Replacement heads for vacuum cleaners

Abstract

A replacement head for a vacuum cleaner, the replacement head for a vacuum device comprising a plastic tray, a filter, and a pad. The plastic tray includes a dust collection chamber having a sealing surface and at least one opening. The opening is provided to allow air, dust, and debris to be drawn into the dust collection chamber during use. The sealing surface defines a sealing surface plane, while the opening defines an opening plane. The relative angle between the sealing surface plane and the opening plane is preferably between approximately -20 degrees and +150 degrees. The pad is attached to the underside of the plastic tray and contacts the ground during cleaning. The filter is connected to the plastic tray so that the filter substantially covers the top opening in the dust collection chamber.

Description

Technical Field

[0001] The present disclosure relates generally 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 multiple, mixed-media debris is present. In some cases, it's necessary to vacuum up dry, loose debris, wipe up stuck debris, and absorb any wet debris that may be present. Existing tools such as vacuum cleaners, dry mops, and wet mops can handle some of these media types, but not all at once. Therefore, many people typically sweep up dry debris and then mop up wet or stuck debris.

[0003] Known tools that can handle both dry and wet media take longer to set up than broom / mop combinations, and after-use maintenance can be particularly laborious when liquids are involved. If combination tools are not properly cleaned after each use, they can become smelly and unpleasant. Finally, cleanup can be messy, requiring 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 without effort or mess. 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, a first connector lip and a second connector lip. The dust collection chamber has a bottom wall, a front wall, a rear wall, a left wall and a right wall, and defines a top opening defined by a sealing surface. The sealing surface defines a sealing surface plane. The bottom wall of the dust collection chamber defines an outer bottom surface. The opening extends through at least one of the walls (preferably the front wall) into the dust collection chamber and defines an opening plane. Preferably, the relative angle between the opening plane and the sealing surface plane is between approximately -20 degrees and +150 degrees. The gasket includes at least one material layer 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 is generally opposite to the first surface. The filter is connected to the plastic tray so that the filter substantially covers the top opening.

[0006] According to another aspect of the present invention, it is preferred that the relative angle between the plane of the opening and the plane of the sealing surface is between approximately +45 degrees and +135 degrees.

[0007] According to another aspect of the present invention, it is preferred that the relative angle between the plane of the opening and the plane of the sealing surface is between approximately +60 degrees and +100 degrees.

[0008] According to yet another aspect of the present invention, it is preferred that a relative angle between the plane of the opening and the plane of the sealing surface is approximately 78 degrees.

[0009] According to yet another aspect of the present invention, the replacement head includes first and second connector lips to selectively attach the replacement head to the vacuum head.

[0010] According to one aspect of the present invention, a replacement head is provided, comprising: a plastic tray, which includes a dust collection chamber defining a top opening bounded by a sealing surface, the dust collection chamber also 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 outer bottom surface, and the sealing surface generally defining a sealing surface plane; an opening, which extends through at least one of the walls into the dust collection chamber, the opening generally defining an opening surface plane; and a gasket, which has at least one material layer, 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, which is connected to the plastic tray so that the filter substantially covers the top opening; wherein the relative angle between the sealing surface plane and the opening plane is between approximately -20 degrees and +150 degrees.

[0011] Preferably, the opening is located entirely on the front wall.

[0012] Preferably, said relative angle between the sealing surface plane and said opening plane is limited to between approximately +45 degrees and +135 degrees.

[0013] Preferably, said relative angle between the sealing surface plane and said opening plane is limited to between approximately +60 degrees and +100 degrees.

[0014] Preferably, the relative angle between the sealing surface plane and the opening plane is approximately 78 degrees.

[0015] Preferably, the opening has an area between about 0.5 square inches (10 square centimeters) and 3.0 square inches (19 square centimeters).

[0016] Preferably, the opening plane comprises a curve.

[0017] Preferably, the opening is substantially rectangular in shape.

[0018] Preferably, the plastic pallet comprises more than one opening.

