Replacement head for vacuum cleaner

Abstract

A replacement head for a vacuum cleaner, the replacement head for a vacuum device comprising a plastic tray, a filter and a gasket. The plastic tray includes a dust collection chamber and an opening that permits air, dust and debris to be drawn into the dust collection chamber during use. The gasket is attached to the underside of the plastic tray and contacts the floor during cleaning. The filter is connected to the plastic tray such that the filter substantially covers a top opening in the dust collection chamber. The filter is preferably made of a nonwoven material having a basis weight between about 20 and 70 gsm and having a thickness of less than about 1.0 mm.

Description

Technical Field

[0001] The present disclosure generally relates to replacement heads for cleaning devices, and more particularly, to replacement heads for certain vacuum devices. Background Art

[0002] Cleaning hard floors can be challenging when there are multiple types of mixed media debris. In some cases, it is necessary to vacuum dry loose debris, wipe stuck debris, and absorb any wet debris that may be present. Existing technology tools such as vacuum cleaners, dry mops, and wet mops can handle some of these types of media, but not all at once. Therefore, many people typically vacuum dry debris and then mop wet or stuck debris.

[0003] The setup time of known tools that can handle dry and wet media is higher than that of a broom / mop combination, and when it comes to liquids, post-use maintenance can be particularly laborious. If the combination tool is not properly cleaned after each use, the tool may smell and be uncomfortable. Finally, the cleaning work can be messy and may require the user to get their hands dirty and / or wear gloves.

[0004] Therefore, there is a need for an improved hard floor cleaner that can be easily attached to and detached from a vacuum device, and is not laborious or messy. Summary of the Invention

[0005] According to one aspect of the present invention, the replacement head includes a filter, a plastic tray, and a gasket. The plastic tray includes a dust collection chamber and a top opening defined by a sealing surface. The dust collection chamber also has a bottom wall, a front wall, a rear wall, a left wall, and a right wall. The bottom wall of the dust collection chamber defines an external bottom surface. The opening extends through at least one of the walls (preferably the front wall) into the dust collection chamber. The gasket includes at least one layer of material and defines a first surface and a second surface. The first surface is connected to the bottom wall of the plastic tray, and the second surface faces generally away from the first surface. The filter is connected to the plastic tray such that the filter substantially covers the top opening. The filter is substantially made of non-woven material, has a thickness of less than about 1.5 mm, and includes an unsupported area between about 50 square centimeters and 125 square centimeters over the top opening.

[0006] According to another aspect of the present invention, the filter has a thickness of less than about 1 mm.

[0007] According to another aspect of the present invention, the filter material has at least two holes to allow air to pass through, and the holes have an area of less than about 1.5 square millimeters.

[0008] According to yet another aspect of the present invention, there is provided a replacement head, comprising: a plastic tray including a dust collection chamber defining a top opening bounded by a sealing surface, the dust collection chamber further having a bottom wall, a front wall, a rear wall, a left wall and a right wall, the bottom wall of the dust collection chamber defining an external bottom surface; an opening extending through at least one of the walls into the dust collection chamber; a gasket having at least one layer of material, the gasket defining a first surface and a second surface, the first surface being connected to the bottom wall of the plastic tray, and the second surface generally facing away from the first surface; and a filter connected to the plastic tray such that the filter substantially covers the top opening, wherein the filter is substantially made of a non-woven material, is less than about 1.0 mm thick, and includes an unsupported area between about 50 square millimeters and 110 square millimeters over the top opening; and wherein the filter is located behind an internal space defined by a front protective portion.

[0009] Preferably, the filter is made of a material having a basis weight between about 20 and 70 gsm.

[0010] Preferably, the basis weight of the filter material is between about 30 and 50 gsm.

[0011] Preferably, the basis weight of the filter material is approximately 40 gsm.

[0012] Preferably, the filter material has at least two holes, each hole having an area of less than about 1.5 square millimeters.

[0013] Preferably, each hole has an area of less than about 1.0 square millimeters.

[0014] Preferably, at least one hole is in an oval shape.

[0015] Preferably, the filter is positioned above the top opening such that the filter material is substantially flat.

[0016] Preferably, the filter is positioned above the top opening such that the filter material includes at least one fold so that it generally forms a pleated portion.

[0017] Preferably, the area of the top opening covered by the filter is about 100 square millimeters to 115 square millimeters.

