Vacuum cleaner

Abstract

A vacuum cleaner (10) includes a separation system (100), a suction motor (1004) for generating an airflow through the separation system, a motor housing (1002) housing the suction motor, and a battery assembly (2000) for powering the suction motor, where the battery assembly is releasably connected to the motor housing such that a first portion of the battery assembly is located within the motor housing.

Description

Background Art

[0001] Vacuum cleaners rely on a suction generator to generate an airflow that is used to pick up dirt from the surface to be cleaned. The airflow passes through one or more separation stages to separate dirt from the airflow before it is discharged from the vacuum cleaner. Some vacuum cleaners are so-called "handheld" vacuum cleaners, where the user can and is intended to support the main unit of the vacuum cleaner in their hand during use. Some vacuum cleaners may also be battery powered so that they do not need to be plugged in to be used. Summary of the invention

[0002] A first aspect of the present disclosure describes a vacuum cleaner comprising a separation system, a suction motor for generating an airflow through the separation system, a motor housing for accommodating the suction motor, and a battery assembly for powering the suction motor, wherein the battery assembly is releasably connected to the motor housing such that a first portion of the battery assembly is located within the motor housing.

[0003] According to an embodiment of the first aspect of the present disclosure, the motor housing includes an opening configured to receive a first portion of the battery assembly.

[0004] According to an embodiment of the first aspect of the present disclosure, the first portion of the battery assembly includes an interface portion configured to prevent the battery assembly from rotating within the motor housing opening. The opening includes a planar interior surface, and the interface portion is planar and located below the planar interior surface.

[0005] According to an embodiment of the first aspect of the present disclosure, the motor housing includes a battery locking mechanism configured to releasably engage the battery assembly. The first portion of the battery assembly includes a positioning recess configured to releasably engage the battery locking mechanism.

[0006] According to an embodiment of the first aspect of the present disclosure, the battery assembly further includes a plurality of battery cells, and at least one battery cell is located in a first portion of the battery assembly. The battery assembly further includes a second portion accommodating at least one battery cell. The battery management system has a planar battery circuit board located in the second portion of the battery assembly. In one embodiment, the plurality of battery cells are aligned along a common axis and are parallel to the plane of the battery circuit board. The plurality of battery cells are four battery cells, and the battery circuit board covers three battery cells located in the second portion of the battery assembly. The battery assembly includes an inner sleeve, which is an elongated tube having a central axis, wherein the common axis of the plurality of battery cells is parallel to the central axis.

[0007] According to an embodiment of the first aspect of the present disclosure, the second portion is located outside the motor housing. The second portion and the motor housing each include an outer surface that defines at least a portion of an outer surface of the main unit of the vacuum cleaner.

[0008] According to an embodiment of the first aspect of the present disclosure, the vacuum cleaner has a central longitudinal axis, and the separation system, the suction motor and the battery assembly are aligned along the central longitudinal axis. The suction motor has a rotation axis coaxial with the central longitudinal axis. The battery assembly has a central axis coaxial with the central longitudinal axis.

[0009] According to an embodiment of the first aspect of the present disclosure, the separation system includes a bin body, the battery assembly includes a battery housing, the bin body, the motor housing and the battery housing are coupled together to define a main unit of the vacuum cleaner, and the bin body, the motor housing and the battery housing are each an elongated tubular portion.

[0010] According to an embodiment of the first aspect of the present disclosure, the battery assembly can be separated from the motor housing in a direction parallel to the central longitudinal axis. The battery housing includes an outer sleeve at least partially formed of a non-slip material.

[0011] According to an embodiment of the first aspect of the present disclosure, the vacuum cleaner further comprises a cleaning head assembly fluidly connected to the separation system. The cleaning head assembly comprises at least two brush bars, each brush bar is conical. The at least two brush bars are four brush bars arranged in two pairs.

[0012] According to an embodiment of the first aspect of the present disclosure, the separation system has a length to diameter ratio of at least 0.01.

[0013] According to an embodiment of the first aspect of the present disclosure, the vacuum cleaner further comprises a main unit, which is a pole structure comprising a separation system, a suction motor and a battery assembly. An outer sleeve of the battery assembly defines a handle of the vacuum cleaner.

[0014] According to an embodiment of the first aspect of the present disclosure, the separation system is a non-cyclonic separation system. The separation system includes a chamber having an airflow inlet; and a filter arranged in the chamber for filtering the airflow from the airflow inlet. The main surface of the filter extends parallel to the direction of the bulk airflow entering the chamber. The separation system includes an elongated bin body having a central axis, and the bulk airflow direction is parallel to the central axis.

[0015] A second aspect of the present disclosure describes a vacuum cleaner comprising a main unit having a handle and a cleaning head comprising a cleaning head housing, a neck for connecting to the main unit, the neck extending from the cleaning head housing, and more than two brush bars located within the cleaning head housing, wherein the handle and the neck share a common central axis.

[0016] According to an embodiment of the second aspect of the invention, the cleaning head comprises four brush bars located within the cleaning head housing. Each brush bar is substantially frusto-conical.

[0017] According to an embodiment of the second aspect of the present invention, each brush bar can rotate around the corresponding brush bar axis, and the cleaning head is located on a horizontal surface to be cleaned, the common central axis is vertically positioned relative to the horizontal surface to be cleaned, and each brush bar axis is inclined relative to the common central axis and / or inclined relative to the horizontal surface to be cleaned.

[0018] According to an embodiment of the second aspect of the present disclosure, the common central axis is vertically positioned relative to the horizontal surface on which the cleaning head is located, and when viewed along the direction of the common central axis, the cleaning head housing has a generally rectangular shape, and the common central axis is orthogonal to and intersects the central short axis of the cleaning head housing. At least two brush bars are positioned so that they are located on opposite sides of the central short axis.

[0019] According to an embodiment of the second aspect of the present disclosure, each brush bar includes an outer surface formed of nylon.

[0020] According to an embodiment of the second aspect of the present disclosure, the common central axis is vertically positioned relative to the horizontal surface on which the cleaning head is located, and when viewed along the direction of the common central axis, the cleaning head housing has a generally rectangular shape, and the common central axis is orthogonal to and spaced from the central main axis of the cleaning head housing.

[0021] According to an embodiment of the second aspect of the invention, the cleaning head includes a biasing mechanism for biasing the neck to a predetermined orientation relative to the cleaning head housing. The cleaning head is located on a horizontal surface to be cleaned, and the biasing mechanism is configured to bias the neck so that the common central axis extends substantially vertically relative to the horizontal surface to be cleaned. In addition, the cleaning head is located on a horizontal surface to be cleaned, and the main unit is separated from the cleaning head, and the biasing mechanism is configured to bias the neck so that the central axis of the neck extends substantially vertically relative to the horizontal surface to be cleaned.

[0022] According to an embodiment of the second aspect of the present disclosure, a vacuum cleaner comprises a separation system, a suction motor for generating an airflow through the separation system, and a battery assembly for powering the suction motor, wherein the separation system, the suction motor and the battery assembly are aligned along a common central axis. The battery assembly defines a handle.

[0023] According to an embodiment of the second aspect of the present disclosure, the separation system is a non-cyclonic separation system. The separation system has a central axis coaxial with the common central axis. The suction motor has a rotation axis coaxial with the common central axis.

[0024] According to an embodiment of the second aspect of the present disclosure, the battery assembly has a central axis coaxial with the common central axis. The suction motor is located between the separation system and the battery assembly. The separation system includes an air inlet, and a large amount of airflow direction through the air inlet is parallel to the common central axis.

[0025] According to an embodiment of the second aspect of the present disclosure, the separation system includes a bin body, a suction motor is accommodated in a motor housing, a battery assembly includes a battery housing, and the bin body, the motor housing and the battery housing are connected together to define a main unit of the vacuum cleaner. The bin body, the motor housing and the battery housing are each an elongated tubular portion.

[0026] According to an embodiment of the second aspect of the present disclosure, the main unit has a maximum outer diameter, and one or more of the compartment body, the motor housing, and the battery housing share the maximum outer diameter. The maximum outer diameter is 50 mm or less. The maximum outer diameter is 38 mm.

[0027] According to an embodiment of the second aspect of the present disclosure, two or more of the cartridge body, the motor housing, and the battery housing have the same maximum outer diameter.

[0028] According to an embodiment of the second aspect of the invention, the neck is movably mounted to the cleaning head housing. The neck comprises first and second arms pivotally connected to the cleaning head housing. The neck comprises a tubular body, the first and second arms are inclined relative to the tubular body so that a common central axis is vertically positioned relative to a horizontal surface on which the cleaning head is located, and the common central axis is parallel to and spaced apart from the central cleaning head axis.

[0029] A third aspect of the present disclosure describes a vacuum cleaner, comprising a separation system, a suction motor for generating an airflow through the separation system, and a control circuit for controlling the suction motor, wherein the control circuit is mounted on a control circuit board, and the control circuit board defines a plane extending in a direction parallel to the rotation axis of the suction motor.

[0030] According to an embodiment of the third aspect of the present disclosure, the control circuit board is located downstream of the suction motor. The control circuit board is positioned so that the airflow downstream of the suction motor is split at first and second opposite sides of a plane defined by the control circuit board to form a Y-shaped airflow.

[0031] According to an embodiment of the third aspect of the present disclosure, the suction motor and the control circuit board are contained in a common chassis. The suction motor is softly mounted in the common chassis, and the control circuit board is hard mounted in the common chassis. The suction motor is contained in a first part of the common chassis, the control circuit board is contained in a second part of the common chassis, and the second part of the common chassis is fluidically isolated from the first part of the common chassis. No airflow filter is provided between the suction motor and the control circuit board.

[0032] According to an embodiment of the third aspect of the present disclosure, the cable extends between the second portion of the common chassis and the first portion of the common chassis, and the second portion of the common chassis includes a sealing member through which the cable extends.

[0033] According to an embodiment of the third aspect of the present disclosure, the second portion of the common chassis at least partially defines the first and second airflow paths downstream of the suction motor. The common chassis includes a first chassis half and a second chassis half, and the first and second chassis halves are discrete components that, when combined together, define the common chassis.

[0034] According to an embodiment of the third aspect of the present disclosure, a vacuum cleaner includes a motor housing, a suction motor and a control circuit board are located in the motor housing, the motor housing includes a first and a second airflow outlet, and the first and second airflow outlets are located on opposite sides of a plane defined by the control circuit board. In one embodiment, a common chassis is located in the motor housing, and the first and second airflow paths are in fluid communication with a corresponding one of the first and second airflow outlets.

[0035] According to an embodiment of the third aspect of the present disclosure, the control circuit board has a substantially rectangular cross-sectional shape, and wherein the main axis of the control circuit board extends in a direction parallel to the rotation axis of the suction motor. The smaller dimension of the control circuit board substantially corresponds to the outer diameter of the suction motor. The smaller dimension of the control circuit board is less than 38 mm.

[0036] According to an embodiment of the third aspect of the present disclosure, a vacuum cleaner includes a battery assembly including a plurality of battery cells arranged in a row, a control circuit board having a substantially rectangular cross-sectional shape, and a main axis of the control circuit board extending in a direction parallel to the battery cell rows.

[0037] According to an embodiment of the third aspect of the present disclosure, the separation system includes a central separation system axis, the control circuit board has a generally rectangular cross-sectional shape, and a major axis of the control circuit board extends in a direction parallel to the central separation system axis.

[0038] According to an embodiment of the third aspect of the present disclosure, the separation system includes an airflow inlet, the control circuit board has a substantially rectangular cross-sectional shape, and the main axis of the control circuit board extends in a direction parallel to a direction of a large amount of airflow through the airflow inlet.

[0039] According to an embodiment of the third aspect of the present disclosure, a vacuum cleaner includes a battery assembly and a power connection circuit board connected to the battery assembly and configured to supply power from the battery assembly to a suction motor, wherein the power connection circuit board defines another plane orthogonal to the plane defined by the control circuit board. The power connection circuit board and the control circuit board jointly define a T-shaped structure. The power connection board is accommodated in a third portion of a common chassis, and the second portion of the common chassis is located between the first and third portions of the common chassis.

[0040] According to an embodiment of the third aspect of the present disclosure, a vacuum cleaner includes an acoustic foam located downstream of a suction motor. The vacuum cleaner includes a radiator located downstream of the suction motor, and the radiator is positioned to guide the airflow downstream of the suction motor. The radiator includes a first radiator member located on a first side of the rotation axis of the suction motor and a second radiator member located on a second opposite side of the rotation axis of the suction motor.

[0041] According to an embodiment of the third aspect of the present disclosure, a vacuum cleaner comprises a user interface, which comprises a user interface circuit board, and the user interface circuit board defines another plane rotated by approximately 90 degrees relative to the plane defined by the control circuit board.