[0019] Preferably, the opening is substantially oval in shape.

[0020] Preferably, the opening is substantially circular.

[0021] Preferably, the front suction chamber is located between the front guard portion and the dust collecting chamber.

[0022] Preferably, the liner comprises at least a first layer and a second layer, the first and second layers of the liner being ultrasonically welded together.

[0023] Preferably, the ultrasonic weld is substantially continuous along at least one edge of the pad.

[0024] Preferably, at least one edge of the gasket has at least two local weld locations spaced apart from each other.

[0025] Preferably, the ultrasonic weld is located away from the edge of the pad.

[0026] One advantage of the present invention is that a user can easily remove a soiled replacement head and replace it with a new one in a short time with little mess. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 An isometric view showing the vacuum device and replacement head of the present invention;

[0028] Figure 2 Shown separately Figure 1 Isometric view of the vacuum unit and replacement head;

[0029] Figure 3 Show Figure 1 a cross-sectional view taken along line 3-3 showing the vacuum head and replacement head attached with the connector arm in a locked position;

[0030] Figure 3A Show Figure 1 A cross-sectional view taken along line 3A-3A showing the vacuum head and replacement head attached with the connector arm in an open position;

[0031] Figure 4 showing an isometric view of a replacement head of the present invention;

[0032] Figure 5 Shown from different angles Figure 4 Isometric view of the replacement head;

[0033] Figure 6 An isometric view showing a plastic pallet of the present invention;

[0034] Figure 7 Showing a front view of the plastic pallet of the present invention;

[0035] Figure 8 A rear view of the plastic pallet of the present invention is shown;

[0036] Figure 9A side view of a plastic pallet according to the present invention is shown;

[0037] Figure 10 A bottom view of the plastic pallet of the present invention is shown;

[0038] Figure 11 A top view of a plastic pallet according to the present invention is shown;

[0039] Figure 12 Show Figure 4 A cross-sectional view taken along line 12-12 depicting the opening cover in a closed position;

[0040] Figure 12A Show Figure 4 A cross-sectional view taken along line 12A-12A depicting the opening cover in the open position;

[0041] Figure 13 showing an enlarged front view of one side of the replacement head;

[0042] Figure 14 Show Figure 4 A cross-sectional view taken along line 14-14 depicting the shape of the first connector lip;

[0043] Figure 15 Show Figure 1 A cross-sectional view along line 15-15 depicting the interaction between the vacuum head and the front guard portion of the plastic pallet;

[0044] Figure 16 An exploded view showing one embodiment of a pad of the present invention;

[0045] Figure 17 Show Figure 5 A cross-sectional view taken along line 17-17 depicts an embodiment of the present invention;

[0046] Figure 18 Shown with Figure 17 A similar view of another embodiment of the present invention; and

[0047] Figure 19 Shown with Figure 17 Similar views of another embodiment of the present invention. DETAILED DESCRIPTION

[0048] Figure 1 and Figure 2A perspective view of a vacuum device 2 and a replacement head 4 is shown, 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 (e.g., a cleaning fluid), a jet nozzle 12, and a user-activated button 14 for selectively ejecting fluid from the jet nozzle 12. Preferably, the jet nozzle 12 is intended to eject fluid from the jet nozzle 12 to a position in front of the replacement head 4 when the button 14 is activated by the user during normal use. Now referring to Figure 3 and Figure 3A , the vacuum head 10 includes a vacuum sealing surface 16 and at least two connector arms 18, 20. In the embodiment shown, at least one connector arm 18 can be in a closed position ( Figure 3 ) and open position ( Figure 3A ) to move between.

[0049] Now refer to Figures 4 to 6 , the replacement head 4 includes a plastic tray 22, a liner 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 the front protective portion 32.