[0018] Preferably, the area of the top opening covered by the filter is about 105 square millimeters to 110 square millimeters.

[0019] An advantage of the present invention is that the user can easily remove the dirty replacement head and replace it with a new one in a short time with little mess. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Isometric view showing the vacuum device and the replacement head of the present invention;

[0021] Figure 2 Showing separated from each other Figure 1 Isometric view of the vacuum device and the replacement head;

[0022] Figure 3 Showing Figure 1 Cross-sectional view along line 3-3 showing the attached vacuum head and the replacement head, where the connector arm is in the locked position;

[0023] Figure 3A Showing Figure 1 Cross-sectional view along line 3A-3A showing the attached vacuum head and the replacement head, where the connector arm is in the open position;

[0024] Figure 4 Isometric view showing the replacement head of the present invention;

[0025] Figure 5 Showing the replacement head at different angles Figure 4 Isometric view of the replacement head;

[0026] Figure 6 Isometric view showing the plastic tray of the present invention;

[0027] Figure 7 Front view showing the plastic tray of the present invention;

[0028] Figure 8 Rear view showing the plastic tray of the present invention;

[0029] Figure 9 Side view showing the plastic tray of the present invention;

[0030] Figure 10 Bottom view showing the plastic tray of the present invention;

[0031] Figure 11 Top view showing the plastic tray of the present invention;

[0032] Figure 12 Showing Figure 4 Cross-sectional view along line 12-12 depicting the open lid in the closed position;

[0033] Figure 12A Showing Figure 4 Cross-sectional view along line 12A-12A depicting the open lid in the open position;

[0034] Figure 13 Enlarged front view of one side of the replacement head;

[0035] Figure 14 shows Figure 4 A cross-sectional view taken along line 14-14, depicting the shape of the first connector lip;

[0036] Figure 15 shows Figure 1 A cross-sectional view taken along line 15-15, depicting the interaction between the vacuum head and the front guard of the plastic tray; and

[0037] Figure 16 Shows an exploded view of an embodiment of the gasket of the present invention. Detailed Description

[0038] Figure 1 and Figure 2 shows a perspective view of the vacuum device 2 and the replacement head 3, which can be selectively attached and detached. The vacuum device 2 includes a handle 6, a vacuum body 8 including a suction source (not visible), a vacuum head 10, and a trigger 11 for selectively activating the suction source. The vacuum device 2 may also include a container for holding a fluid (such as a cleaning fluid), a jet nozzle 12, and a user-actuated button 14 for selectively ejecting the fluid from the jet nozzle 12. Preferably, the jet nozzle 12 is designed to eject fluid from the jet nozzle 12 to a position in front of the replacement head 4 when actuated by the user-actuated button 14 during normal use. Now refer to Figure 3 and 3A , the vacuum head 10 includes a vacuum sealing surface 16 and at least two connector arms 18, 20. In the illustrated embodiment, at least one connector arm 18 can move between a closed position ( Figure 3 ) and an open position ( Figure 3A ).

[0039] Now refer to Figures 4 to 6 , the replacement head 4 includes a plastic tray 22, a gasket 24, and a filter 26. The plastic tray 22 includes a dust collection chamber 28, a sealing surface 30 (see, for example, Figure 6 ) and a front guard portion 40.

[0040] The plastic tray 22 can be made of any suitable material (including non-plastic); however, a material that is inexpensive and easy to dispose of is preferred. For example, polyethylene terephthalate (or "PET") is considered a preferred material, in part because PET is inexpensive and can be easily thermoformed into the desired shape. Injection molding, blow molding, or any other common manufacturing process is also an acceptable alternative. As shown, the plastic tray 22 can be formed from a single integral piece, or can be composed of two or more components that are connected or joined during the assembly of the replacement head 4.