[0042] According to an embodiment of the third aspect of the present disclosure, the separation system includes a bin body, a suction motor and a circuit board are accommodated in a motor housing, and the vacuum cleaner includes a battery assembly, which includes a battery housing, the bin body, the motor housing, and the battery housing are coupled together to define a main unit of the vacuum cleaner, the control circuit board has a substantially rectangular cross-sectional shape, and the main axis of the control circuit board extends in a direction parallel to the central longitudinal axis of the main unit. Each of the bin body, the motor housing, and the battery housing is an elongated tube, and at least two of the bin body, the motor housing, and the battery housing have the same maximum width. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 is a perspective view of a vacuum cleaner;

[0044] Figure 2 is a perspective view of a vacuum cleaner positioned in a docking station;

[0045] Figure 3 is a perspective view of a main unit of a vacuum cleaner having a transparent bin body;

[0046] Figure 4 This is an exploded view of the main unit;

[0047] Figure 5 is a perspective view of the separation system of the main unit;

[0048] Figure 6 is a cross-sectional view of a bin assembly of a separation system;

[0049] Figure 7 It is an exploded view of the bin assembly;

[0050] Figure 8 is a perspective view of a wiper of a bin assembly;

[0051] Fig. 9 is a perspective cutaway view of a wiper of a bin assembly;

[0052] Fig.10is a schematic diagram of a cleaning head interlock system for a vacuum cleaner;

[0053] Fig.11 is a perspective view of a filter assembly of a separation system;

[0054] Fig.12 is a cross-sectional view of the filter assembly;

[0055] Fig.13 is a cross-sectional view of another filter assembly assembled to a core with a bin body;

[0056] Fig.14 is an exploded view of the filter assembly;

[0057] Fig.15 is a perspective view of a partially disassembled filter assembly;

[0058] Fig.16 is a perspective view of the core of the separation system with the auxiliary net;

[0059] Fig.17 is a perspective view of the core of the separation system without the auxiliary net;

[0060] Fig.18 is a cross-sectional view through the core;

[0061] Fig.19 is a first side view of a valve assembly of a separation system;

[0062] Fig. 20 is an upstream perspective view of the valve assembly;

[0063] Fig.21 is a downstream perspective view of the valve assembly;

[0064] Fig. 22 is a schematic diagram of the operation of the valve assembly;

[0065] Fig.23 is an exploded view of the motor assembly of the main unit;

[0066] Fig.24 is a perspective view of the motor assembly;

[0067] Fig.25 is a perspective view of a motor housing of a motor assembly;

[0068] Fig.26 is another perspective view of a motor housing of the motor assembly showing an insert of a battery assembly;

[0069] Fig. 27 is a first schematic cross-sectional view of a motor assembly;

[0070] Fig.28 is a second schematic cross-sectional view of the motor assembly;

[0071] Fig.29 is a schematic diagram of a suction motor of a motor assembly;

[0072] Fig.30 is a perspective view of a motor mount of a motor assembly;

[0073] Fig.31 is an exploded view of the user interface of the motor assembly;

[0074] Fig.32 is a cross-sectional view showing a user interface of a motor assembly;

[0075] Fig.33 is a cross-sectional view showing a housing insert of a motor assembly;

[0076] Fig.34 is a perspective view of a battery assembly of the main unit;

[0077] Fig.35 is a perspective view of a battery chassis of a battery subassembly;

[0078] Fig.36 is an exploded view of a battery subassembly of a battery assembly;

[0079] Fig.37 is a cross-sectional view of a battery assembly;

[0080] Fig.38 is a perspective view of a cleaning head of a vacuum cleaner;

[0081] Fig.39 is a side view of the cleaning head;

[0082] Fig.40 is a schematic diagram of the neck of the cleaning head;

[0083] Fig.41 is a schematic bottom view of the cleaning head;

[0084] Fig.42 is an exploded view of the dock;

[0085] Fig.43 It is a rear perspective view of the docking station;

[0086] Fig.44 is a side view of the docking station with the cleaning head;

[0087] Fig.45 is a side view of the main unit positioned vertically relative to a horizontal surface to be cleaned;

[0088] Fig.46 is a side view of a vacuum cleaner positioned vertically relative to a horizontal surface to be cleaned;

[0089] Fig.47 is a front view of a vacuum cleaner positioned vertically relative to a horizontal surface to be cleaned;

[0090] Fig.48 is a schematic diagram showing the airflow through the main unit in use, viewed from the side of the vacuum cleaner; and

[0091] Fig.49 is a schematic diagram showing the airflow through the main unit in use, viewed from the front of the vacuum cleaner. DETAILED DESCRIPTION

[0092] exist Figure 1 and Figure 2 The vacuum cleaner 10 is shown without and with a docking station.

[0093] The vacuum cleaner 10 comprises a main unit 12 and a cleaning head 3000. The vacuum cleaner 10 is a so-called "handheld" vacuum cleaner, in which the user can and is intended to support the main unit 12 in his hand during use, and is battery powered. Figure 2 As shown, a docking station 4000 may be provided to hold the vacuum cleaner 10 when not in use.

[0094] The main unit 12 is Figure 3 and 4 1 and 2. The detachable system 100 is shown separately in FIG. 1 and includes a separation system 100, a motor assembly 1000 and a battery assembly 2000.

[0095] Separation system 100 Figures 5 to 22 , and includes a cartridge assembly 102 , a filter assembly 200 , and a core 300 .

[0096] The cartridge assembly 102 includes a cartridge body 108 , a first connecting ferrule 110 , a second connecting ferrule 112 , a wiper 114 , and a cartridge interlock member 115 .

[0097] The bin body 108 is elongated and generally cylindrical and includes a first end 116, a second end 118, and a pair of rails 120. The bin body 108 is hollow, and the interior volume of the bin body 108 defines a debris collection chamber 122 of the separation system 100. When the filter assembly 200 is attached to the core 300 and located within the bin body 108, the debris collection chamber 122 has a substantially constant cross-sectional area in an area corresponding to the filter assembly 200. The bin body 108 has an outer diameter of approximately 38 mm, although diameters or other diameters in the range of 35 mm to 50 mm are also contemplated. The bin body 108 has an axial length of approximately 38 cm measured in a direction substantially parallel to the central bin axis B of the bin body 108. Therefore, the ratio of the diameter of the bin body 108 to the axial length of the bin body 108 is 0.01 (i.e., 38 / 3800). In other words, the diameter of the bin body 108 is approximately 1% of the axial length of the bin body 108. The bin body 108 is formed of a plastic material and is generally transparent. However, those skilled in the art will recognize that materials other than plastic may be used without departing from the art. The bin body 108 defines a separator housing of the separation system 100.

[0098] The guide rails 120 are generally elongated and linear in form and extend along the inner surface of the bin body 108 in a direction substantially parallel to the central bin axis B of the bin body 108. The guide rails 120 are integrally formed with the bin body 108 as part of the same molding process. The guide rails 120 are disposed diametrically opposite to each other and are in the same plane as the central bin axis B of the bin body 108.

[0099] The guide rails 120 extend between the first end 116 and the second end 118 of the bin body 108, and the guide rails 120 are spaced a certain length from the periphery of the first end 116 of the bin body 108 in a direction parallel to the central bin axis B. The length is determined by the size of the valve assembly 304 to accommodate the valve assembly 304 switching between the open and closed positions. Therefore, each guide rail 120 has an axial length of about 30 cm, which is measured in a direction parallel to the central bin axis B. Each guide rail 120 has a radial extent such that the guide rail protrudes a distance of about 5 mm into the debris collection chamber 122. The bin body 108 is slidably attached to the core 300 via the guide rails 120 and the guide surface 332 of the core 300.

[0100] The first connection ferrule 110 is located at the first end 116 of the cartridge body 108 and is shaped and sized so that the free end 3030 of the neck 3004 of the cleaning head 3000 can be received within the first connection ferrule 110. The first connection ferrule 110 includes a bend 124 and an engagement lip 142, the engagement lip 142 being shaped and sized to selectively engage with a cleaning head lock 3040 of the neck 3004 of the cleaning head 3000, as will be discussed in more detail below, and having a circular cross-sectional shape when viewed in a plane orthogonal to the central cartridge axis b. The end 130 of the first connection ferrule 110 proximate the cartridge body 108 has a circular cross-sectional shape when viewed in a plane orthogonal to the central cartridge axis B. The bend 124 has a diameter of approximately 38 mm, although diameters in the range of 35 mm to 50 mm or other diameters are also contemplated.

[0101] A planar surface 126 is provided that is shaped and dimensioned to be located below the electrical connections 318 of the core 300 when the cartridge body 108 is located about the core 300. A gap 136 is located between the bottom surface of the core 300 and the cartridge body 108. The gap 136 is configured such that a free end 3030 of the neck 3004 of the cleaning head 3000 may be received in the gap 136, as will be discussed in more detail below.

[0102] The first connection collar 110 partially defines an airflow inlet 140 of the separation system 100 .

[0103] The second connection collar 112 is located at the second end 118 of the cartridge body 108 and is generally cylindrical and hollow. The outer diameter of the second connection collar is approximately 38 mm, although diameters in the range of 35 mm to 50 mm or other diameters are also contemplated. The second connection collar 112 includes a cartridge buckle receiving portion 144 and two internal ribs 146.

[0104] The cartridge latch receiver 144 is located on a side of the cartridge body 108 opposite the engagement lip 142 of the first connection ferrule 110. The cartridge latch receiver 144 includes a latch member 148 shaped and sized to engage with a cartridge latch 1040 of the motor housing 1002 of the motor assembly 1000, as will be described in more detail below. The latch receiver 144 takes a different form than the engagement lip 142 of the first connection ferrule 110.

[0105] Internal ribs 146 are formed on the inner surface of the second connection ferrule 112 and are spaced radially opposite each other while being in the same plane as the central cartridge axis B. The internal ribs 146 extend along the length of the second connection ferrule 112 and are positioned such that the internal ribs 146 are substantially adjacent to the guide rails 120 at the second end 118 of the cartridge body 108.

[0106] Wiper 114 in Figure 8 and 9 15 and includes a first portion 154 and a second portion 152 secured by a screw 156. Another screw 155 is used to secure the wiper 114 to the second connecting ferrule 112. The first portion 154 includes a curved exposed wiper sheet 151, the shape and size of which substantially correspond to the main net 202 of the filter assembly 200. The first portion 154 also includes a mounting surface 153. The second portion 152 includes a wall 157, and the cross-sectional shape of the wall 157 is approximately semicircular when viewed in a plane orthogonal to the central bin axis B. The second portion 152 also includes a mounting surface 149. The screw 156 is used to secure the first portion 154 and the second portion 152 together via the respective mounting surfaces 153 and 149. The wiper 114 is formed of rubber or any material suitable for wiping the surface of the main net 202.

[0107] Fig.10 The cartridge interlocking member 115 is schematically shown, and includes a first engagement end 158 and a second engagement end 158 opposite to the first engagement end 158. The cartridge interlocking member 115 is formed of an elastically deformable material and is fixed to the core 300 so that the first engagement end 158 and the second engagement end 1581 are free floating. The first engagement end 158 defines an inclined contact surface for contacting the free end 3030 of the neck 3004 of the cleaning head 3000. When the cleaning head 3000 is inserted into the first connecting ferrule 110, the engagement lip 142 engages with the cleaning head lock 3040 of the neck 3004, and at the same time, the free end 3030 of the neck 3004 of the cleaning head 3000 engages with the first engagement end 158, causing the cartridge interlocking member 115 to pivot, so that the second engagement end 1581 moves toward the cartridge body 108 and abuts against the recess 1151 of the cartridge body, thereby preventing the cartridge body from further moving. In the absence of an applied force, the first engagement end 158 of the cartridge interlock member 115 is generally aligned with the gap 136 between the core 300 and the cartridge body 108 , while the second engagement end 1581 is not in contact with the cartridge body 108 .

[0108] The filter assembly 200 is Figures 11 to 15 , and includes a main net 202, a bracket 204, a retainer 206, and a filter medium 208. The bracket 204 includes an upper tray 2041 and a lower tray 2042. In view of the nature of the filter assembly 200, the separation system 100 can be considered a non-cyclonic separation system. The main net 202 and the filter medium 208 can be considered to include a first and a second separation mechanism, respectively.

[0109] The filter assembly 200 consists of a main net 202 and a filter medium 208. The main net 202 acts as the main separation layer to capture particles larger than 350um. This is equivalent to about 70% of the dust. The filter medium 208 captures all particles with a size less than 350um. Much of this dust will be located between the main net 202 and the filter medium 208. For reasons of hygiene and product safety, it is necessary to ensure that the user is not exposed to this trapped dust during the filter removal process. It is also found that during the cleaning process, the filter medium 208 is cleaned independently of the main net 202, which is important for the service life of the filter. This ensures more effective cleaning and shorter drying time. Therefore, the main net 202 and the filter medium 208 are fixed by an upper tray 2041 and a lower tray 2042, respectively, with a predetermined gap between the upper tray and the lower tray to capture as many dust particles with a size less than 350um as possible between the main net 202 and the filter medium 208. In one embodiment, the predetermined gap is about 1.5mm. The gap between the upper tray 2041 and the lower tray 2042 completely encapsulates small particles, resulting in minimal dust showing on surrounding components during the filter removal step. Even if the filter assembly is exposed to violent motion and rotated upside down, most of the dust is still encapsulated between the upper tray 2041 and the lower tray 2042.

[0110] The upper tray 2041 and lower tray 2042 are secured together in normal use and during the filter assembly removal process, but are capable of being separated once detached from the rest of the vacuum cleaner.

[0111] The main net 202 is used to filter coarse debris from the air flow during use, and therefore may also be referred to as a filter, or in fact a coarse filter. In some examples, the main net 202 is referred to as a first filter. The main net 202 is formed of a metal such as aluminum or other metallic materials, and includes through holes distributed along the length of the main net 202. Each through hole has a chamfered edge and has a diameter of about 350um. Therefore, dust particles larger than 350um will be prevented from passing through the main net 202. This means that most of the dust particles will be trapped in the dust collection chamber defined between the main net 202 and the bin body 108.