[0050] The plastic tray 22 can be made of any suitable material (including non-plastics); however, a material that is inexpensive and easily disposed of is preferred. For example, polyethylene terephthalate (or "PET") is considered a preferred material, in part because PET is inexpensive and easily thermoformed into a desired shape. Injection molding, blow molding, or any other common manufacturing process are also acceptable and suitable alternatives. As shown, the plastic tray 22 can be formed from a single, unitary piece, or can be composed of two or more component parts that are connected or joined during assembly of the replacement head 4.

[0051] like Figures 6 to 12 The illustrated plastic tray 22 includes a dust chamber 28 that is sized and shaped to collect and retain dust and debris that is drawn into the plastic tray 22 during use. In the illustrated embodiment, the dust 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 chamber 28 is a top opening 46. Together, the walls and the top opening 46 generally define a volume of space that can collect and retain typical household dust and debris. It will be understood by those skilled in the art that changing the size and shape of the walls and the top opening 46 will increase or decrease the overall volume of the dust chamber without departing from the spirit of the invention. Although the rear wall 38 and the left and right walls 40, 42 are Figure 9 and Figure 10 Although shown as being generally straight, the wall may include at least one curve or bend, or include other features that make it non-straight. Figure 10The front wall 36 shown includes a series of curves and features. The curves and bends increase structural stability without increasing material thickness, among other benefits. The bottom wall 34 defines a bottom surface 48 and may include a ridge 50 (see FIG. Figure 8 and Figure 10 ) helps retain in place dust that accumulates at the bottom of the dust collection chamber 28 during use. Alternatively, the bottom wall 34 can be generally flat.

[0052] Now refer to Figure 3 、 Figure 3A 、 Figure 6 and Figure 11 , the sealing surface 30 extends circumferentially around the top opening 46 of the plastic tray 22. 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 the preferred embodiment where the sealing surface 30 and the vacuum surface 16 are in indirect contact, the filter 26 can be sandwiched between the sealing surface and the vacuum surface during use (see, for example, Figure 3 ). To promote an effective seal to prevent loss of suction during use, the sealing surface must be held in place against the vacuum sealing surface with sufficient force. In the embodiment shown, the sealing surface is a generally rectangular ring with a generally flat surface. The term generally rectangular is intended to describe a shape that is wider than it is long. However, the shape is not intended to be limited to a precise rectangle. For example, Figure 10 As shown in , the generally rectangular shape includes rounded corners. Other embodiments may have chamfered corners or non-straight sidewalls.

[0053] refer to Figure 5 、 Figure 10 and Figure 11 , there is at least one opening 52 that enables air, dust and debris to be drawn into the dust collection chamber 28 from a location outside the replacement head 4 during use. In a preferred embodiment, a single rectangular opening 52 is located on the front wall 36 of the dust collection chamber 28. The opening 52 can have any size or shape determined by the designer. In the illustrated embodiment, the opening 52 is approximately 2.2 inches (5.5 cm) wide and 0.7 inches (1.8 cm) wide, and has an area of ​​approximately 1.5 square inches (10 square centimeters). Although the above area is preferred, without departing from the scope of the present invention, the opening can have an area between approximately 0.5 square inches (3.2 square centimeters) and approximately 3.0 square inches (19 square centimeters). In addition, in embodiments with more than one opening, the total area of ​​all openings is preferably within the range disclosed above.

[0054] refer to Figure 17, the sealing surface 30 generally defines a sealing surface plane (SSP), while the opening 52 defines an opening plane (OP). The designer of the replacement head 4 of the present invention may determine the angle (α) between the sealing surface plane (SSP) and the opening plane (OP); however, certain relative angles (α) have been determined to have particular utility. According to the present invention, the relative angle (α) between the sealing surface plane (SSP) and the opening plane (OP) is measured from a starting position within the top opening 46 on the sealing surface plane (SSP) toward the side of the opening plane (OP) inside the dust collection chamber 28. In some embodiments, for example Figure 18 In the embodiment shown in FIG, wherein the opening 52 is significantly rotated inwardly into the dust collection chamber 28, a negative angle (α) may be measured. Preferably, the relative angle (α) between the sealing surface plane (SSP) and the opening plane (OP) is between about -20 degrees and +150 degrees (see FIG. Figure 19 ). More preferably, the relative angle (α) is between about +45 degrees and +135 degrees. Even more preferably, the relative angle (α) is between about +60 degrees and +100 degrees. In a preferred embodiment, the relative angle (α) is about 78 degrees, such as Figure 17 shown.