[0041] As Figures 6 to 12The plastic tray 22 shown includes a dust collection chamber 28 sized and shaped to collect and retain dust and debris sucked into the plastic tray 22 during use. In the illustrated embodiment, the dust collection chamber 28 has a bottom wall 34, a front wall 36, a rear wall 38, a left wall 40, and a right wall 42. At the top of the dust collection chamber 28 is a top opening 46. The walls and the top opening 46 together generally define a volume of space capable of collecting and retaining common household dust and debris. Those skilled in the art will understand that changing the size and shape of the walls and the top opening 46 will increase or decrease the total volume of the dust collection chamber without departing from the spirit of the invention. Although the rear wall 38 and the left and right walls 40 and 42 are shown in Figure 9 and Figure 10 as being generally straight, the walls may include at least one curve or bend, or include other features that make them non-straight. For example, as Figure 10 shown, the front wall 36 includes a series of curves and features. Curves and bends can increase structural stability, among other benefits, without increasing the material thickness. The bottom wall 34 defines a bottom surface 48 and may include ridges 50 (see Figure 8 and 10 ) to help retain dust accumulating at the bottom of the dust collection chamber 28 during use in place. Alternatively, the bottom wall 34 may be generally flat.

[0042] Now referring to Figure 3 , Figure 3A , Figure 6 and Figure 11 , a sealing surface 30 extends circumferentially around the top opening 46 of the plastic tray 28. The sealing surface 30 is complementary to the vacuum sealing surface 16 on the vacuum head 10. During use, the sealing surface 30 and the vacuum sealing surface 16 are in direct or (preferably) indirect contact with each other. In a preferred embodiment where the sealing surface 30 and the vacuum surface 16 are in indirect contact, the filter 26 may be sandwiched between the sealing surface and the vacuum surface during use (see, for example, Figure 3 ). To promote an effective seal to prevent suction loss during use, the sealing surface must be held in place against the vacuum sealing surface with sufficient force. In the illustrated embodiment, the sealing surface is a generally rectangular ring having a generally flat surface. The term generally rectangular is intended to describe a shape where the width is greater than the length. However, the shape is not intended to be limited to an exact rectangle. For example, as Figure 10 shown, a generally rectangular shape includes rounded corners. Other embodiments may have chamfered corners or non-straight sidewalls.

[0043] Referring to Figure 5 , Figure 10 and Figure 11, there is at least one opening 52, and the at least one opening enables air, dust, and debris to be inhaled from a location external to the replacement head 4 into the dust collection chamber 28 during use. In a preferred embodiment, a single rectangular opening 52 is located on the front wall 36 of the dust collection chamber 28. Those skilled in the art will understand that although not shown, alternative embodiments may include: multiple openings on a single wall; openings extending on two or more adjacent walls; an opening on at least one wall and another opening on another wall; or any combination of the above alternatives.

[0044] Preferably, the opening 52 is covered by an opening cover 54. The opening cover 54 can be made of any suitable material; however, in two preferred embodiments, the material is spunbond polypropylene, 1.25 oz extruded PET, 0.7 Mil, or 80 gsm spunbond PP. Preferably, the opening cover 54 is a cantilevered flap that, when open ( Figure 12A ) allows air, dust, and debris to enter the dust collection chamber, and when closed ( Figure 12 ) substantially covers the opening 52 to retain the collected dust and debris within the dust collection chamber 28. Although the cantilevered flap described above is a cost-effective solution, alternatives may include, for example, an opening cover 54 made of plastic or metal. Preferably, the opening cover 54 is attached to the lower side of the filter 26. However, although not shown, the opening cover 54 can be attached to, for example, a plastic tray. Additionally, although the preferred embodiments generally rely on the flexibility and resilience of the material of the opening cover 54, the opening cover 54 can also use a hinge or a living hinge that defines a pivot axis.

[0045] In some embodiments, with reference now to Figure 5 , the opening may also include opening ribs 55. Preferably, the opening ribs 55 are integral with the dust collection chamber 28 and provide a stop surface to prevent the opening cover 54 from getting stuck in or disengaging from the opening 52 during shipping or normal use.