[0112] When observed in a plane orthogonal to the longitudinal separator axis S, the main net 202 has a generally U-shaped cross-sectional shape. In other words, when observed along the length direction of the main net 202, the main net 202 has a generally U-shaped cross-sectional shape. The curvature of the main net 202 causes the free ends of the U-shaped cross-sectional shape to diverge from each other, so the main net 202 has a relatively shallow curvature. The main net 202 has an axial length of about 28 cm measured in a direction parallel to the longitudinal separator axis S. The groove formed by the upstream surface of the main net 202 forms an airflow channel for a large amount of airflow from the airflow inlet. The upstream surface of the main net 202 can also be referred to as the main surface.

[0113] The upper tray 2041 includes a first end wall 214 and a second end wall 216, a first edge wall 218 and a second edge wall 220, and seven cross members 222. The first end wall 214 and the second end wall 216 each have a curved upper surface, which is shaped and sized so that the main net 202 is located on the curved upper surface. Each of the first end wall 214 and the second end wall 216 has a specific area located below the main net 202. The first end wall 214 includes an end wall clip 224, which is shaped and sized to engage with a corresponding end wall lip 246 of the first end wall 234 of the lower tray 2042. The shape and size of the second end wall 216 are designed to abut the core connection portion 248 of the lower tray 2042. When the upper tray and the lower tray are slidably coupled together, the end wall clip 224 engages with the end wall lip 246, and together can be inserted into a corresponding groove provided on the core 300, and the core connection portion 248 is further moved to engage with the positioning channel 311 of the core 300, locking the filter assembly to the core 300.

[0114] The first edge wall 218 and the second edge wall 220 extend outwardly from the first end wall 214 and the second end wall 216 and define a track 226, which is shaped and sized to be slidably received in the corresponding track channel 254 of the lower tray 2042. The first edge wall 218 and the second edge wall 220 have an axial bending length of about 31 mm, and thus have the same axial length as the main net 202.

[0115] The cross members 222 each extend between the first edge wall 218 and the second edge wall 220 and are curved to correspond to the curvature of the main net 202. The cross members 222 are evenly spaced along the axial length of the first edge wall 218 and the second edge wall 220 and define a support surface on which the main net 202 is located. Each cross member 222 is located under the main net 202. The cross members 222 are used to divide the main net 202 into eight sub-areas.

[0116] The retainer 206 is bent about an axis substantially parallel to the longitudinal separator axis S such that the retainer 206 has a generally U-shaped cross-sectional shape when viewed in a plane orthogonal to the longitudinal separator axis S. The retainer 206 is shaped and dimensioned to be positioned below the upper tray 2041 and above the filter media 208. The retainer 206 has a width measured in a direction orthogonal to the longitudinal separator axis S that corresponds to the filter media 208. The retainer 206 includes a repeating pattern of cutouts 228 that repeats across the entire length of the filter media 208.

[0117] The filter media 208 is any form of filter media commonly used in vacuum cleaners, and includes a filter media body 230 and filter wings 232. The filter media body 230 has a width of about 30 mm measured in a first direction orthogonal to the longitudinal separator axis S, and such that the filter media body 230 can be accommodated within the filter media chamber 244 of the lower tray 2042. The filter media body 230 has a thickness measured in a second direction orthogonal to the longitudinal separator axis S and orthogonal to the first direction, such that the filter media body 230 can be accommodated within the filter media chamber 244 of the lower tray 2042.

[0118] Filter wings 232 extend from opposite sides of the top end of the filter media body 230, and each filter wing 232 extends from the filter media body 230. The filter wings 232 also extend axially from the end of the filter media body 230. The filter wings 232 are shaped and sized to cover a portion of the upper edge 242 of the lower tray 2042, and are shaped and sized to be located between the track channels 254 of the lower tray 2041. The form of the filter media body 230 and the filter wings 232 is such that when viewed in a plane orthogonal to the longitudinal separator axis S, the filter media 208 has a generally T-shaped cross-sectional shape, although slightly curved about the longitudinal separator axis S.

[0119] The lower tray 2042 includes a first end wall 234 , a second end wall 236 , a side wall 238 extending between the first end 234 and the second end 236 , three cross members 240 extending between the side walls 238 , and an upper edge 242 .

[0120] The first end wall 234 and the second end wall 236 each have a width in a direction orthogonal to the longitudinal separator axis S. The side walls 238 each have a length in a direction parallel to the longitudinal separator axis S. The first and second end walls 234, 236, the side walls 238, and the cross member 240 collectively define a filter media chamber 244. The filter media chamber 244 is shaped and sized to accommodate the filter media body 230 of the filter media 208.

[0121] The upper edge 242 is formed on the upper surface of the first and second end walls 234, 236 and the side wall 238 and extends outwardly to overhang the first and second end walls 234, 236 and the side wall 238. A first portion of the upper edge 242 corresponding to the first end wall 234 defines an end wall lip 246 to releasably engage the end wall clip 224 of the first end wall 214 of the net bracket 204. A second opposing portion of the upper edge 242 corresponding to the second end wall 236 includes a core connection portion 248.

[0122] The filter media 208 is inserted into the filter media chamber 244, and ultrasonic welding is applied to weld the filter media 208 to the filter media chamber 244. Thereafter, the retainer 206 is placed on top of the filter media 208, and further ultrasonic welding is applied to weld the retainer to the lower tray 2042, thereby enclosing the filter media 208 between the lower tray 2042 and the retainer 206. In particular, the retainer 206 is welded to the upper edge 242 of the lower tray 2042.

[0123] The core connection portion 248 includes a locating protrusion 250 and an upright wall 252. The shape and size of the locating protrusion 250 are suitable for being accommodated in the locating channel 311 of the core 300. The locating protrusion 250 has a different form than the end wall clip 224, so that the end wall clip 224 cannot be located in the locating channel 311. Therefore, the filter assembly 200 can be asymmetric about an axis orthogonal to the longitudinal separator axis S, and an error-proofing arrangement can be defined. The upright wall 252 has a height in a direction orthogonal to the longitudinal separator axis S, so that when the filter assembly 200 is assembled, the upright wall 252 is substantially adjacent to the second end wall 216 of the net bracket 204.

[0124] The portion corresponding to the upper edge 242 of the side wall 228 includes a track channel 254 that is shaped and dimensioned to slidably receive the track 226 of the first edge wall 218 and the second edge wall 220 of the net bracket 204 .

[0125] Fig.13 Another embodiment of a lower tray 2042 is shown in which the filter media 208 is a pleated media filter having a rectangular cross-sectional shape when viewed in a plane orthogonal to the longitudinal separator axis S.

[0126] The filter media 208 can be a hygroscopic media such that when the hygroscopic media becomes wet, it will expand beyond or through the opening of the holder 206, causing interference between the lower tray 2041 and the upper tray 2042 to prevent a wet or damp filter from being attached or inserted into the core 300. In other words, if the hygroscopic media is wet, the hygroscopic media will expand through the opening of the holder, preventing the lower tray 2042 from being able to be slidably coupled to the upper tray 2041. In addition, a water-colored indicator can be applied to the surface of the filter media 208 as a visual aid for the user to know whether the filter media is wet or dry. For example, the water-colored indicator can be applied to the bottom surface of the filter media 208 so that when the filter media 208 is wet, the water-colored indicator is exposed through the portion defined by the three cross members 240.

[0127] Figures 16 to 33 A core 300 is shown including a core body 302 and a valve assembly 304 .

[0128] The core body 302 is elongated and includes a first end 306, a second end 308, an outlet channel 310, an auxiliary mesh 312, an outlet conduit 314, an emergent channel 316, and an electrical connection 318. The auxiliary mesh 312 may be considered a third separation mechanism. Fig.16 A core 300 with an auxiliary web 312 is shown, and Fig.17 The core 300 is shown without the auxiliary mesh 312 .

[0129] The core body 302 has a maximum axial length of about 33 cm measured in a direction parallel to the central longitudinal axis C of the core body 302 between the valve assembly 304 and the second end 308. Such a length substantially corresponds to the length of the cartridge assembly 102. The core body 302 has a maximum width of slightly less than 38 mm measured in a first direction orthogonal to the central longitudinal axis C of the core body 302. The core body 302 has a maximum height of about 21 mm measured in a second direction orthogonal to the central longitudinal axis C of the core body 302 and orthogonal to the first direction. The dimensions of the core body 302 are such that the core body 302 can be selectively received within the cartridge assembly 102.

[0130] The valve mounting channel 320 and the ramp 322 are located toward the first end 306 of the core body 302. The valve mounting channel 320 is shaped and sized to accommodate the valve seat 340 of the valve assembly 304. The valve mounting channel 320 extends across the entire width of the core body 302 and is shaped to define half of a dovetail joint. The lower surface of the valve mounting channel 320 includes a locating recess 321, which is shaped and sized to receive a corresponding locating protrusion 350 of the valve seat 340 of the valve assembly 304. The ramp 322 is upright relative to the valve mounting channel 320 and includes a cutout 324. The cutout 324 is generally U-shaped, and the curvature of the cutout 324 substantially corresponds to the curvature of the main mesh 204 of the filter assembly 200. The ramp 322 is spaced apart from the valve mounting channel 320 in a direction measured parallel to the central longitudinal axis C of the core body 302. This distance provides clearance for the valve assembly 304 to move between the open and closed positions.

[0131] The second end 308 of the core body 302 includes a plane wall 309 and a positioning channel 311. The plane wall 309 stands upright from the same side of the core body 302 as the inclined surface 322 and extends orthogonally to the central longitudinal axis C of the core body 302. The positioning channel 311 is located on the side of the plane wall 309 facing the inclined surface 322 and extends upward in a direction orthogonal to the central longitudinal axis C of the core body 302. The positioning channel 311 is defined by two opposing walls 313, and the free ends of the opposing walls 313 are inclined toward each other. The shape and size of the positioning channel 311 are suitable for receiving the positioning protrusion 250 of the core connecting portion 248 of the filter assembly 200.

[0132] The outlet channel 310 is formed in the upper surface of the core body 302, on the same side of the core body 302 as the inclined surface 322, and between the inclined surface 322 and the first end 306 of the core body 302. The lower surface of the outlet channel 310 near the second end 308 of the core body 302 defines an inclined surface 326 toward the outlet conduit 314. The shape and size of the outlet channel 310 are suitable for accommodating a portion of the lower tray 2042 and the filter media body 230. The outlet channel 310 is located below the main net 202. The outlet channel 310 extends in a direction parallel to the main net 202 extending along the chamber 122. The direction in which the outlet channel 310 extends is also parallel to the direction of the bulk airflow entering the separation system 100 through the airflow inlet 140. In addition, the direction in which the main net 202 extends in the chamber 122 is parallel to the central handle axis of the outer sleeve 2018. In use, the minimum distance between the airflow inlet 140 and the primary mesh 202 measured in a direction parallel to the direction of bulk airflow through the airflow inlet 140 is about 5 mm, and in some examples may not exceed 10 mm.

[0133] The shape and size of the upper perimeter 328 of the outlet channel 310 are designed to contact the upper edge 242 of the lower tray 2042 so that the upper edge 242 of the lower tray 2042 can be supported on the upper perimeter 328 of the outlet channel 310. In general, the lower tray 2042, the filter media body 230, the auxiliary net 312 and the outlet channel 310 are used to partially define the airflow outlet 330 of the separation system 100.

[0134] Located beyond the side edges of the upper perimeter 328 of the outlet passage 310 are guide surfaces 332 that are shaped and dimensioned to slidably receive the rails 120 of the bin body 108 of the bin assembly 100 thereon.

[0135] The auxiliary net 312 is used to filter coarse debris from the air flow during use, and therefore can also be referred to as a filter, or in fact a fine filter. When the separator cartridge 200 is removed from the outlet passage 310, the auxiliary net 312 is also used to prevent any debris from falling from the separator cartridge 200 into the outlet passage 310, which will be discussed in more detail below.

[0136] The auxiliary net 312 is formed of a metal such as aluminum and includes through holes evenly distributed along the length of the auxiliary net 312. Each through hole has a chamfered edge. When measured in a direction parallel to the central longitudinal axis C of the core body 302, the auxiliary net 312 has an axial length corresponding to the cutout that accommodates the filter assembly 200. The auxiliary net 312 has a width measured in a direction orthogonal to the central longitudinal axis C of the core body 302, which corresponds to the cutout that accommodates the filter assembly 200. The shape and size of the auxiliary net 312 are configured to be accommodated in the outlet channel 310, and so that the auxiliary net 312 can be located below the filter assembly 200. When viewed in the direction in which the auxiliary net 312 extends, the auxiliary net 312 has a cross-sectional shape that is substantially different from the cross-sectional shape of the main net 202. For example, the auxiliary net 312 can have a substantially flat cross-sectional shape.

[0137] The auxiliary net 312 is installed in the outlet channel 310. The auxiliary net 312 is located below the main net 202.

[0138] The outlet duct 314 is located at the second end 308 of the core body 302 and is in fluid communication with the outlet channel 310. Therefore, the outlet duct 314 can also be considered to form a part of the airflow outlet 330 of the separation system 100. The outlet duct 314 has a maximum cross-sectional area greater than the maximum cross-sectional area defined between the lower tray 2042 and the base of the outlet channel 310 when viewed from a plane orthogonal to the central longitudinal axis C. The end of the outlet duct 314 away from the outlet channel 310 is open.