[0055] In certain embodiments, the opening 52 may have a shape that is not planar (e.g., forming a curved surface). In such cases, one skilled in the art will appreciate that the relative angle (α) can be measured by determining a reasonable number of local angles at various locations across the opening 52 along the surface formed by the non-planar opening 52 and averaging them to determine the effective relative angle (α) between the opening plane (OP) and the sealing surface plane (SSP).

[0056] Now refer to, for example Figure 5 , the opening 52 is shown as being positioned generally in the center of the front wall 36. However, in other embodiments (not shown), the opening 52 may be positioned offset to one side or the other of the plastic pallet 22 such that the opening is asymmetrical. Additionally, the opening 52 may have a non-rectangular shape (e.g., circular, oval, etc.). In further embodiments, one or more openings 52 may be present on the left wall 40, right wall 42, rear wall 38, or bottom wall 34 of the plastic pallet 22 in addition to or in lieu of the opening 52 on the front wall 36.

[0057] 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, 1.25oz extruded PET, 0.7Mil or 80gsm spunbond PP. Preferably, the opening cover 54 is a cantilevered flap that, when opened ( Figure 12A ) allows air, dust and debris to enter the dust chamber, while when closed ( Figure 12) substantially covers the opening 52 to retain collected dust and debris within the dust collection chamber 28. While the cantilevered flap described above is a cost-effective solution, alternatives may include an opening cover 54 made of, for example, plastic or metal. Preferably, the opening cover 54 is attached to the underside of the filter 26. However, although not shown, the opening cover 54 may be attached to, for example, a plastic tray. Additionally, while preferred embodiments generally rely on the flexibility and resiliency of the material used for the opening cover 54, the opening cover 54 may also utilize a hinge or living hinge defining a pivot axis.

[0058] In some embodiments, reference is now made to Figure 5 , the opening may further include an opening rib 55. Preferably, the opening rib 55 is integral with the dust collection chamber 28 and provides a stop surface to prevent the opening cover 54 from getting stuck in or disengaging from the opening 52 during shipping or normal use.

[0059] refer to Figures 7 to 11 and Figure 13 , the first connector lip 56 extends outwardly from the left wall 40 of the dirt collection chamber 28 to the exterior of the sealing surface 30. In addition, at least a portion of the first connector lip 56 is located between the front wall 36 and the rear wall 38 of the dirt collection chamber, for example Figure 11 The first connector lip 56 includes a lower surface 58 located below the sealing surface 30. More specifically, and as shown Figure 13 and Figure 14 As 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 chosen by the designer. However, it is preferred that the first connector lip 56 have a cross-sectional shape that includes at least one curve in order to increase stiffness and reduce material. 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 As 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 refill head 4 engages the vacuum sealing surface 16 either directly or indirectly.

[0060] In some embodiments, reference is now made to Figure 10 and Figure 11, the first connector lip 56 can extend behind the rear wall 38 and / or in addition in front of the front wall 36. In still further embodiments, the first connector lip 56 can extend in front of the front guard portion 32 (described below). The first connector lip 56 can be integrally formed with other features of the plastic pallet 22 (e.g., a dust chamber), or can be a separate component that is combined with the remaining features of the plastic pallet 22 prior to ultimate use.