[0046] With reference to Figures 7 to 11 and Figure 13 , a first connector lip 56 extends outward from the left wall 40 of the dust collection chamber 28 to the outside of the sealing surface 30. Additionally, at least a portion of the first connector lip 56 is located between the front wall 36 and the rear wall 38 of the dust collection chamber, as shown, for example, in Figure 11 . The first connector lip 56 includes a lower surface 58 located below the sealing surface 30. More specifically, and as shown in Figure 13 and Figure 14As shown, the lower surface 58 of the first connector lip 56 is located between the horizontal plane of the sealing surface 30 and the second surface 60 of the gasket 24 (described in more detail below). Even more specifically, in some embodiments, the lower surface 58 of the first connector lip 56 is closer to the sealing surface 30 than the second surface 60 of the gasket 24. The cross-sectional shape of the first connector lip 56 can be any shape selected by the designer. However, preferably, in order to increase stiffness and reduce material, the first connector lip 56 has a cross-sectional shape that includes at least one curve. The actual relative positioning of the lower surface 58 of the first connector lip 56 should be complementary to the design of the vacuum head 10 and the connector arms 18, 20. In the locked position, as Figure 3 shown, the connector arms 18, 20 of the vacuum head engage the lower surface 58 of the first connector lip 56. When held in place by the connector arms 18, 20 of the vacuum head 10, the sealing surface 30 of the replacement head 4 engages the vacuum sealing surface 16 directly or indirectly.

[0047] In some embodiments, referring now to Figure 10 and Figure 11 , the first connector lip 56 may extend behind the rear wall 38 and / or additionally in front of the front wall 36. In a further embodiment, the first connector lip 56 may extend in front of the front guard 32 (described below). The first connector lip 56 may be integrally formed with other features of the plastic tray 22 (such as the dust collection chamber), or may be a separate element that is combined with the remaining features of the plastic tray 22 prior to final use.

[0048] Referring to Figures 7 to 11 and Figure 13 , the second connector lip 62 extends outward from the right wall 42 of the dust collection chamber 28 to the outside of the sealing surface 30. Additionally, at least a portion of the second connector lip 62 is located between the front wall 36 and the rear wall 38 of the dust collection chamber 28, such as shown in Figure 10 and Figure 11 . Similar to the first connector lip 56 shown in Figure 13 and Figure 14 , the second connector lip 62 includes a lower surface 64 that is located below the horizontal plane of the sealing surface 30 (see, for example, Figure 7 and Figure 8)。More specifically, the lower surface 64 of the second connector lip 62 is located between the horizontal plane of the sealing surface 30 and the second surface 60 of the gasket 24 (described in more detail below). Even more specifically, in some embodiments, the lower surface 64 of the second connector lip 62 is closer to the sealing surface 30 than the second surface 60 of the gasket 24. The cross-sectional shape of the second connector lip 62 can be any shape selected by the designer and can be the same as or different from the first connector lip 56. Preferably, for the same reasons as above, the second connector lip 62 has a cross-sectional shape that includes at least one curve. The relative positioning of the lower surface 64 of the second connector lip 62 should be set such that it is complementary to the design of the vacuum head 4 and the connector arms 18, 20. In the locked position, as Figure 3 shown, the connector arms 18, 20 of the vacuum head 4 engage the lower surface 64 of the second connector lip 62. When held in place by the connector arms 18, 20 of the vacuum head, the sealing surface 30 of the replacement head 4 engages the vacuum sealing surface 16 directly or indirectly.

[0049] In some embodiments, now referring to Figure 10 and Figure 11 , the second connector lip 62 may extend behind the rear wall 38 and / or additionally in front of the front wall 36. In further embodiments, the second connector lip 62 may extend in front of the front guard 32 (described below). The second connector lip 62 may be integrally formed with other features of the plastic tray 22 (such as the dust collection chamber 28) or may be a separate element that is combined with the remaining features of the plastic tray 28 before final use. In some embodiments, the first connector lip 56 and the second connector lip 62 may be separate elements, while in other embodiments, such as Figure 6 shown in