[0139] Emergence channel 316 extends from first end 306 to second end 308 of core body 302 and is located beneath outlet channel 310 and outlet conduit 314. Emergence channel 316 is a hollow chamber that accommodates electrical connections extending from motor assembly 1000 and battery assembly 2000, as will be discussed in more detail below.

[0140] The electrical connection 318 extends outwardly from the first end 306 of the core body 302 in a direction away from the valve assembly 304. The electrical connection 318 is elevated relative to a lower wall of the core body 302 that defines an outer wall of the looming channel 316. The electrical connection 318 is shaped and dimensioned to be received within the cartridge assembly 102 and to releasably engage with a corresponding cleaning head electrical connection 3036 of the cleaning head 3000, as will be discussed in greater detail below.

[0141] The electrical connection portion 318 accommodates three terminal connections 336, and the lower surface of the electrical connection portion 318 located below the valve mounting passage 320 defines an abutment surface 338 for selectively engaging the engagement end 158 of the cartridge interlock member 115. A silicone film 3181 is provided at one end of the electrical connection portion 318 facing the electrical connection portion 3036. The silicone film 3181 includes an "o" or "+" cutout for terminal insertion. This prevents dust from entering the electrical connection portion 318.

[0142] The valve assembly 304 is Figures 14 to 16 , and includes a valve seat 340 , a flexible member 342 and a rigid member 344 .

[0143] The valve seat 340 is relatively rigid. The valve seat 340 is elongated in form and is shaped and sized to be slidably received within the valve mounting passage 320. The valve seat 340 has a structure that is T-shaped in cross section, forming the valve mounting passage 320. The valve seat 340 has a width measured in a direction orthogonal to the central longitudinal axis C of the core body 302, so that the valve seat 340 extends substantially across the entire width of the core body 302 when located in the valve mounting passage 320.

[0144] The valve seat 340 clamps the flexible member 342 and holds the flexible member 342 in an upright manner, together forming the T-shaped valve assembly 304. Additional fixing means are provided to fix the flexible member 342 to the valve seat 340. At least two keyholes are provided on the valve seat and are shaped and sized to receive a predetermined amount of flexible material, which is formed as part of the overmolding process to form the flexible member 342 and is used to fix the flexible member 342 to the valve seat 340. The predetermined amount of flexible material forming the flexible member 342 extending through the keyholes forms the locating protrusions 350. These locating protrusions 350 extend away from the lower surface of the valve seat 340 and are shaped and sized to be received in the locating recesses 321 of the valve mounting passage 320. The height of the locating protrusions 350 is such that the locating protrusions 350 can be removed from the locating recesses 321 when sufficient force is applied to the valve assembly 304 in the direction of the valve seat 340 without causing damage to the locating protrusions 350. The positioning protrusion 350 is substantially centrally located along the valve seat 340 .

[0145] The flexible member 342 is formed of silicone. The flexible member 342 is overmolded onto the valve seat 340 and has a substantially semicircular cross-sectional shape.

[0146] The rigid member 344 includes a body 356 and a first contact portion 358 and a second contact portion 360. The body 356 is of a generally semicircular cross-sectional shape, while the first body 358 and the second body 360 are of a generally square or rectangular cross-sectional shape. The first contact portion 358 and the second contact portion 360 extend generally radially outward from the body 356 in the region of the linear portion of the body 356 and extend beyond the flexible member 342, clamping the edge of the flexible member 342. The upstream face of the body 356 includes three molded protrusions 362 extending through the opening of the flexible member 324.

[0147] As part of the overmolding process to form the flexible member 342, the rigid member 344 is embedded within the flexible member 342. The rigid member 344 is only partially embedded within the flexible member 342, leaving the downstream face of the rigid member 344 exposed. The flexible member 342 extends substantially around the entire perimeter of the body 356 of the rigid member 344 to define a sealing lip 364.

[0148] The flexible member 342 and the rigid member 346 together define a valve member 366 of the valve assembly 304, and the valve member 366 has an upstream face 368 and a downstream face 370. The upstream face 368 is defined by the flexible member 342, the first contact portion 358 and the second contact portion 360 of the rigid member 344, and the molded protrusion 362 of the rigid member 344. The downstream face 370 is defined by the sealing lip 364 of the flexible member 342, the body 356 of the rigid member 344, the first contact portion 358 and the second contact portion 360 of the rigid member 344.

[0149] Rigid member 344 is embedded within flexible member 342 such that the flexible material of flexible member 342 is located between valve seat 340 and rigid member 344, with such flexible material having a predetermined height between valve seat 340 and rigid member 344. This portion of flexible material effectively defines a living hinge 372 that enables flexible member 342, and therefore valve member 366, to move relative to valve seat 340. Valve seat 340 effectively defines a hinge axis about which valve member 366 can rotate.

[0150] The receiving channel 354 extends linearly across the upper surface 352 of the valve seat 340 and receives a predetermined amount of flexible material that forms the flexible member 342 as part of the overmolding process. The height of the receiving channel 354 is selected to allow a predetermined amount of movement of the flexible member 342, which will be discussed in more detail below. The receiving channel 354 is offset from the center of the valve seat 340, and the receiving channel 354 is located closer to the upstream end of the valve assembly 304 than the downstream end of the valve assembly 304. It should be understood that the terms upstream and downstream as used herein are provided relative to the airflow through the vacuum cleaner 10 in use.

[0151] Given the offset nature of the receiving passage 354 extending linearly through the upper surface 352 of the valve seat 340, and the height of the flexible material defining the living hinge 372, the valve member 366 can be asymmetrically rotated about the valve seat to varying degrees. The valve member 366 can be rotated in a downstream direction such that the downstream face 370 forms a minimum angle of approximately 40° with an axis parallel to the central longitudinal axis C of the core body 302. Although Fig.17 The minimum angle shown is approximately 40°, but those skilled in the art will recognize that other angles may be used without departing from the art. The valve member 366 may be rotated in an upstream direction so that the upstream face 368 is positioned substantially parallel to the central longitudinal axis C of the core body 302. Further operation of the valve assembly 304 will be discussed in more detail below.

[0152] Motor assembly 1000 Figures 24 to 33 , and includes a motor housing 1002, a suction motor 1004, a motor mount 1006, a motor control circuit board 1008, a power terminal 1010, an electronic device chassis 1012, a first heat insulation cover 1014 and a second heat insulation cover 1016, a first acoustic foam insert 1018 and a second acoustic foam insert 1020, a user interface assembly 1024 and a housing insert 1026.

[0153] The motor housing 1002 is generally elongated, cylindrical and hollow in form and includes a first end 1028 , a second end 1030 , a cartridge latch receiving aperture 1032 , a user interface aperture 1034 , first and second air flow outlets 1036 , 1038 , and a battery latch receiving aperture 1039 .

[0154] The motor housing 1002 has a diameter of about 38 mm, although diameters in the range of 35 mm to 50 mm are also contemplated. The housing has a thickness of about 0.7 mm, measured in a radial direction relative to the longitudinal motor housing axis MH, and is formed from cold rolled aluminum.

[0155] A cartridge latch receiving aperture 1032 is formed at a periphery of the first end 1028 of the motor housing 1002 and is shaped and dimensioned to receive a portion of a cartridge latch 1040. The cartridge latch 1040 is resiliently pivotally mounted to the first end 1028 of the motor housing 1002 and is shaped and dimensioned to selectively engage a latch member 148 of a cartridge latch receiving portion 144 of the cartridge body 108.

[0156] The user interface aperture 1034 is formed toward the second end 1030 of the motor housing 1002 and is shaped and sized such that the LCD screen 1100, the power button 1108, and the mode button 1110 of the user interface assembly 1024 are visible through the user interface aperture 1034. The user interface aperture 1034 is located on the same side of the motor housing 1002 as the cartridge buckle receiving aperture 1032.

[0157] The first airflow outlet 1036 and the second airflow outlet 1038 are disposed diametrically opposite to each other on the cylindrical surface of the motor housing 1002 such that corresponding points of the first airflow outlet 1036 and the second airflow outlet 1038 are approximately 180 degrees apart from each other around the circumference of the motor housing 1002. The central regions of the first airflow outlet 1036 and the second airflow outlet 1038 are each disposed approximately 90 degrees relative to each of the cartridge buckle receiving aperture and the user interface aperture 1034 around the circumference of the motor housing 1002. The first airflow outlet 1036 and the second airflow outlet 1038 are disposed approximately halfway along the axial length of the motor housing 1002 measured in a direction parallel to the motor housing longitudinal axis MH.

[0158] The first airflow outlet 1036 and the second airflow outlet 1038 are each formed by a series of slots formed in the motor housing 1002 .

[0159] The battery lock receiving hole 1039 is positioned toward the second end 1030 of the motor housing 1002 and is located on a side of the motor housing 1002 opposite the user interface hole 1034. The battery lock receiving hole 1039 is positioned along the motor housing 1002 so that it is generally located between the user interface hole 1034 and the first air flow outlet 1036 and the second air flow outlet 1038 in a direction parallel to the motor housing longitudinal axis MH. The battery lock receiving hole 1039 is shaped and sized to receive the battery lock mechanism 1022.

[0160] The suction motor 1004 is schematically shown in Fig.29 and includes a stator assembly 1042 , a rotor assembly 1044 and a housing assembly 1046 .

[0161] The stator assembly 1042 includes a stator core 1048 and a winding 1050 wound around the stator core 1048. It should be understood that a variety of different stator assembly arrangements can be envisioned. The rotor assembly 1044 includes a shaft 1052, a permanent magnet 1054 mounted to the shaft 1044, and an impeller 1056 mounted to the shaft 1052. The shaft 1052 defines the axis of rotation R of the suction motor 1004. The impeller 1056 is mounted to the shaft 1052 downstream of the permanent magnet 1054, so that the suction motor 1004 is an outlet cooling motor. The impeller 1056 is a mixed flow impeller.

[0162] The housing assembly 1046 defines a casing for the suction motor 1004 and houses the stator assembly 1042 and the rotor assembly 1044. The housing assembly 1046 defines a diffuser stage 1058 upstream of the impeller 1056, which acts as an axial diffuser.

[0163] The motor mount 1006 is in a generally cylindrical and hollow form. The motor mount 1006 therefore acts as a soft mount for the suction motor 1004. The motor mount 1006 includes a first sealing lip 1060 and a second sealing lip 1062, and a plurality of mounting tubes 1064. The first sealing lip 1060 and the second sealing lip 1062 are each located around the corresponding periphery of the free end of the motor mount 1006, and stand upright from the outer surface of the motor mount 1006. The mounting tubes 1064 are arranged in multiple rows of three mounting tubes 134, each row extending between the first sealing lip 1060 and the second sealing lip 1062 in a direction parallel to the rotation axis R of the suction motor 1004. Since the stator assembly 1042 is placed in the housing, the three mounting tubes 134 in a row are arranged closer to the first sealing lip 1060. In essence, the three mounting tubes 134 in a row are arranged around the stator assembly 1042. The inner diameter of the motor mount 1006 is designed so that the motor mount 1006 can fit snugly around the housing assembly 1046 of the suction motor 1004 .

[0164] The motor control circuit board 1008 includes a first portion 1066 on which a control circuit is mounted and a second portion 1068 on which a power supply terminal 1010 is mounted. The control circuit may include an inverter and one or more processors of the suction motor 1004. The first portion 1066 is in a generally planar form and is positioned so that an extension line of the rotation axis R of the suction motor 1004 extends within a plane defined by the motor control circuit board 1008. The first portion 1066 has a generally rectangular cross-sectional shape, and the smaller dimension of the first portion is less than 38 mm. In some examples, the smaller dimension of the first portion 1066 substantially corresponds to the outer diameter of the suction motor 1004. The second portion 1068 is in a generally planar form and is positioned so that the second portion 1068 is substantially orthogonal to the first portion 1066. The first portion 1066 is electrically connected to the suction motor 1004 via a flexible cable 1070 of the wiring harness assembly 1013. The motor control circuit board 1008 is hard mounted within the electronic device chassis 1012. Power terminals 1010 define electrical connections for receiving power from battery assembly 2000 .

[0165] The electronic device chassis 1012 includes a first portion 1072 and a second portion 1074, which together define a motor receiving portion 1076, a printed circuit board (PCB) receiving portion 1078, and an electrical connection housing 1080. The motor receiving portion 1076 is generally cylindrical and hollow in form, with opposite open ends. The shape and size of the motor receiving portion 1076 are designed to receive the suction motor 1004 and the motor mount 1006.

[0166] The PCB receiving portion 1078 is located between the motor receiving portion 1076 and the electrical connection housing 1080. The PCB receiving portion 1078 includes a housing whose shape and size are suitable for receiving the first portion 1066 of the motor control circuit board 1006. The PCB receiving portion 1078 includes a cutout 1082, which enables the flexible cable 1070 to extend between the motor receiving portion 1076 and the PCB receiving portion 1080, and thus between the suction motor 1004 and the motor control circuit board 1008. The periphery of the cutout 1082 includes a grommet 1084, through which the flexible cable 1070 extends. The PCB receiving portion 1078 is fluidly isolated from the motor receiving portion 1076. This enables the absence of an airflow filter between the suction motor 1004 and the motor control circuit board 1008. Relative to the motor receiving portion 1076 and the electrical connection housing 1080, the PCB receiving portion 1078 has a reduced width measured in a direction orthogonal to the rotation axis R of the suction motor 1004. This arrangement of the PCB receiving portion 1078 helps to divide the airflow from the suction motor 1004 into two paths that leave the first airflow outlet 1036 and the second airflow outlet 1038 respectively. Thus, a Y-shaped airflow is formed between the inlet of the suction motor 1004 and the first airflow outlet 1036 and the second airflow outlet 1038.