[0061] refer to Figures 7 to 11 and Figure 13 , the second connector lip 62 extends outwardly from the right wall 42 of the dust collection chamber 28 to the exterior of the sealing surface 30. In addition, 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, for example Figure 10 and Figure 11 As shown in . Similar to Figure 13 and Figure 14 The first connector lip 56 is shown in FIG. 1 , and the second connector lip 62 includes a lower surface 64 located below the level of the sealing surface 30 (see, e.g., FIG. 1 ). 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 chosen by the designer and can be the same as or different from the first connector lip 56. Preferably, the second connector lip 62 has a cross-sectional shape that includes at least one curve, for the same reasons described above. The relative positioning of the lower surface 64 of the second connector lip 62 should be arranged so that it complements the design of the vacuum head 10 and the connector arms 18, 20. In the locked position, as Figure 3 As shown, the connector arms 18, 20 of the vacuum head 10 engage the lower surface 64 of the second connector lip 62. The sealing surface 30 of the replacement head 4 engages the vacuum sealing surface 16 directly or indirectly when held in place by the connector arms 18, 20 of the vacuum head.

[0062] In some embodiments, reference is now made 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 still further embodiments, the second connector lip 62 may extend in front of the front guard portion 32 (described below). The second connector lip 62 may be integrally formed with other features of the plastic pallet 22 (e.g., the dust collection chamber 28), or may be a separate element that is combined with the remaining features of the plastic pallet 22 prior to final use. In some embodiments, the first connector lip 56 and the second connector lip 62 may be separate elements, while in other embodiments, for example Figure 6 In the embodiment shown in FIG, the first connector lip 56 and the second connector lip 62 may be interconnected across the front and / or rear of the plastic pallet 22 .

[0063] Reference Figure 5 、 Figure 7 、 Figure 9 and Figure 10 , the plastic tray 22 may include a front guard portion 32 located at least partially 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 interior 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 portion 32 can be any suitable shape; however, a generally triangular cross-section (such as Figure 9 Preferably, the lowest portion of the bottom surface 66 is very close to the floor being cleaned to assist in controlling the airflow into the dust collection chamber 28. In some embodiments, for example Figure 5 and Figure 7 As shown in FIG, the front guard portion 32 preferably includes one or more castellated portions 70. While it is desirable that portions of the front guard portion 32 be in close proximity to the ground during the cleaning process, the castellated portions 70 provide a portion that permits larger debris (e.g., grain flakes) to be in close proximity to the opening 52 of the dust collection chamber 28 so as to be drawn into the dust collection chamber 28. Figure 11 As shown in FIG, the interior space 68 of the front guard portion 32 provides space to receive a corresponding complementary feature 72 on the vacuum head 10. Preferably, the interior space 68 is located at an asymmetrical position on the plastic pallet 22 so that if the replacement head 4 is accidentally turned upside down by the end user, the feature on the front of the vacuum head 10 will contact the plastic pallet material (e.g., the sealing ring), thereby indicating to the end user that the replacement head 4 is improperly attached. The vacuum head 10 may include a single feature that enters the interior space 68 of the front guard portion 32 during attachment, or as shown in FIG. Figure 3 As shown in , a number of features may be included. As noted above, the shape of the interior space 68 may be generally triangular. In these embodiments, the generally converging walls of the interior space 68 serve to assist the user in positioning the vacuum head 10 into the proper attachment position by slightly pushing the vacuum head forward or backward during attachment.

[0064] Reference Figure 9 , the interior space 68 may have a partial vertical wall 86 on the side closer to the dust collection chamber 28. The partial vertical wall 86 may interact with features on the vacuum head 10 to prevent movement relative to the vacuum head 10 during the pullback stroke.

[0065] 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. Figure 9 As 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 of the dust collection chamber and the opening 52. The size and shape can be determined by the designer; however, the front suction chamber 88 is preferably shaped in a manner that promotes airflow to guide dust and dirt toward the opening 52.

[0066] Filter 26 is made of a suitable material that allows air to pass through it during use but blocks at least most of the dust drawn into dust chamber 28 during cleaning. Furthermore, it is desirable that filter 26 be capable of absorbing and / or blocking moisture before it enters vacuum device 2. It is desirable to select a material that is inexpensive to manufacture, easy to cut to size, and easy to attach to plastic tray 22. In the illustrated embodiment, filter 26 is a nonwoven hydrophobic material made of SMS polypropylene 40 gsm. In embodiments where the filter material is printable, additional printed graphics, including, for example, a logo or directions for use, may be present on filter 26.