[0050] Now referring to Figure 5 , Figure 7 , Figure 9 and Figure 10 , the plastic tray 22 may include a front guard portion 32 that is at least partially located in front of the dust collection chamber 28. In the illustrated embodiment, the front guard portion 32 is located in front of the dust collection chamber 28 and defines a shaped bottom surface 66 and an internal space 68, and generally extends from the right side to the left side of the plastic tray 22. The cross-sectional shape of the front guard 32 can be any suitable shape; however, a generally triangular cross-section (as Figure 9 shown) has been shown to have particular utility. Preferably, the lowest portion of the bottom surface 66 is extremely close to the floor being cleaned to assist in controlling the airflow into the dust collection chamber 28. In some embodiments, such as Figure 5 and 7As shown, preferably, the front guard 32 includes one or more castellated portions 70. Although it is desirable for portions of the front guard 32 to be very close to the ground during the cleaning process, the portions provided by the castellated portions 70 allow larger debris (such as grain flakes) to be very close to the opening 52 of the dust collection chamber 28 so as to be sucked into the dust collection chamber 28. As Figure 11 As shown, the internal space 68 of the front guard 32 provides a space for receiving corresponding complementary features 72 on the vacuum head 10. Preferably, the internal space 68 is located at an asymmetric position on the plastic tray 22 such that in the case where the replacement head 4 is inadvertently inverted by the end user, the features on the front portion of the vacuum head 10 will contact the plastic tray material (such as the sealing ring 30), thereby prompting the end user that the replacement head 4 is improperly attached. The vacuum head 10 may include a single feature that enters the internal space 68 of the front guard 32 during attachment, or as Figure 3 As shown, may include multiple features. As noted above, the shape of the internal space 68 may be generally triangular. In these embodiments, the generally converging walls of the internal space 68 are used to assist the user in positioning the vacuum head 10 to the proper attachment position by slightly pushing the vacuum head forward or backward during attachment.

[0051] Now referring to Figure 9 , the internal space 68 may have a partially vertical wall 86 on the side closer to the dust collection chamber 28. The partially vertical wall 86 may interact with the features on the vacuum head 10 to prevent movement relative to the vacuum head 10 during the retraction stroke.

[0052] The front suction chamber 88 is located between the front guard portion 32 and the dust collection chamber 28. The front suction chamber 88 extends across both sides of the plastic tray 22. As Figure 9 shown, the front suction chamber 88 is bounded at the front by the rear side of the front guard portion 32 and at the rear by the front wall 36 and the opening 52 of the dust collection chamber. The size and shape can be determined by the designer; however, preferably the front suction chamber 88 is shaped in a way that promotes the flow of air towards the opening 52 to direct dust and dirt.

[0053] The filter 26 is made of a suitable material that will allow air to pass through it during use but block at least most of the dust sucked into the dust collection chamber 28 during cleaning. Additionally, it is desirable for the filter 26 to be able to absorb and / or block moisture before it enters the vacuum device 2. It is desirable to select a material that is low in manufacturing cost, easy to cut to size, and easy to attach to the plastic tray 22. In the illustrated embodiment, the filter 26 is a non-woven hydrophobic material made of SMS polypropylene 40 gsm. In embodiments where the filter material can be printed, as Figure 2 shown, additional printed patterns including, for example, logos or usage directions may be presented on the filter 26.

[0054] The filter 26 is attached to the plastic tray 22 such that substantially the entire top opening 46 is covered, as Figure 4 shown. It is desirable that during vacuum suction, even if not all, most of the air that is to be drawn into the dust collection chamber 28 passes through the filter 26 before entering the vacuum device 2, such that the amount of dust, debris, and moisture that enters and thus may damage the suction source is minimized. Figure 3 In the embodiment shown in, the filter 26 is attached to the sealing surface 30 such that when the replacement head 4 is attached to the vacuum head 10, the filter 26 is sandwiched between the sealing surface 30 of the plastic tray 22 and the vacuum sealing surface 16. While it is desirable that the filter 26 substantially completely covers the top opening 46 of the dust collection chamber 28, it is preferred that the filter 26 does not cover the internal space 68 of the front guard 32, such that the features 72 on the vacuum head 10 can enter the internal space 68 of the front guard 32 unobstructed during attachment (see, for example, Figure 15 ). The filter 26 can be attached to the plastic tray 22 in any acceptable manner. Suitable methods include using heat and using glue and adhesives to bond materials together. While it is preferred that the filter 26 is attached to the plastic tray 22 in a permanent manner, other embodiments may have a removable connection. Further embodiments may include the end user placing the filter 26 above the top opening 46 during use.

[0055] The filter 26 is positioned above the top opening 46 such that the area of the filter 26 between about 50 square centimeters and 125 square centimeters is substantially unsupported below. More preferably, the unsupported area is approximately 100 square centimeters to 115 square centimeters. Most preferably, the unsupported area is approximately 105 square centimeters to 110 square centimeters. In the embodiment shown, the filter 26 lies substantially flat on the top opening 46; however, although not shown, the filter 26 can be, for example, pleated such that the area of the filter 26 material used is greater than the area of the top opening 46 that it covers. Thus, the area of the filter 26 material on the top opening 46 can be between approximately 50 square centimeters and 350 square centimeters. However, in embodiments where the filter 26 is applied to the top opening 46 in a substantially flat manner, the area of the filter 26 material on the top opening 46 is between about 40 square centimeters and 175 square centimeters. Most preferably, the area of the filter material is approximately 130 square centimeters.