[0167] The electrical connection housing 1080 is generally cylindrical in form and is adjacent to the PCB receiving portion 1078 at the end of the electronic device chassis 1012 opposite the motor receiving portion 1076. The transition between the PCB receiving portion 1078 and the electrical connection housing 1080 is smooth, and the shape and size of the electrical connection housing 1080 generally corresponds to the internal dimensions of the motor housing 1002. The shape and size of the electrical connection housing 1080 are suitable for receiving the second portion 1068 of the motor control circuit board 1008, the power terminals 1010, and the communication connection 1086 of the wiring harness assembly 1013.

[0168] The wiring harness assembly includes flexible cables 1070 and communication connections. Some of the flexible cables 1070 extend through the motor housing 1002 and through the looming channel 316, and are electrically connected to the electrical connection portion 318 of the core 300. In some examples, the flexible cables 1070 include a charging cable for transmitting power from the cleaning head to the battery assembly 2000, which will be discussed in more detail below. Some of the flexible cables 1070 are electrically connected to the suction motor 1004. The communication connection includes pins for releasably connecting to the battery assembly 2000, and is also connected to the motor control circuit board 1008.

[0169] The first heat shield 1014 and the second heat shield 1016 are substantially similar in form and are formed of metal or any material for directing airflow from the suction motor 1004 out of the first airflow outlet 1036 and the second airflow outlet 1038. The shape and size of the first heat shield 1014 and the second heat shield 1016 are designed to cover the side area of ​​the PCB receiving portion 1078 of the electronic device chassis 1012 and act as a heat sink. The first heat shield 1014 and the second heat shield 1016 receive the first acoustic foam insert 1018 and the second acoustic foam insert 1020. Each of the first heat shield 1014 and the second heat shield 1016 includes cutouts 10141 and 10161. For simplicity, Fig.18 Only one side of a pair of heat shields, a pair of acoustic foam inserts, and a first portion of the electronics chassis 1012 are shown.

[0170] The battery lock mechanism 1022 includes a lock insert 1090 and a lock member 1092. The lock insert 1090 is located within the motor housing 1002 in the area of ​​the battery lock receiving hole 1039, and the lock member 1092 is resiliently mounted to the lock insert 1090. The lock member 1092 includes a hook 1094 shaped and sized to releasably engage with the positioning recess 2048 of the battery assembly 2000, which will be discussed in more detail below.

[0171] The user interface component 1024 is Fig.26 1090 , and includes an interface base 1096 , an interface PCB 1098 , an LCD screen 1100 , a screen bracket 1102 , a button bracket 1104 , a button seal 1106 , a power button 1108 , a mode button 1110 , and a window portion 1112 .

[0172] The interface base 1096 is shaped and sized to receive the interface PCB 1098 and is shaped and sized to sit on top of the planar portion 10301 of the housing insert 1026. The interface PCB 1098 includes a micro switch 1114 corresponding to the power button 1108 and the mode button 1110, and the LCD screen 1100 is mounted to the interface PCB 1098. The screen bracket 1102 is shaped and sized to cover the LCD screen 1100 and includes a through hole 1116 through which the LCD screen 1100 is visible.

[0173] The button holder 1104 is shaped and sized to be located below the power button 1108 and the mode button 1110 and includes a through hole 1118 that enables the power button 1108 and the mode button 1110 to selectively contact the corresponding micro switch 1114 via the button seal 1106. The button seal 1106 is formed of silicone and is shaped and sized to be located within the button holder 1104, between the button holder 1104 and the power button 1108 and the mode button 1110. A polyethylene terephthalate (PET) sheet is provided between the button seal 1106 and the micro switch 1114 to protect the button seal 1106 from being pierced by the micro switch 1114. The thickness of the PET sheet is about 0.10 mm.

[0174] The shape and size of the window portion 1112 are set to cover the interface base 1096, so that the interface PCB 1098, the LCD screen 1100, the screen bracket 1102, the button bracket 1104, the button seal 1106, the power button 1108 and the mode button 1110 are located between the interface base 1096 and the window portion 1112. The window portion 1112 includes a hole 1120 through which the LCD screen 1100, the power button 1108 and the mode button 1110 are visible and accessible to the user. A screen protector 1119 is set between the window portion 1112 and the screen bracket 1102 to protect the LCD screen 1100.

[0175] The housing insert 1026 is generally elongated and hollow in form and is shaped and sized to be received within the second end 1030 of the motor housing 1002 .

[0176] The housing insert 1026 has a first end 1122 and a second end 1124. The housing insert 1026 has an axial length of about 10 cm measured in a direction parallel to the motor housing axis MH between the first end 1122 and the second end 1124. Such a length generally corresponds to a length slightly greater than a single battery cell 2002 of the battery assembly 2000, which will be discussed in more detail below. The first end 1122 is open so that the power terminals 1010 and the communication connection can extend into the first end 1122. The shape and size of the inner surface 1123 of the first end 1122 corresponds to the interface portion 2046 of the battery assembly 2000, which will be discussed in more detail below, and the upper inner surface of the first end 1122 is substantially planar 10301 in form. The second end 1124 is open and is shaped and sized to receive the first sleeve portion 2042 of the battery assembly 2000. In one example, the housing insert 1026 can accommodate a quarter of the length of the battery assembly 2000 or less.

[0177] The upper outer surface 1126 of the housing insert 1026 between the first end 1122 and the second end 1124 is generally planar in form and is shaped and sized to receive the interface base 1096 of the user interface assembly 1024. This arrangement prevents rotational movement of the battery assembly 2000 relative to the motor housing 1002. This may be referred to as an anti-rotation mechanism.

[0178] Battery Pack 2000 Figures 28 to 32 2000, and includes four battery cells 2002, a first battery cell bracket 2004 and a second battery cell bracket 2006, a battery cell chassis 2008, a power terminal 2010, a communication terminal 2012, a battery management system, an inner sleeve 2016 and an outer sleeve 2018. The inner sleeve 2016 and the outer sleeve 2018 together define a battery housing of the battery assembly 2000. The inner sleeve 2016 and the outer sleeve 2018 may be formed of a plastic material.

[0179] Each battery cell 2002 is a cylindrical lithium-ion battery cell. The outer diameter and axial length of each battery cell 2002 are design choices and depend on the size of the battery housing, the available space within the battery housing, and the battery capacity required to operate the vacuum cleaner. Each battery cell 2002 can be considered a rechargeable battery cell, and the combination of battery cells 2002 can be considered a rechargeable battery.

[0180] The first battery tray 2004 and the second battery tray 2006 each have substantially the same form and include an upper tray portion 2020 and a lower tray portion 2022. The upper tray portion 2020 and the lower tray portion 2022 are each shaped to correspond to one of the respective upper and lower halves of a pair of battery cells 2002 arranged in a linear row. The battery cells 2002 are located in the first battery cell tray 2004 and the second battery cell tray 2006, and the terminal tabs connect the terminals of adjacent battery cells together. When arranged in the first battery tray 2004 and the second battery tray 2006, the battery cells 2002 extend in a row along an axis parallel to the longitudinal battery housing axis BH.

[0181] The battery cell chassis 2008 is of generally elongated form and includes a first end 2024, a second end 2026, and a planar wall 2030. The first end 2024 of the battery cell chassis 2008 includes a receiving hole 2032 for receiving the corresponding power terminal 2010 and the communication terminal. When viewed from a direction parallel to the longitudinal battery housing axis BH, the first end 2024 and the second end 2026 of the battery cell chassis have a generally semicircular cross-sectional shape.

[0182] The planar wall 2030 extends from the second end 2026 toward the first end 2024, but stops short of reaching the first end 2024. The planar wall 2030 corresponds to a portion of the linear perimeter of the second end 2026. The planar wall 2030 is shaped and sized to be located below approximately half of a battery circuit board 2036 of the battery management system 2014.

[0183] The first end 2024, the second end 2026, the curved wall 2028 and the planar wall 2030 collectively define a partially open chamber 2034. The partially open chamber 2034 is shaped and sized to accommodate the first battery tray 2004 and the second battery tray 2006, thereby accommodating four battery cells 2002.

[0184] The power terminal 2010 is located at the first end 2024 of the battery cell chassis 2008 and is in electrical communication with the battery cell 2002. The power terminal 2010 is shaped and sized to releasably engage with the power terminal 1010 of the motor assembly 1000, thereby selectively defining an electrical connection between the battery assembly 2000 and the motor assembly 1000.

[0185] The communication terminal 2012 is located at the first end 2024 of the battery cell chassis 2008 and is communicatively coupled to the battery management system. The communication terminal 2012 is shaped and sized to releasably engage with the communication connection 1086 of the wiring harness assembly.

[0186] The battery management system includes a battery circuit board 2036 and a connecting lug. The battery circuit board 2036 is of generally planar form, with its axial length extending in a direction parallel to the longitudinal battery housing axis BH. The battery circuit board 2036 extends only partially along the length of the planar wall 2030 and is positioned so that the battery circuit board 2036 covers three battery cells 2002, but does not cover one battery cell 2002. This means that the battery housing overlaps the motor housing in the direction of the central longitudinal passage, and the overlap is approximately one quarter of the length of the battery housing in the direction of the central longitudinal axis CL. The control circuit of the battery management system is mounted to the battery circuit board 2036. The connecting lug extends between the battery circuit board 2036 and the communication terminal 2012.

[0187] The battery cell 2002 , the first and second battery cell carriers 2004 , 2006 , the battery cell chassis 2008 , the power terminals 2010 , the communication terminals 2012 , and the battery management system 2014 collectively define a battery subassembly.

[0188] The battery assembly 2000 further includes a shock absorber disposed between the battery assembly 2000 and the motor housing. The shock absorber includes a plunger 2011 and a spring 2013 to absorb shock received along the axial axis.

[0189] The inner sleeve 2016 includes a first sleeve portion 2042 and a second sleeve portion 2044. The first sleeve portion 2042 is a hollow form, and its shape and size are designed to receive a portion of the battery subassembly corresponding to the first end 2024 of the battery cell chassis. The portion of the battery subassembly 2040 accommodated in the first sleeve portion 2042 is a portion corresponding to the first battery cell 2002 in the row of battery cells, and is a portion corresponding to the area of ​​the battery subassembly in which the battery circuit board 2036 is not located.

[0190] The first sleeve portion 2042 includes an interface portion 2046, a locating recess 2048, and an electrical connection opening 2050. The interface portion 2046 is generally planar in form and is shaped and dimensioned to be positioned below the planar inner surface 1123 of the housing insert 1024. The locating recess 2048 is located on a side of the first sleeve portion 2042 opposite the interface portion 2046 and is shaped and dimensioned to releasably engage with the hook 1094 of the battery latch mechanism 1022 to retain the battery assembly 2000 relative to the motor assembly 1000. The electrical connection opening 2050 is located at an end of the first sleeve portion 2042 distal from the second sleeve portion 2044 and is shaped and dimensioned to allow access to the respective power terminals 2010 and communication terminals 2012.

[0191] The second sleeve portion 2044 is generally cylindrical and hollow. The shape and size of the second sleeve portion 2044 are suitable for being accommodated in the outer sleeve 2018. One end of the second sleeve portion 2044 away from the first sleeve portion 2042 is open so that the battery subassembly 2040 can be inserted into the inner sleeve 2016.

[0192] The outer sleeve 2018 is a generally cylindrical and hollow form, with a first end 2052 and a second end 2054. The outer sleeve 2018 has an axial length of about 24cm measured in a direction parallel to the longitudinal battery housing axis BH between the first end 2052 and the second end 2056. The outer sleeve 2018 has an outer diameter of about 38mm. It is also conceivable that the outer diameter is in the range of 35mm to 50mm. The outer sleeve 2018 is formed by metal, plastic or other materials, and has an internal volume sufficient to accommodate the second sleeve portion 2044 of the inner sleeve 2016 and a part of the battery subassembly. The outer sleeve 2018 serves as the handle of the vacuum cleaner 10 in use. The outer sleeve 2018 can be at least partially covered with a non-slip material to prevent the main unit 12 from sliding relative to the surface (e.g., wall) against which it may abut. Alternatively, the non-slip material can be arranged around the second end 2054 of the outer sleeve 2018.

[0193] The first end 2052 of the outer sleeve 2018 is open and defines a hole for receiving the second sleeve portion 2044 of the inner sleeve 2016 and a portion of the battery subassembly. The second end 2054 of the outer sleeve 2018 is closed and is generally hemispherical in form. A user indicator 2060 is provided to be exposed through the opening 2051 located closer to the first end 2052 of the outer sleeve 2018, and the user indicator 2060 takes the form of a light source that can be illuminated to display the status of the battery unit 2002 to the user.

[0194] The outer sleeve 2018 is fixed to the inner sleeve 2016 by screws or other suitable fasteners. When assembled, the inner sleeve 2016 and the outer sleeve 2018 give the battery assembly 2000 an axial length of about 34 cm measured in a direction parallel to the longitudinal battery housing axis BH. When the battery assembly 2000 is assembled with the motor assembly 1000, the exposed portion of the battery assembly 2000 has an axial length of 24 cm measured in a direction parallel to the longitudinal battery housing axis BH. This means that the insert 1026 has a length of about 10 cm measured in a direction parallel to the longitudinal battery housing axis BH to receive the inner sleeve 2016.