[0067] The filter 26 is attached to the plastic tray 22 so that substantially the entire top opening 46 is covered, as shown. Figure 4 It is desirable that most, if not all, of the air drawn into the dust collection chamber 28 during vacuuming pass through the filter 26 before entering the vacuum device 2, minimizing the amount of dust, debris, and moisture that enters and thus potentially damages the suction source. Figure 3 In the embodiment shown in FIG, filter 26 is attached to sealing surface 30 such that when refill head 4 is attached to vacuum head 10, filter 26 is sandwiched between sealing surface 30 of plastic tray 22 and vacuum sealing surface 16. While it is desirable that filter 26 substantially completely cover top opening 46 of dust collection chamber 28, it is preferred that filter 26 not cover interior space 68 of front guard portion 32, allowing unobstructed access to interior space 68 of front guard portion 32 by features 72 on vacuum head 10 during attachment. Filter 26 can be attached to plastic tray 22 in any acceptable manner. Suitable methods include the use of heat and the use of glue or adhesives to bond materials together. While it is preferred that filter 26 be permanently attached to plastic tray 22, other embodiments may have a removable connection. Further embodiments may include an end user placing filter 26 over top opening 46 during use.

[0068] The liner 24 includes a first surface 74 and a second surface 60 and is made of any suitable material that is preferably useful for wiping the surface being cleaned and / or absorbing moisture. The liner 24 is well known in the art and may include one or more layers. For example, a single layer liner made of 100% PET material or 58 gsm carded spunlace PET, 10 gsm spunbond PP may be used. Alternatively, Figure 16 As shown in FIG, the liner 24 may include, for example, four layers each providing a utility (e.g., absorption, retention, wiping). Exemplary layers include:

[0069] Layer 1: Air laid retention layer; 180 gsm, 47% pulp, 53% Bico material

[0070] Layer 2: Airlaid acquisition layer; 100gsm, 47% pulp, 53% Bico material Layer 3: Top layer; Carded spunlace PET, 58gsm; Spunbond PP, 10gsm

[0071] Layer 4: Multifunctional strip; meltblown PP, 35gsm

[0072] refer to Figure 4 and Figure 5 , a multi-layer liner 24 is shown. In order to bond the various layers together, a number of methods are shown. Figure 5 In some embodiments, additional welds may be created in the body of the filter, such as Figure 5 Continuous welds along the leading and trailing edges tend to provide adequate bonding between the layers to prevent delamination. Figure 4 , flat head welds are shown at localized locations along the front and rear edges. In some embodiments, a total of about eight (8) weld locations are provided. In other embodiments, about fifty (50) weld locations may be suitable. In addition, still referring to Figure 4 , spaced apart weld locations may be positioned along the edge of the liner 24. In other embodiments, as shown along Figure 4In embodiments where the welds are moved back from the front edge of the liner 24, the weld location can be moved back. By welding the layers together at localized locations, the welds have been shown to maintain acceptable adhesion between the layers while allowing for some expansion therebetween. Expansion between the welds has been found to allow for additional liquid absorption during use. For example, in some situations where a continuously welded, multi-layer liner might tend to displace a certain amount of water from the ground in front of or behind the vacuum device 2, an intermittently welded liner can absorb liquid due to the slight delamination that may occur between the welds. In embodiments where the welds are moved back from the edge of the liner 24, localized delamination can be increased, and in some cases, performance can be improved. The number and location of the welds between the front and back of the liner 24 can be the same or different, depending on the designer's discretion.

[0073] In embodiments where the second surface 60 of the liner 24 is printable, additional printed graphics including, for example, a logo or directions for use may be present.

