shut-off mechanism 270 to an upper extent of a forward passageway 274 (FIG. 10) associated with the final filter housing 242. Thus, when the dirt cup assembly 218 is mounted to the vacuum cleaner B, the dirt cup forward inlet duct 228 is in selective fluid communication with the brushroll chamber 254 through the flexible hose 272 and the shut-off mechanism 270 to establish a substantially straight dirty airflow pathway for suction air that is drawn by a source of suction power (e.g. fan/motor assembly 370) through the brushroll chamber 254 from the nozzle inlet 256 and then along a leading or forward edge of the upper assembly 204 to the dirt cup separation chamber 226.

[0064] With reference now to FIG. 12, in the embodiment being described, the airflow shut-off mechanism 270 includes a generally-tubular housing 380 that is secured, such as by screws, etc., to the floor nozzle base 250. The housing 380 includes an inner side wall 382 that defines a cylindrical dirty air flow passage 384 through the housing 380. A housing first end 386 is generally L-shaped and mates with the brushroll chamber rear wall 262 and upper wall 376. A housing second end 388 is generally circular and engages (e.g. threadably, frictionally, adhesively) with a forward end of the discharge hose 272.

[0065] A dirt passage door 292 is pivotally mounted within the dirty air flow passage 384. More particularly, the dirt passage door 292 extends from an integral pin 312 that pivots about an approximately horizontal axis 313. A cover 390 is secured to the housing 380 and retains the pin 312. As best shown in FIG. 13, an inner surface of the cover 390 is recessed or otherwise contoured to accommodate the dirt passage door 292 when the dirt passage door is pivoted into engagement with the cover 390 in a “door open” position.

[0066] Referring again to FIG. 12, the dirt passage door 292 includes a concave or arcuate surface 392 which conforms to the shape of, or is otherwise flush with, the cylindrical dirty air flow passage 384 when the door 292 is in the door open position. Thus, in the door open position, the dirty air flow passage 384 retains a substantially cylindrical shape along a central longitudinal axis 394 of the housing to minimize the chances of becoming blocked, and to maintain maximum suction air flow through the housing 380.

[0067] A hook member 316 is formed at a first end of the pin 312, and a notch 318 is formed at a second end of the pin. A link arm 294 includes a first end 352 secured to the hook member 316, and a second end 350 secured to a generally L-shaped lever 296 that is pivotally secured to the nozzle base 250. A coil spring 298 encompasses the second end of pin 312 such that an arm 324 of the spring is positioned within the notch 318 to bias the door 292 in the door open position. As with the vacuum cleaner A, the motor housing 240 includes a forwardly projecting nub (e.g. 160, FIG. 8) that is positioned to contact the lever 296 when the upper assembly 204 is pivoted into a fully forward position relative to the floor nozzle 202.

[0068] During on-the-floor cleaning operations utilizing the nozzle base 202, the upper assembly 204 is pivoted rearward relative to the nozzle base 202. As a result, the motor housing nub does not contact the lever 296. Thus, the spring force generated by the spring 298 urges the dirt passage door 292 to pivot upward around the axis 313 into the “door open” position within the dirty air flow passage 384. If desired, the user may activate the brushroll 258 by depressing the on/off switch 375. Accordingly, dirty airflow is drawn by the motor/fan assembly 340 within motor housing 240 along a substantially straight dirty air flow pathway from the brushroll chamber 254 through aperture 260 and dirty air flow passage 384, and then through the discharge duct 272, upper portion of passageway 274, and dirt cup inlet duct 228 along the leading edge of the upper assembly 204, and then into the cyclonic airflow passage 368 within the dirt cup separation chamber 226.

[0069] Referring again to FIG. 13, when the housing 380 is secured to the nozzle base 250, the dirty air flow passage 384 communicates with the aperture 260 and extends upward and rearward therefrom. More particularly, the housing longitudinal axis 394 extends at an angle α in the range of about 50° to about 75° relative to a floor surface, and more preferably in the range of about 60° to about 65°. The discharge duct 272 extends at varying angles from the housing longitudinal axis 394 depending upon the position of the upper assembly 204 relative to the floor nozzle 202.

[0070] For instance, when the upper assembly 204 is positioned in a fully-forward position relative to the floor nozzle 202 during above-the-floor cleaning operations, such as shown in FIG. 10, the discharge duct 272 extends at an angle β of about 35° relative to the housing longitudinal axis 394. However, when the upper assembly 204 is released from the floor nozzle 202 and pivoted rearward during on-the-floor cleaning operations, such as shown in FIG. 14, the discharge duct 272 extends at an angle λ that varies in a range of about 0° to about 20° relative to the housing longitudinal axis 394 (depending upon the position of the floor nozzle 202 relative to the user). It should be appreciated that such a slight bend in the discharge duct 272 (i.e. less than about 20° relative to the housing longitudinal axis 394) provides a substantially straight dirty air flow pathway along the leading edge of the upper assembly 204 that does not impede the flow of suction air therethrough.

[0071] High suction power through the dirty air flow pathway is achieved and maintained during on-the-floor cleaning operations by i) minimizing the length of the dirty air flow pathway, and ii) maintaining a substantially constant diameter of the dirty air flow pathway. The length of the dirty air flow pathway is minimized by i) maintaining a substantially straight dirty air flow pathway from the brushroll chamber 254 to the dirt cup separation chamber 226, ii) locating the dirty air flow pathway along a leading edge of the upper assembly 206 forward of the lower handle portion legs 206, and iii) centering the dirty air flow pathway in a widthwise manner along the upper assembly leading edge. The diameter of the dirty air flow pathway is maintained substantially constant by i) providing a dirty air flow passage 384 with the substantially the same diameter as the discharge duct 272, and ii) providing the dirt passage door 292 with a curved surface 392 to conform with the dirty air passage 384.

[0072] As with vacuum cleaner A, dirty air flow drawn from the inlet duct 228 is diverted to a tangential path within the separation chamber 226 resulting in a cyclonic or vortex-type flow that spirals downward within the separation chamber 226. Thereafter, the suction airstream is drawn axially downward through a central suction duct of the final filter housing 242 and through the motor/fan assembly 370 within the motor housing 240, before being redirected back up through an annular exhaust flow passageway surrounding the motor/fan assembly and into an exhaust plenum of the final filter housing 242. Thereafter, the suction airstream is discharged radially outwardly through the final filter assembly 372.

[0073] Referring now to FIG. 10, during above-the-floor cleaning operations, the upper assembly 204 is pivoted fully forward relative to the nozzle base 202. As a result, i) the motor housing nub contacts the lever 296 and pivots it rearward, which drives the depending control link 294 rearward and rotates the dirt passage door 292 downward about axis 313 to block air flow through the dirty air passage 384 and the dirty air flow pathway. Stopping or otherwise blocking the flow of suction air through the discharge duct 272 during above-the-floor cleaning operations results in diverting more suction air to the above-the-floor cleaning tool.

[0074] The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of this specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.