[0195] The cleaning head 3000 is schematically shown in Figures 38 to 41 The cleaning head 3000 includes a main cleaning head housing 3002 and a neck 3004 .

[0196] The main cleaning head housing 3002 is generally hollow and includes an internal chamber 3006. The base 3008 of the main cleaning head housing 3002 includes an airflow inlet 3010. Four brush bars 3012 and four corresponding drive motors are located in the chamber 3006, and the drive motors are each configured to drive the corresponding brush bars 3012 in the internal chamber 3006 to rotate. Each brush bar 3012 is in the form of a generally truncated cone and includes a nylon outer surface. The brush bars 3012 are arranged in two pairs.

[0197] The neck 3004 includes a rigid body 3016 and a flexible conduit 3018. The rigid body 3016 includes a first connecting arm 3020 and a second connecting arm 3022, a first tubular body 3024 and a second tubular body 3026. The first connecting arm 3020 and the second connecting arm 3022 are each pivotally mounted to the main cleaning head housing 3002 and fixedly mounted to the first tubular body 3024. The first cleaning head arm 3020 and the second cleaning head arm 3022 are each pivotally mounted to the main cleaning head housing 3002 at respective positions, which are approximately half of the depth of the cleaning head 3000 measured in a direction orthogonal to the central cleaning head axis CC. The first cleaning head arm 3020 and the second cleaning head arm 3022 can rotate relative to the main cleaning head housing around a first cleaning head rotation axis orthogonal to the central cleaning head axis CC. In some examples, a biasing mechanism is provided that biases the neck 3004 of the cleaning head 3000 to a position where the central axis of the neck is parallel to the central cleaning head axis CC. This means that the centre axis of the separation system is aligned with the centre axis of the neck 3004 of the cleaning head 3000 .

[0198] The first tubular body 3024 is substantially hollow in form and upstanding from the first connecting arm 3020 and the second connecting arm 3022. The first tubular body 3024 is shaped and sized to receive a portion of the flexible conduit 3018.

[0199] The second tubular body 3026 includes a fixed end 3028 , a free end 3030 , first and second charging contacts 3032 , a cleaning head electrical connection portion 3036 , a positioning magnetic portion 3038 , and a cleaning head lock 3040 .

[0200] The fixed end 3028 is pivotally mounted to the first tubular body 3026 so that the second tubular body 3026 can rotate relative to the first tubular body 3024 about a second cleaning head rotation axis orthogonal to the first cleaning head rotation axis and the central cleaning head axis CC. The fixed end 3028 is shaped and sized to receive a portion of the flexible conduit 3018. The flexible conduit 3018 terminates within the fixed end 3028 and is in fluid communication with the free end 3030 of the second tubular body 3026.

[0201] The free end 3030 is shaped and sized to be received within the first connecting ferrule 110 of the cartridge assembly 102 and is shaped and sized to selectively engage with the engagement end 158 of the cartridge interlock member 115 .

[0202] The first and second charging contacts 3032 are each located on an outer surface of the second tubular body 3026 and are disposed substantially diametrically opposite to each other. The first and second charging contacts 3032 are each disposed about 90 degrees to the cleaning head latch 3040 around the periphery of the second tubular body 3026. When the second tubular body 3026 extends in a direction substantially parallel to the central cleaning head axis CC, and when the cleaning head 3000 is located on a horizontal surface HS to be cleaned, the first and second charging contacts 3032 are located at a height from the horizontal surface HS to be cleaned, such that the first and second charging contacts 3032 are each electrically connected to the cleaning head electrical connection 3036. The first and second charging contacts 3032 may also be referred to as charging connectors, and in some examples may include spring-loaded contact pins.

[0203] The cleaning head electrical connection portion 3036 is shaped and sized to engage and form an electrical connection with the electrical connection portion 318 of the core body 302. The cleaning head electrical connection portion 3036 is in electrical communication with the first and second charging contacts 3032 and the control circuit of the drive motor 3014.

[0204] The positioning magnetic portion 3038 is embedded in the wall of the second tubular body 3026 and is located approximately 90 degrees from each of the first and second charging contacts 3032 around the periphery of the second tubular body 3026. The positioning magnetic portion 3038 is located on the same side of the second tubular body 3026 as the cleaner head lock 3040, which is closer to the free end 3030 than the positioning magnetic portion 3038. In some examples, more than one positioning magnetic portion is provided. The positioning magnetic portion can include a permanent magnet or a ferromagnetic material.

[0205] The cleaning head latch 3040 includes a resiliently biased hook for selectively engaging the engagement lip 142 of the planar portion 126 of the first coupling ferrule to selectively retain the cleaning head 3000 relative to the cartridge assembly 102 .

[0206] The docking station 4000 for the vacuum cleaner 10 is Figures 42 to 44 Shown in.

[0207] The docking station 4000 includes a base 4002 and a retaining arm 4004 .

[0208] The base 4002 includes a lower base body 4006 and an upper base body 4008. The lower base body 4006 has a generally oval cross-sectional shape, and the lower surface of the lower base body 4006 includes a non-slip material to prevent the lower base body 4006 from sliding relative to the surface on which the lower base body 4006 is located during use. The upper base body 4008 is mounted to the lower base body 4006 by complementary coupling means or screws. The size of the upper base body 4008 is greater than or equal to the maximum size of the cleaning head 3000.

[0209] The upper base body 4008 has a generally oval cross-sectional shape, and the upper surface of the upper base body 4008 includes an arm receiving hole, which is shaped and sized to receive the first arm portion 4012 of the retaining arm 4004. The arm receiving hole is located away from the center of the upper base body 4008 and toward the area of ​​the upper base body 4008 having the smallest width.

[0210] The retaining arm 4004 includes a first arm portion 4012 , a charging port 4014 , a battery receiving hole 4016 , a second arm portion 4018 , a third arm portion 4020 , a positioning magnet 4022 , first and second resilient charging contacts 4024 , 4026 , and first and second tool storage devices 4028 , 4030 .

[0211] The first arm portion 4012 is received in the arm receiving hole of the upper base body 4008 and stands upright from the upper base body 4008 in a direction substantially orthogonal to the upper base body 4008. The first arm portion 4012 defines a cleaning head abutment surface 4032 that faces inwardly toward the central area of ​​the upper base body 4008 and is shaped and sized to abut a portion of the cleaning head 3000 when the cleaning head 3000 is held in position on the docking station 4000.

[0212] The charging port 4014 is located on an area of ​​the first arm 4012 that faces outwardly toward the periphery of the upper base body 4008. The charging port 4014 is shaped and sized to receive and form an electrical connection with an electrical connector for connecting the charging port to an external power source, such as a mains power source.

[0213] The battery receiving hole 4016 is formed at the interface between the first arm 4012 and the second arm 4018 and is positioned so that the opening perimeter of the battery receiving hole 4016 faces away from the upper base body 4008. The battery receiving hole 4016 is shaped and sized to receive the first sleeve portion 2042 of the inner sleeve 2016 of the battery assembly 2000. The battery receiving hole 4016 accommodates electrical connections so that the battery assembly 2000 can be connected to a power source via the charging port 4014 for recharging. In some examples, the battery receiving hole is omitted.

[0214] The second arm 4018 is integrally formed with the first arm 4012 and extends away from the first arm 4012 such that an angle of approximately 45 degrees is formed between the first arm 4012 and the second arm 4018. The second arm 4018 extends inwardly from the first arm 4012 toward the central species axis D but does not reach the central docking axis D.

[0215] The third arm portion 4020 is integrally formed with the second arm portion 4018 and extends away from the second arm portion 4018 such that the third arm portion 4020 extends in a direction substantially parallel to the first arm portion 4012 .

[0216] The third arm portion 4020 is generally convex, and the arm insert 4034 is located within the curved recess defined by the third arm portion 4020. The arm insert 4034 has an inner curvature that generally corresponds to the curvature of the second tubular body 3026 of the cleaning head 3000, and defines a cleaning head receiving channel 4035. It should be understood that the arm insert 4034 can also be considered to define an abutment surface for abutting the second tubular body 3026 of the cleaning head 3000. The arm insert 4034 is used to hold the magnet 4022 and the first and second resilient charging contacts 4024, 4026 relative to the third arm portion 4020.

[0217] The positioning magnet 4022 is located on the third arm 4020 at a height from the upper base body 4008 so that when the cleaning head is resting on the docking station 4000, the positioning magnet 4022 is aligned with the positioning magnetic portion 3038. The positioning magnet 4022 includes 2 magnets stacked together to increase the magnetic field strength.

[0218] The first elastic charging contact 4024 and the second elastic charging contact 4026 are electrically connected to the charging port 4014 through a cable extending through the first arm 4012, the second arm 4018 and the third arm 4020. Each of the first elastic charging contact 4024 and the second elastic charging contact 4026 extends through a corresponding hole formed in the arm insert 4034 so that the contact surface of the first elastic charging contact 4024 and the second elastic charging contact 4026 is exposed. The first elastic charging contact 4024 and the second elastic charging contact 4026 are located at the same height as the positioning magnet 4022. The first elastic charging contact 4024 and the second elastic charging contact 4026 are each located about 90 degrees away from the positioning magnet 4022 around the periphery of the third arm 4020, and the positioning magnet 4022 is centered between the first elastic charging contact 4024 and the second elastic charging contact 4026.

[0219] The first tool storage device 4028 and the second tool storage device 4030 are substantially similar in form and are shaped and sized to receive tools for attachment to the main unit 12 of the vacuum cleaner 10 so that the tools are retained relative to the docking station 4000. The first tool storage device 4028 and the second tool storage device 4030 extend from opposite sides of the third arm 4020 to the cleaning head receiving channel 4035.

[0220] The main unit 12 is Fig.45 3000 is shown in an assembled cleaning configuration, with the cleaning head 3000 in Fig.46 Attached to the main unit 12, in an assembled cleaning configuration. Fig.47 A front view of the vacuum cleaner 10 resting on the docking station 4000 is shown.

[0221] With the main unit 12 in the assembled cleaning configuration, the bin assembly 102 is positioned so that the central bin axis B of the bin body 108 is coaxial with the central longitudinal axis CL of the main unit 12. Thus, the bin body 108 extends annularly around the central longitudinal axis CL of the main unit 12. The filter assembly 200 and the core 300 are housed within the bin body 108, and the bin latch 1040 of the motor housing 1002 engages with the latch member 148 of the bin latch receiving portion 144 of the second connecting collar 112 to retain the bin assembly 102 relative to the motor housing 1002. With the filter assembly 200 and the core 300 housed within the bin body 108, the debris collection chamber 122 of the separation system 100 occupies approximately 30% to 40% of the bin body 108 and has a self-compacting arrangement in which dust entering the debris collection chamber 122 is compacted against the wiper 114. This is because the filter assembly 200 is arranged in parallel with the filter assembly 300 accommodated in the bin body 108, and the suction motor 1004 is arranged downstream of the separation system 100.

[0222] The core 300 is positioned within the cartridge assembly 102 such that the electrical connection portion 318 of the core 300 covers the inner surface 134 of the planar portion 126 of the first connection ferrule 110, defining a gap 136 between the inner surface 134 and the electrical connection portion 318. The valve member 366 of the valve assembly 304 engages the valve seat 135 such that the valve member 366 blocks the airflow inlet 140. The hinge axis H of the valve seat 340 of the valve assembly extends in a direction orthogonal to the central longitudinal axis CL of the main unit 12.

[0223] The guide rail 120 of the cartridge body 108 is positioned such that the guide rail 120 extends in a direction substantially parallel to the central longitudinal axis CL of the main unit 12. The guide rail 120 is located on the guide surface 332 of the core body 302 of the core and is positioned such that the guide rail 120 is axially aligned with a respective one of the first contact portion 358 and the second contact portion 360 of the rigid member 344 of the valve assembly 304 in a direction parallel to the central longitudinal axis CL of the main unit 12.

[0224] The filter assembly 200 is positioned so that the locating protrusion 250 of the core connection portion 248 is received within the locating channel 311 of the core 300, proximate the outlet conduit 314, and so that the end wall clip 224 and the end wall lip 246 of the filter assembly are positioned away from the outlet conduit 314. The upper edge 242 of the lower tray 2042 is supported on the upper periphery 328 of the outlet channel 310 of the core body 302 so that the lower area of ​​the filter media body 230 is located within the outlet channel 310. The lower tray 2042, the filter media body 230 and the outlet channel 310 partially define the airflow outlet 330 of the separation system 100. The portion of the airflow outlet 330 defined by the outlet channel 310 is spaced apart from the central longitudinal axis CL of the main unit 12. The filter assembly 200 and therefore the main screen 202 and the filter media 208 serve to separate the coarse debris collection chamber 122 and the outlet channel 310.

[0225] The upstream face of the main net 202 faces away from the central longitudinal axis CL of the main unit 12, and therefore faces away from the central axis B of the bin body 108. The main net 202 and the filter medium 208 are spaced apart from each other by about 1.4 mm in a direction orthogonal to the central longitudinal axis CL of the main unit 12, which direction can be considered to be a transverse direction. The main net 202 and the filter medium 208 are each elongated, have parallel longitudinal axes, and overlap each other longitudinally. The parallel longitudinal axes of the main net 202 and the filter medium 208 are also parallel to the bulk airflow direction from the airflow inlet 140 to the separation system 100. The generally U-shaped cross-section of the main net 202 causes the grooves provided by the upstream face of the main net 202 to form an airflow channel for air flowing out of the airflow inlet 140 of the separation system 100.