[0074] The outer shape of the liner 24 can be any suitable shape known to those skilled in the art. Figure 5 As shown, the pad 24 can be generally rectangular. The first surface 74 of the pad 24 is attached to the bottom surface 48 of the dirt collection chamber 28 so that the second surface 60 of the pad 24 material contacts the floor during cleaning. Preferably, the first surface 74 of the pad 24 covers at least a majority of the bottom surface 48 of the dirt collection chamber 28, and even more preferably, covers the entirety of the bottom surface 48. The pad 24 can extend outwardly from the bottom surface 48 of the dirt collection chamber 28. Figure 4 and Figure 5 , the liner 24 extends rearwardly to each side of the bottom surface 48 of the dirt chamber 28. While it is acceptable for the liner 24 to extend forward of the front wall 36 of the dirt chamber 28, such an arrangement may hinder usability by, for example, blocking the opening 52 to the dirt chamber 28 and / or possibly causing the liner 24 to fold or bend when the vacuum device 2 is pushed forward by the user during cleaning.

[0075] The liner 24 can be attached in any suitable manner. Preferably, the first surface 74 of the liner 24 is permanently attached to the bottom surface 66 of the dust collection chamber 28. Suitable methods include using heat bonding or adhesives. Alternatively, the liner 24 can be replaced and removably attached, for example, by hook and loop fasteners.

[0076] When using, refer 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 so that the filter 26 material package is sandwiched between the sealing surface 30 of the plastic tray 22 and the vacuum sealing surface 16. The at least one connector arm 18, 20 is then released so that the connector arms engage 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. The user then activates the vacuum device 2, thereby generating suction. The air drawn into the dust collection chamber 28 causes the opening cover 54 to move to the open position (as shown in FIG. 1 ). Figure 12A 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 below the front guard portion 32 in front of the replacement head 4 and into the dust chamber 28 through the opening 52. Once inside the dust chamber 28, the air, dust, and debris are drawn toward the filter 26, through which the air passes. Dust and debris cannot pass through the filter 26 and are retained in the dust chamber 28. If desired, 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. The user can then use the second surface 60 of the pad 24 to wipe the floor with the cleaning fluid to thoroughly clean the floor.

[0077] During the cleaning process, one or more of the following will occur: dust chamber 28 will fill with dust and debris; filter 26 will become clogged; and liner 24 will become dirty. A user can selectively replace replacement head 4 at any time by moving at least one of connector arms 18, 20 to an open position, thereby disengaging first connector lip 56 and second connector lip 62 from vacuum head 10. Advantageously, in the depicted embodiment, a user can replace the entire replacement head 4 all at once without mess and replace it with a newer replacement head 4 for future use.

[0078] Those skilled in the art will appreciate that additional embodiments or variations of the above description may be implemented without departing from the spirit or scope of the present invention. For example, various alternatives for connecting the replacement head to the vacuum head may be utilized (e.g., replacing the connector lip, wrapping an elastic band around the vacuum head, etc.). Additionally, the term "about" is used herein to describe additional ranges of values ​​known to those skilled in the art to be equivalent to the stated range. When the term "about" is used in the context of a range, the term is intended to apply to both ends of the range.

Claims

1. A replacement head, comprising: a tray comprising a dust collection chamber having a front wall and a bottom wall including an exterior surface, the dust collection chamber defining a generally enclosed area having a top surface configured to be coupled to a suction source, the top surface defining an air permeable passageway originating from an interior of the dust collection chamber; an opening extending through a front wall of the dust chamber to allow debris to flow into the dust chamber and to allow debris to be retained in the dust chamber both with and without suction applied to the dust chamber; as well as a liner having at least one layer of material, the liner being connected to the tray and having a cleaning surface configured to be positioned over a surface to be cleaned; wherein a horizontal line extending forward from the bottom of the bottom wall forms an acute angle with the outer surface of the front wall; wherein the top surface is substantially parallel to the bottom wall; and Wherein, when the cleaning surface of the pad is positioned on the surface to be cleaned, the opening is open to the surface to be cleaned.