[0056] Preferably, the filter 26 is made of a thin material, particularly in embodiments where the edges of the filter 26 are sandwiched between the sealing surface 30 of the plastic tray 22 and the vacuum sealing surface 16 during use. Thus, it is preferred that the thickness of the filter 26 material is less than about 1.0 mm thick. More preferably, the thickness of the filter 26 material is less than about 0.5 mm thick. Filters having a thickness of approximately 0.3 mm have been shown to have particular utility.

[0057] To achieve proper filtering function, materials having a basis weight of about 20 to 70 gsm have been found to have particular utility. More preferably, the basis weight is about 30 to 50 gsm. Materials having a basis weight of approximately 40 gsm have been shown to have particular utility. For the purposes of the present invention, the ASTM D6242-98 test method can be used to measure the basis weight.

[0058] To ensure proper vacuum function, the filtration is preferably between about 0.001 and 0.05 inH2O / FPM. More preferably, the filtration is between about 0.01 and 0.025 inH2O / FPM. Materials having a measured filtration of about 0.016 inH2O / FPM have been shown to have particular utility.

[0059] Additionally, in some embodiments, it may be desirable to increase the airflow through the filter material by including relatively small holes in the filter material. The size of the holes is typically set to allow increased airflow through the filter but not so large as to allow a significant amount of dust, dirt, debris, and / or liquid to pass through. In a preferred embodiment, oval holes having a length of approximately 1 mm and a width of approximately 0.6 mm have been found to have particular utility. However, hole sizes of up to about 1.5 square millimeters are acceptable.

[0060] The gasket 24 includes a first surface 74 and a second surface 60 and is made of any suitable material, which is preferably useful for wiping the surface to be cleaned and / or absorbing moisture. The gasket 24 is well known in the art and may include one or more layers. For example, a single-layer gasket made of 100% PET material or carded spunlace PET of 58 gsm and spunbond PP of 10 gsm can be used. Alternatively, as Figure 16 shown, the gasket 24 may include, for example, four layers each providing a utility (such as absorption, retention, wiping). Exemplary layers include:

[0061] Layer 1: Air laid retention layer; 180 gsm, 47% pulp, 53% Bico material

[0062] Layer 2: Airlaid collection layer; 100 gsm, 47% pulp, 53% Bico material Layer 3: Top layer; carded hydroentangled PET, 58 gsm; spunbonded PP, 10 gsm

[0063] Layer 4: Multi-functional strip; meltblown PP, 35 gsm

[0064] Reference Figure 4 and Figure 5 , showing the multi-layer gasket 24. To bond the various layers together, multiple methods are shown. In Figure 5 , the layers are ultrasonically welded together in a continuous manner along the entire edge. In some embodiments, additional welds can be created in the body of the filter, as shown in a generally hexagonal pattern in Figure 5 . The continuous welds along the front and rear edges tend to provide a suitable bond between the layers to prevent delamination. In Figure 4 , flat head welding is shown at local positions along the front and rear edges. In some embodiments, a total of about eight (8) weld positions are provided. In other embodiments, it has been found that using approximately fifty (50) weld positions is quite effective. Additionally, still referring to Figure 4 , the spaced weld positions can be located along the edge of the gasket 24. In other embodiments, as shown along the front edge of the gasket in Figure 4 , the weld positions can be shifted rearward. By welding the layers together at local positions, it has been shown that the welds will maintain an acceptable attachment between the layers but allow some expansion therebetween. The expansion between the welds has been found to permit the absorption of additional liquid during use. For example, in some cases where a multi-layer gasket with continuous welding may tend to push away a certain amount of water on the ground in front of or behind the vacuum device 2, the intermittently welded gasket can absorb liquid due to the slight delamination that may occur between the welds. In embodiments where the welds are shifted rearward from the edge of the gasket 24, the local delamination can increase and, in some cases, improve performance. The number and position of the welds between the front and rear portions of the gasket 24 can be the same or different depending on the judgment of the designer.