[0226] The outlet duct 314 of the core body 302 is in fluid communication with the motor housing 1002, which extends away from the cartridge body 108 in a direction along the central longitudinal axis CL of the main unit 12 and extends annularly around the central longitudinal axis CL of the main unit 12. The suction motor 1004 is located within the motor housing 1002 such that the impeller 1056 of the suction motor 1004 is located near the outlet duct 314, and the stator assembly 1042 of the suction motor 1004 is located downstream of the impeller 1056. The motor control circuit board 1006 is located downstream of the suction motor 1004 within the motor housing 1002, and the first portion 1066 of the motor control circuit board 1006 is located within the PCB receiving portion 1078 of the electronic equipment chassis 1012. The first portion 1066 of the motor control circuit board 1006 defines a plane extending in a direction parallel to the rotation axis R of the suction motor 1004, and the main axis of the first portion 1066 of the motor control circuit board 1008 extends in a direction parallel to the rotation axis R of the suction motor 1004. The main axis of the first portion 1066 of the motor control circuit board 1008 can also be considered to extend in a direction parallel to the row of battery cells 2002 and parallel to the central axis of the separation system 100. The motor housing 1002, the PCB receiving portion 1078 of the electronics chassis 1012, and the electrical connection housing 1080 of the electronics chassis define a motor outlet channel within the motor housing 1002.

[0227] The first airflow outlet 1036 and the second airflow outlet 1038 are in fluid communication with the motor outlet channel 1079, and the first airflow outlet 1036 and the second airflow outlet 1038 are positioned so that the airflow exits the motor housing 1002 in a direction substantially orthogonal to the central longitudinal axis CL of the main unit 12, forming a Y-shaped airflow from the motor housing to the first airflow outlet 1036 and the second airflow outlet 1038. The LCD screen 1100, the power button 1108, and the mode button 1100 are located on the same side of the motor housing 1000 as the compartment lock 1040 of the motor housing 1002, and the LCD screen 1100, the power button 1108, and the mode button 1110 face in a direction orthogonal to the central longitudinal axis CL of the main unit 12 and orthogonal to the direction in which the airflow exits the motor housing 1000 via the first airflow outlet 1036 and the second airflow outlet 1038.

[0228] The battery assembly 2000 is positioned so that the longitudinal battery housing axis BH is coaxial with the central longitudinal axis CL of the main unit 12. The first sleeve portion 2042 of the inner sleeve 2016 of the battery assembly 2000 is located within the housing insert 1024 of the motor assembly 1000, and the interface portion 2046 of the first sleeve portion 2042 is located below and in contact with the planar inner surface 1123 of the housing insert 1024. The power terminals 2010 of the battery assembly 2000 are connected to the power terminals 1010 of the motor assembly 1000 so that power can be transferred between the battery assembly 2000 and the components within the motor housing 1000. The communication terminals 2012 of the battery assembly 2000 are connected to the communication connections 1086 of the wiring harness assembly 1013 so that communication is established between the battery assembly and the components within the motor housing 1000.

[0229] The locating recess 2048 of the first sleeve portion 2042 engages the hook 1094 of the battery latch mechanism 1022 of the motor assembly 1000 , thereby retaining the first sleeve portion 2042 within the housing insert 1024 and retaining the battery assembly 2000 relative to the motor assembly 1000 .

[0230] The outer sleeve 2018 extends away from the motor housing 1002 in a direction parallel to the central longitudinal axis CL of the main unit 12, and away from the cartridge assembly 1002. The outer sleeve extends away from the motor housing 1002 an axial length of approximately 24 cm measured in a direction parallel to the central longitudinal axis CL of the main unit 12, and defines a handle by which a user can grasp the main unit 12 to move the vacuum cleaner 10 relative to a surface to be cleaned. The row of battery cells 2002 extends in a direction parallel to the central longitudinal axis CL of the main unit 12, but offset therefrom.

[0231] from Fig.45 It can be seen that when the main unit 12 is assembled, the separation system 100, the motor assembly 1000 and the battery assembly 2000 are aligned along the central longitudinal axis CL of the main unit 12 and share the central longitudinal axis. In an alternative example, the alignment of the separation system 100, the motor assembly 1000 and the battery assembly 2000 can be referred to as components arranged in a straight line. The suction motor 1004 is located between the separation system 100 and the battery assembly 2000. The separation system 100, the suction motor 1004 and the battery assembly 200 can also be considered to be aligned along the central longitudinal axis CL of the main unit 12. Similarly, the central axis of any one of the separation system 100, the suction motor 1004 and the battery assembly 2000 can be considered to be coaxial with the central longitudinal axis CL of the main unit 12.

[0232] Each of the separation system 100, the motor assembly 1000 and the battery assembly is elongated and generally tubular in form, so that the main unit 12 is elongated and tubular in form. This makes the main unit 12 have a rod structure, or also referred to as a single tubular structure. The main unit 12 has a total axial length of about 95 cm measured in a direction parallel to the central longitudinal axis CL of the main unit 12. The separation system 100 is approximately 38 cm of the total axial length of the main unit, corresponding to 40% of the axial length of the main unit 12. The motor assembly 1000 constitutes 33 cm of the total axial length of the main unit, corresponding to about 35% of the axial length of the main unit 12. The battery assembly 2000 constitutes 24 cm of the total axial length of the main unit, corresponding to about 25% of the axial length of the main unit 12. The length of the motor housing 1002 in the direction along the central longitudinal axis CL of the main unit 12 is less than the length of the cartridge body 108 in the direction along the central longitudinal axis CL of the main unit 12. When the separator housing, motor housing 1002 and battery housing are coupled together, they define the main unit 12 of the vacuum cleaner 10 .

[0233] The length of the motor assembly 1000 is greater than the exposed portion of the battery assembly 2000. When disassembled, the battery assembly 2000 is slightly longer than the motor assembly 1000 by about 1 cm.

[0234] Each of the cartridge body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 defines an outer surface of the main unit 12. Each of the cartridge body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 shares a common outer diameter of 38 mm, so that the main unit 12 has a substantially constant outer diameter of 38 mm. In an alternative example, the main unit 12 has a maximum outer diameter, and one or more of the cartridge body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 share a maximum outer diameter of 38 mm. In another example, each of the cartridge body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 shares a maximum outer diameter of 38 mm. The maximum outer diameter may be 50 mm or less.

[0235] With the central longitudinal axis CL of the main unit 12 arranged substantially vertically relative to the horizontal surface HS to be cleaned, and the end of the first connecting ferrule 110 of the main unit 12 corresponding to the bin assembly 102 is closer to the horizontal surface HS to be cleaned than the outer sleeve 2018 of the battery assembly 2000, the motor assembly 1000 is located above the separation system 100. This orientation of the main unit 12 can be Fig.45 Seen in.

[0236] With the central longitudinal axis CL of the main unit 12 arranged substantially vertically relative to the horizontal surface HS to be cleaned, and the end of the first connecting ferrule 110 of the main unit 12 corresponding to the bin assembly 102 being closer to the horizontal surface HS to be cleaned than the outer sleeve 2018 of the battery assembly 2000, the battery assembly 2000 is located above the separation system 100. This orientation of the main unit 12 can be Fig.45 Seen in.

[0237] With the central longitudinal axis CL of the main unit 12 arranged substantially vertically relative to the horizontal surface HS to be cleaned, and the end of the first connecting ferrule 110 of the main unit 12 corresponding to the cartridge assembly 102 being closer to the horizontal surface HS to be cleaned than the outer sleeve 2018 of the battery assembly 2000, a portion of the battery assembly 2000 is located above the motor assembly 1000. This orientation of the main unit 12 can be Fig.45 Seen in.

[0238] With the cleaning head 3000 connected to the main unit 12 , the main unit 12 and the neck 3004 of the cleaning head 3000 share a common central axis, which is the central longitudinal axis CL of the main unit 12 .

[0239] With the common central axis positioned vertically relative to the horizontal surface HS on which the cleaning head 3000 is located, the main cleaning head housing 3002 has a generally rectangular shape when viewed in the direction of the common central axis, and the common central axis is orthogonal to and intersects the central minor axis of the main cleaning head housing 3002. The paired brush bars 3014 are arranged such that each pair of brush bars is located on opposite sides of the central minor axis from each other.

[0240] With the cleaning head 3000 connected to the main unit 12, the cleaning head 3000 is located on the horizontal surface HS to be cleaned, and with the central longitudinal axis CL of the main unit 12 arranged substantially vertically relative to the horizontal surface HS to be cleaned, the cleaning head central axis CC is parallel to, but spaced apart from, the central longitudinal axis CL of the main unit 12. The orthogonal distance between the cleaning head central axis CC and the central longitudinal axis CL of the main unit 12 is approximately 20 mm.

[0241] With the cleaning head 3000 connected to the main unit 12 and the cleaning head 3000 positioned on the horizontal surface HS to be cleaned, and with the central longitudinal axis CL of the main unit 12 arranged substantially vertically relative to the horizontal surface HS to be cleaned, the rotation axis of each brush bar 3014 is inclined relative to the central longitudinal axis CL of the main unit 12, as shown in FIG. Fig.47 shown.

[0242] As the cleaning head 3000 is connected to the main unit 12, the engagement end 158 of the cartridge interlock member 115 is biased upward by the free end 3030 of the neck 3004 of the cleaning head 3000, and the engagement end 158 of the cartridge interlock member 115 engages with the abutment surface 338 of the electrical connection portion 318 to prevent movement of the cartridge body 108 relative to the core 300. The cleaning head lock 3040 of the neck 3004 of the cleaning head 3000 engages with the engagement lip 142 of the first connection ferrule 110 to hold the cleaning head 3000 relative to the main unit 12.

[0243] In use, the user can turn on the vacuum cleaner 10 using the power button 1108, and power is provided to the suction motor 1004 from the battery assembly 2000. The vacuum cleaner 10 can operate under one of the low power mode, the medium power mode or the high power mode. When the vacuum cleaner 10 is initially turned on, the vacuum cleaner runs in the medium power mode, and the user can toggle the mode button 1110 to switch between the operating modes. Those skilled in the art will recognize that the default operating mode when turned on can be configured as a low power mode or a high power mode, and the actual operating mode to be implemented is left as a design choice. The suction motor 1004 causes the rotation of the impeller 1056, which produces an airflow through the main unit 12 and the cleaning head 3000.

[0244] The user can grasp the outer sleeve 2018 of the battery assembly 2000, which defines the handle portion of the main unit 12, and by moving their arms, can manipulate the cleaning head 3000 to move over the surface to be cleaned. Power is provided to the cleaning head 3000 from the battery assembly 2000 via the wiring harness assembly 1013, the electrical connection 318 of the core 300, and the cleaning head electrical connection 3036 of the cleaning head 3000. The drive motor 3014 drives the brush bar 3012 to rotate within the internal chamber 3006, and the brush bar 3012 is used to agitate the surface to be cleaned. The drive motor 3014 drives the brush bar 3012 to rotate so that dust from the surface is agitated toward the central axis CC of the cleaning head.

[0245] Fig.48 and 49 The airflow path through the vacuum cleaner 10 is schematically shown. The airflow enters the cleaning head 3000 along with entrained debris such as dust via the airflow inlet 3010. The airflow passes through the internal chamber 3006 and exits the cleaning head 3000 via the flexible conduit 3018 and the free end 3030 of the second tubular body 3026 of the neck 3004.

[0246] The airflow enters the separation system 100 via the first connection collar 110 and flows through the airflow inlet 140. The airflow force through the vacuum cleaner 10 causes the valve member 366 to pivot from its closed position to its open position in the downstream direction, so that the airflow can enter the interior volume of the bin body 108 via the airflow inlet 140. The general direction of the airflow at the airflow inlet 140 is a direction away from the airflow inlet 140 and is substantially parallel to the central longitudinal axis CL of the main unit 12. When the central longitudinal axis CL of the main unit 12 is arranged substantially vertically relative to the horizontal surface HS to be cleaned, and the end of the main unit 12 corresponding to the bin assembly 102 is closer to the horizontal surface HS to be cleaned than the battery assembly 2000, the general direction of the airflow at the airflow inlet 140 can be considered to be a direction from the bottom of the bin assembly 102 to the top of the bin assembly 102. Due to this arrangement, dust will be pressed against the wiper 114.

[0247] The airflow flowing through the bin body 108 flows through the main net 202 of the separator cartridge 200 in a general direction generally parallel to the central longitudinal axis CL of the main unit 12. As the airflow flows through the main net 202, the airflow passes through the through holes of the main net 202, which is used to filter relatively large debris from the airflow. This filtered debris is collected in a coarse debris collection chamber 122 defined by the bin body 108. The valve assembly 304 covers at least a portion of the base of the chamber 122, and the airflow inlet 140 of the separation system 100 is arranged in the plane of the valve assembly 304. Therefore, the airflow enters the chamber 122 at the valve assembly 304, in the manner described above.

[0248] The airflow having passed through the main net 202 then flows through the filter medium 208 in a direction substantially orthogonal to the central longitudinal axis CL of the main unit 12. The filter medium 208 is used to filter debris from the airflow, which is relatively finer than the debris filtered out by the main net 202. The filtered debris accumulates on the filter medium 208, and the airflow flows from the filter medium 208 to the auxiliary net 312.