2. The replacement head of claim 1 , wherein the opening is located entirely on the front wall of the tray.

3. The replacement head of claim 1 , wherein the acute angle between the horizontal line and the outer surface of the front wall is 78 degrees.

4. The replacement head of claim 1, wherein the opening has an area between 0.5 square inches (10 square centimeters) and 3.0 square inches (19 square centimeters). The replacement head of claim 1 , wherein the front wall comprises a curve.

6. The replacement head of claim 1 , wherein the opening is generally rectangular in shape.

7. The refill head of claim 1 , wherein the tray includes more than one opening for allowing debris to flow into the dust collection chamber.

8. The replacement head of claim 1 wherein the opening is generally oval in shape.

9. The replacement head of claim 1 , wherein the opening is generally circular.

10. The replacement head of claim 1, wherein a front suction chamber is located at least partially between a front guard portion and the opening, wherein the front suction chamber is located exterior to the replacement head.

11. The replacement head of claim 1 , wherein the cushion comprises at least a first layer of material and a second layer of material, the first and second layers of the cushion being ultrasonically welded together.

12. The replacement head of claim 11 , wherein the ultrasonic weld is substantially continuous along at least one edge of the liner.

13. The replacement head of claim 11 wherein at least one edge of the liner has at least two localized weld locations spaced apart from one another.

14. The replacement head of claim 11 wherein the ultrasonic weld is located away from an edge of the liner.

15. A replacement head comprising: a tray comprising a dust chamber, the dust chamber having a front wall and a bottom wall including an exterior surface, the dust chamber defining a generally enclosed area having a top surface configured to be coupled to a suction source, the top surface defining an air permeable passage from an interior of the dust chamber to an exterior of the dust chamber, the tray including an opening through the front wall of the dust chamber to allow debris to flow into the dust chamber and to allow debris to be retained in the dust chamber both with and without suction applied to the dust chamber; as well as a liner having at least one layer of material, the liner being connected to the tray and having a cleaning surface configured to be positioned over a surface to be cleaned; wherein a horizontal line extending forward from the bottom of the bottom wall forms an acute angle with the outer surface of the front wall; wherein the top surface is substantially parallel to the bottom wall; and Wherein, when the cleaning surface of the pad is positioned on the surface to be cleaned, the opening is open to the surface to be cleaned.

16. The replacement head of claim 15, wherein the acute angle between the bottom of the bottom wall and the outer plane of the front wall is 78 degrees.

17. The replacement head of claim 15, wherein the opening has an area between 0.5 square inches (10 square centimeters) and 3.0 square inches (19 square centimeters).

18. The replacement head of claim 15, wherein the front wall comprises a curve.

19. The replacement head of claim 15, wherein the opening is generally rectangular in shape.

20. The replacement head of claim 15, wherein the opening is generally oval in shape.

21. The replacement head of claim 15, wherein the opening is generally circular.

22. A replacement head, comprising: A pallet, comprising: a dust collection chamber having a front wall and a bottom wall including an exterior surface, the dust collection chamber defining a generally enclosed area having a top surface configured to be coupled to a suction source, the top surface defining an air permeable passage from an interior of the dust collection chamber to an exterior of the dust collection chamber, a suction inlet extending through a front wall of the dust chamber to allow debris to flow into the dust chamber and to remain in the dust chamber both with and without suction applied to the dust chamber, a sealing surface configured to form a seal with a cleaning device when the refill head is attached to the cleaning device; and a liner having at least one layer of material, the liner being connected to the tray and having a cleaning surface configured to be positioned over a surface to be cleaned; wherein a horizontal line extending forward from the bottom of the bottom wall forms an acute angle with the outer surface of the front wall; wherein the top surface is substantially parallel to the bottom wall; and Wherein, when the cleaning surface of the pad is positioned on the surface to be cleaned, the suction inlet is substantially open to the surface to be cleaned.

23. The replacement head of claim 22, further comprising a filter connected to the tray such that the filter covers the ventilation passageway.

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