[0065] The external shape of the gasket 24 can be any suitable shape known to those skilled in the art. As shown in Figure 5 , the gasket 24 can be generally rectangular. The first surface 74 of the gasket 24 is attached to the bottom surface 48 of the dust collection chamber 28 such that the second surface 60 of the gasket 24 material contacts the ground during cleaning. Preferably, the first surface 74 of the gasket 24 covers at least most, and even more preferably, all of the bottom surface 48 of the dust collection chamber 28. The gasket 24 can extend outward from the bottom surface 48 of the dust collection chamber 28. As shown in Figure 4 and 5As shown, the gasket 24 extends rearwardly to each side of the bottom surface 48 of the dust collection chamber 28. Although it is acceptable for the gasket 24 to extend in front of the front wall 36 of the dust collection chamber 28, such an arrangement may impede usability because, for example, it may block the opening 52 leading to the dust collection chamber 28 and / or may cause the gasket 24 to fold or bend when the vacuum device 2 is pushed forward by the user during cleaning.

[0066] The gasket 24 can be attached in any suitable manner. Preferably, the first surface 74 of the gasket 24 is attached to the bottom surface 66 of the dust collection chamber 28 in a permanent manner. Suitable methods include using heat bonding or an adhesive. Alternatively, the gasket 24 is replaceable and can be attached in a removable manner, for example, by means of a hook-and-loop fastener.

[0067] In use, referring now to Figures 1 to 3A , the end user moves at least one of the connector arms 18, 20 of the vacuum head 10 to the open position and places the replacement head 4 such that the filter 26 material is sandwiched between the sealing surface 30 of the plastic tray 22 and the vacuum sealing surface 16. Then the at least one connector arm 18, 20 is released such that the connector arm engages the first connector lip 56 and the second connector lip 62 on the plastic tray, thereby holding the replacement head 4 in place for use. Then, the user activates the vacuum device 2, thereby creating suction. The air drawn into the dust collection chamber 28 causes the opening cover 54 to move to the open position (as Figure 12A shown). As the user moves the vacuum device 2 and the replacement head 4 over the floor to be cleaned, the suction source draws air, dirt, and debris from the area in front of the replacement head 4 and under the front guard 32 and draws the air, dirt, and debris through the opening 52 into the dust collection chamber 28. Once the air, dust, and debris are inside the dust collection chamber 28, they are drawn towards the filter 26 and the air passes through the filter. The dust and debris cannot pass through the filter 26 and instead remain in the dust collection chamber 28. Optionally, the user can activate the button 14 on the vacuum device 2 to spray fluid onto the floor in front of the replacement head 4. Then, the user can use the second surface 60 of the gasket 24 to wipe the floor with the cleaning fluid to thoroughly clean the floor.

[0068] During the cleaning process, one or more of the following will occur: the dust collection chamber 28 will fill with dust and debris; the filter 26 will become clogged; and the gasket 24 will become dirty. The user can selectively replace the replacement head 4 at any time by moving at least one of the connector arms 18, 20 to the open position, thereby disengaging the first connector lip 56 and the second connector lip 62 from the vacuum head 10. Advantageously, in the described embodiment, the user can replace the entire replacement head 4 all at once without making a mess and replace it with a newer replacement head 4 for future use.

[0069] Alternative embodiments of the embodiments described above exist without departing from the spirit and scope of the present invention. For example, instead of using the first connector lip 56 and the second connector lip 62 to removably attach the replacement head 4 to the vacuum head 10, one or more elastic bands may be employed. Two elastic bands are attached to the replacement head. During use, the user wraps the elastic bands around either side of the vacuum head 4 ( Figure 2 of) in order to hold the replacement head in place during use.

[0070] Another embodiment utilizes a "shower cap" attachment method. In this embodiment, instead of the first connector lip 56 and the second connector lip 62, a ring of flexible material is attached to the replacement head (and preferably to the plastic tray). The flexible material may include additional elastic bands to ensure a proper connection between the replacement head and Figure 2 the vacuum device 2.

[0071] In another embodiment, the replacement head includes a plurality of parts that are not permanently connected. The first interconnecting part includes a first connector lip and a second connector lip that are connected to the vacuum head 4 ( Figure 2 of) in a manner similar to that described above in the previous embodiments. The first interconnecting part is sealed on one side by a vacuum sealing surface and includes an opening to allow air to pass therethrough towards the suction source during use. The first interconnecting part also includes a mechanical connector (e.g., a mechanical connector, a hook and loop fastener, etc.) that attaches additional parts of the replacement head (i.e., the filter, the dust collection chamber, the front guard, and the gasket) to the first interconnecting piece. Although not shown, one or more elements of the replacement head (e.g., the front guard and / or the filter) may be included on the first interconnecting part.

[0072] Those skilled in the art will appreciate that the additional embodiments or variations described above may be implemented without departing from the spirit or scope of the present invention. For example, although various alternatives for attaching the replacement head to the vacuum head have been disclosed (i.e., the first and second connector lips, elastic bands, etc.), additional devices that utilize more than one of the disclosed methods or obvious alternatives are considered to be within the scope of the present invention. Additionally, the term "about" is used herein to describe additional ranges of values that are equivalent to the stated ranges known to those skilled in the art. When the term "about" is used in relation to a range, the term is intended to apply to both end values of the range.

Claims

1. A replacement head, comprising: A tray, which includes a dust collection chamber having a sealing surface defining a first opening, the sealing surface being configured to couple to a suction source, the tray defining a first side, a second side, a front, and a rear; A second opening extending through the front wall of the replacement head, the second opening defining a second opening width extending in a direction from the first side to the second side; A gasket connected to the tray and having a cleaning surface configured to be positioned on a surface to be cleaned; And A filter connected to the tray such that the filter at least partially covers the first opening, the filter defining a filter width extending in a direction parallel to the second opening width; Wherein the filter is made of a non-woven material, is less than 1.0 mm thick, and includes an unsupported area over the first opening; and Wherein the filter width is greater than the second opening width, and the filter is spaced apart from the gasket.

2. The replacement head according to claim 1, wherein the filter is made of a material having a basis weight between 20 gsm and 70 gsm.

3. The replacement head according to claim 2, wherein the basis weight of the filter material is between 30 gsm and 50 gsm.

4. The replacement head according to claim 3, wherein the basis weight of the filter material is 40 gsm.

5. The replacement head according to claim 1, wherein the filter material has at least two holes, each hole having an area less than 1.5 square millimeters.

6. The replacement head according to claim 5, wherein each hole has an area less than 1.0 square millimeters.

7. The replacement head according to claim 5, wherein at least one hole is in an oval shape.

8. The replacement head according to claim 1, wherein the filter is positioned above the first opening such that the filter material is substantially flat.

9. The replacement head according to claim 1, wherein the filter is positioned above the first opening such that the filter material includes at least one fold so that it forms a pleated portion.

10. A replacement head, comprising: A tray including a dust collection chamber, a first side wall, a second side wall, a front wall, and a rear wall, the tray having a first opening configured to couple to a suction source and a sealing surface defining the first opening, and a second opening configured to receive debris passing therethrough and defining a second opening width extending in a direction from the first side to the second side; An absorbent gasket having at least one layer of material, the gasket being coupled to the tray, and the gasket having a surface configured to contact a surface to be cleaned; And A hydrophobic filter having a filter width, the hydrophobic filter being connected to the tray along the sealing surface such that when a suction source is coupled to the tray, the filter substantially prevents debris and moisture in the dust collection chamber from passing through the first opening, Wherein the hydrophobic filter is spaced apart from the absorbent gasket, and the filter width is greater than the second opening width.

11. The replacement head according to claim 10, wherein the filter is made of a material having a basis weight between 20 gsm and 70 gsm.

12. The replacement head according to claim 11, wherein the basis weight of the filter material is between 30 gsm and 50 gsm.

13. The replacement head according to claim 12, wherein the basis weight of the filter material is 40 gsm.

14. The replacement head according to claim 10, wherein the filter is positioned above the first opening such that the filter material is substantially flat.

15. The replacement head according to claim 10, wherein the filter material has at least two holes, each hole having an area of less than 1.5 square millimeters.

16. The replacement head according to claim 15, wherein each hole has an area of less than 1.0 square millimeters.

17. The replacement head according to claim 15, wherein at least one hole is in an oval shape.

18. The replacement head according to claim 10, wherein the filter is positioned above the first opening such that the filter material includes at least one fold so that it forms a pleated portion.

19. The replacement head according to claim 10, wherein the filter comprises at least polypropylene.

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