[0249] The airflow flows through the auxiliary net 312 in a direction substantially orthogonal to the central longitudinal axis CL of the main unit 12. The auxiliary net 312 can be similar to the main net and is used to prevent debris from entering the outlet passage 310 during removal of the filter assembly 200. In another embodiment, the auxiliary net 312 is used to filter debris from the airflow, which is relatively fine compared to the debris filtered out by the filter media 208. The filtered debris accumulates on the auxiliary net 312, and the airflow enters the outlet passage 310 from the auxiliary net 312. The airflow flows through the outlet passage 310 and the outlet duct 314, exits the separation system 100 and enters the motor assembly 1000.

[0250] The airflow passes through the impeller and then through the diffuser stage 1058 in a direction substantially parallel to the central longitudinal axis CL of the main unit 12. The airflow leaves the diffuser stage 1058 and is split on the PCB receiving portion 1078 of the electronic equipment chassis 1012 of the motor assembly 1000. The airflow is thus located on opposite sides of the plane defined by the first portion 1066 of the motor control circuit board 1008. The airflow flows through the motor outlet channel 1079 to the first airflow outlet 1036 and the second airflow outlet 1038. The airflow then leaves the motor housing 10002 via the first airflow outlet 1036 and the second airflow outlet 1038, forming a Fig.49 Y-shaped airflow shown.

[0251] During use of the vacuum cleaner 10, the coarse debris collection chamber 122 is filled with debris. Therefore, the user may wish to empty the debris from the coarse debris collection chamber 122. To do this, the user must first remove the cleaning head 3000 from the main unit 12. The user can release the cleaning head latch 3040 of the neck 3004 of the cleaning head 3000 from engagement with the engagement lip 142 of the first connecting ferrule 110, and the main unit 12 can slide away from the cleaning head 12 in a direction substantially parallel to the central longitudinal axis CL of the main unit 12.

[0252] As the free end 3030 of the neck 3004 of the cleaning head 3000 is removed from the first connecting ferrule 110, the free end 3030 of the neck 3004 is no longer engaged with the engagement end 158 of the cartridge interlock member 115, and the engagement end 158 of the cartridge interlock member 115 is no longer engaged with the abutment surface 338 of the electrical connection portion 318 of the core 300. Therefore, the cartridge interlock member 115 no longer prevents movement of the cartridge body 108 relative to the core 300.

[0253] The user can release the cartridge latch 1040 from engagement with the cartridge latch receiving portion 144 and can slide the cartridge body 108 away from the motor assembly 1000 by grasping the cartridge body 108. The cartridge body 1008 slides away from the motor assembly 1000 in a direction substantially parallel to the central longitudinal axis CL of the main unit 12. As the cartridge body 108 slides away from the motor assembly 1000, the guide rail 120 slides along the guide surface 332 of the main body 302 of the core and contacts the respective first contact portions 358 and second contact portions 360 of the rigid member 344 of the valve assembly 304.

[0254] As the cartridge body 108 continues to slide, the contact of the guide rail 120 with the respective first and second contact portions 358, 360 of the rigid member 344 of the valve assembly 304 pushes the valve member 366 to its open upstream position and holds the valve member 366 in that position. In such a position, the valve member 366 is substantially parallel to the central longitudinal axis CL of the main unit 12, and debris is able to pass through the valve member 366 and fall out of the first connecting ferrule 110 of the cartridge assembly 102. As the cartridge body 108 slides relative to the core 300, the wiper member 152 contacts the upstream face of the primary net 202 to wipe debris from the upstream face of the primary net 202, which debris is able to pass through the valve member 366 and fall out of the first connecting ferrule 110 of the cartridge assembly 102.

[0255] The cartridge body 108 slides away from the motor assembly 1000 until the cartridge assembly 102 is separated from and no longer covers the filter assembly 200 and the core 300. This enables a user to remove the filter assembly 200 from the core 300 by moving the filter assembly 200 away from the inner core 300 in a direction substantially orthogonal to the central longitudinal axis CL of the main unit 12. When the filter assembly 200 is removed from the core 300, the auxiliary net 312 can capture debris that falls from the separator cartridge 200, thereby preventing large debris from accumulating in the outlet channel 310 of the core body 302.

[0256] Once the filter assembly 200 is removed from the core 300, the user can separate the net bracket 204 from the upper tray 2041 and the lower tray 2042 by releasing the end wall clip 224 of the net bracket 204 from the end wall lip 246 of the lower filter frame 210 and sliding the net bracket 204 away from the upper tray 2041 and the lower tray 2042, thereby separating the main net 202 from the filter media 208. The user can then clean the upper tray 2041 with the main net 202 and the lower tray 2042 with the filter media 208, respectively.

[0257] When desired, the user can reassemble the filter assembly 200 and reattach the filter assembly 200 to the core body 302. In an embodiment using a hygroscopic filter media 208, if the filter media 208 is still wet, the filter media 208 will expand beyond the retainer, preventing the upper tray 2041 and the lower tray 2042 from being assembled together. The bin body 108 can be slid back onto the combined filter assembly 200 and core 300 and reattached to the main unit 12. The cleaning head 3000 can be reattached to the main unit 12 so that the user can resume cleaning if desired, or can store the vacuum cleaner 10 if cleaning is complete.

[0258] To store the vacuum cleaner 10, the user 10 can position the vacuum cleaner 10 relative to the docking station 4000. The docking station 4000 is freestanding on a horizontal surface to be cleaned. To position the vacuum cleaner 10 relative to the docking station 4000, the cleaning head 3000 is positioned on the upper base body 4008 of the docking station 4000 so that the main cleaning head housing 3002 abuts against the cleaning head abutment surface 4032 of the first arm portion 4012 of the retaining arm 4004. The second tubular body 3026 of the neck 3004 of the cleaning head 3000 is positioned within the cleaning head receiving channel 4035 within the third arm portion 4012 so that the cleaning head 3000 contacts the docking station 4000 in two spaced-apart vertical positions. When the cleaning head 3000 is positioned on the docking station 4000, the retaining arm 4004 can be considered to partially surround the main cleaning head housing 3002. When the cleaning head 3000 is located in the dock 4000, contact of the dock 4000 and the cleaning head 3000 at two locations (these portions of the dock 4000 may be considered abutments of the dock) may be used to maintain the vacuum cleaner 10 in a substantially upright position relative to a horizontal surface to be cleaned.

[0259] With the second tubular body 3026 of the neck 3004 of the cleaner head 3000 positioned within the cleaner head receiving channel 4035, the positioning magnet 4022 of the docking station 4000 interacts with the positioning magnetic portion 3038 of the cleaner head 3000 to hold the cleaner head 3000 relative to the docking station 4000, and therefore more generally the vacuum cleaner 10. The position of the vacuum cleaner 10 within the docking station 4000 can be considered an upright position and / or a vertical position. The first and second resilient charging contacts 4024 and 4026 of the docking station 4000 are in contact with the first and second charging contacts 3032 of the second tubular body 3026 of the cleaner head 3000. With a power source electrically connected to the charging port 4014 of the docking station 4000, power can be transmitted from the docking station 4000 to the cleaner head 3000, and from the cleaner head 3000 to the battery assembly 2000 through the main unit 12 to recharge the battery assembly 2000.

[0260] An additional battery assembly may also be charged in parallel with the battery assembly 2000 that is charged via the cleaning head, the additional battery assembly being located within the battery receiving aperture 4016 .

[0261] It will also be appreciated that the battery assembly 2000 may be charged via the battery receiving aperture 4016 without requiring charging via the cleaning head 3000 when the remainder of the vacuum cleaner 10 is held by the dock, or when the remainder of the vacuum cleaner 10 is away from the dock.

[0262] To remove the battery assembly 2000 from the motor housing 1000, the user can actuate the battery latch mechanism 1022 to remove the hook 1094 from engagement with the locating recess 2048 of the battery assembly 2000, thereby enabling the battery assembly 2000 to slide relative to the motor assembly 1000. The user can grasp the outer sleeve 2018 of the battery assembly 2000 and slide the battery assembly 2000 away from the motor assembly in a direction parallel to the central longitudinal axis CL of the main unit 12.

[0263] Alternative tools to the cleaning head 3000 may also be used interchangeably with the main unit 12, these tools being connected to the main unit 12 in a similar manner as the cleaning head 3000 described above. It should be understood that such alternative tools may not necessarily include rechargeability, but may still include motorized components, such as driven brush bars, etc.

[0264] It should be understood that in the context of the description herein, the separation system 100 may be considered a separator, a dirt separator, a debris separator, a dirt separation system, or a debris separation system.

[0265] In an embodiment of the present disclosure, a vacuum cleaner may be provided with the following provisions.

[0266] 1. A vacuum cleaner comprising: a main unit having a handle, and a cleaning head comprising a cleaning head housing, a neck for connecting to the main unit, the neck extending from the cleaning head housing, and more than two brush bars located in the cleaning head housing, wherein the handle and the neck share a common central axis.

[0267] 2. A vacuum cleaner according to clause 1, wherein the cleaning head comprises four brush bars located within the cleaning head housing.

[0268] 3. A vacuum cleaner according to clause 1 or 2, wherein each brush bar is substantially frusto-conical.

[0269] 4. A vacuum cleaner according to any of the preceding clauses, wherein each brush bar is rotatable about a corresponding brush bar axis, and the cleaning head is located on a horizontal surface to be cleaned, the common center axis is vertically positioned relative to the horizontal surface to be cleaned, and each brush bar axis is inclined relative to the common center axis and / or inclined relative to the horizontal surface to be cleaned.

[0270] 5. A vacuum cleaner according to any of the preceding clauses, wherein the common central axis is vertically positioned relative to a horizontal surface on which the cleaning head is located, the cleaning head housing has a generally rectangular shape when viewed in the direction of the common central axis, and the common central axis is orthogonal to and intersects the central short axis of the cleaning head housing.

[0271] 6. A vacuum cleaner according to clause 5, wherein at least two brush bars are positioned such that they are located on opposite sides of the central minor axis.

[0272] 7. A vacuum cleaner according to any preceding clause, wherein each brush bar comprises an outer surface formed from nylon.

[0273] 8. A vacuum cleaner according to any of the preceding clauses, wherein the common central axis is vertically positioned relative to a horizontal surface on which the cleaning head is located, the cleaning head housing has a generally rectangular shape when viewed in the direction of the common central axis, and the common central axis is orthogonal to and spaced from a central spindle of the cleaning head housing.

[0274] 9. A vacuum cleaner as claimed in any preceding clause, wherein the cleaner head comprises a biasing mechanism for biasing the neck to a predetermined orientation relative to the cleaner head housing.

[0275] 10. A vacuum cleaner according to clause 9, wherein the cleaning head is located on a horizontal surface to be cleaned, the biasing mechanism being configured to bias the neck so that the common central axis extends substantially vertically relative to the horizontal surface to be cleaned.

[0276] 11. A vacuum cleaner according to clause 9 or 10, wherein the cleaning head is located on a horizontal surface to be cleaned and the main unit is separated from the cleaning head, and the biasing mechanism is configured to bias the neck so that the central axis of the neck extends substantially vertically relative to the horizontal surface to be cleaned.

[0277] 12. A vacuum cleaner according to any of the preceding clauses, wherein the vacuum cleaner comprises a separation system, a suction motor for generating an airflow through the separation system, and a battery assembly for powering the suction motor, wherein the separation system, the suction motor and the battery assembly are aligned along a common central axis.

[0278] 13. The vacuum cleaner of clause 12, wherein the battery assembly defines a handle.

[0279] 14. A vacuum cleaner as claimed in claim 12 or 13, wherein the separation system is a non-cyclonic separation system.

[0280] 15. The vacuum cleaner according to any of clauses 12 to 14, wherein the separation system has a central axis which is coaxial with the common central axis.

[0281] 16. A vacuum cleaner according to any of clauses 12 to 15, wherein the suction motor has an axis of rotation which is coaxial with the common centre axis.

[0282] 17. A vacuum cleaner according to any of clauses 12 to 16, wherein the battery assembly has a central axis which is coaxial with the common central axis.

[0283] 18. The vacuum cleaner according to any of clauses 12 to 17, wherein the suction motor is located between the separation system and the battery assembly.

[0284] 19. A vacuum cleaner according to any of clauses 12 to 18, wherein the separation system comprises an air inlet, and wherein a majority of the airflow directions through the air inlet are parallel to the common central axis.

[0285] 20. A vacuum cleaner according to any one of clauses 12 to 19, wherein the separation system comprises a bin body, the suction motor is accommodated in a motor housing, and the battery assembly comprises a battery housing, the bin body, the motor housing and the battery housing being coupled together to define a main unit of the vacuum cleaner.

[0286] 21. The vacuum cleaner of clause 20, wherein the bin body, the motor housing and the battery housing are each elongated tubular portions.

[0287] 22. A vacuum cleaner according to clause 20 or 21, wherein the main unit has a maximum outer diameter and one or more of the bin body, the motor housing and the battery housing share the maximum outer diameter.

[0288] 23. A vacuum cleaner according to clause 22, wherein the maximum outer diameter is 50 mm or less.

[0289] 24. A vacuum cleaner according to clause 23, wherein the maximum outer diameter is 38 mm.

[0290] 25. A vacuum cleaner according to any of clauses 22 to 24, wherein two or more of the bin body, the motor housing and the battery housing have the same maximum outer diameter.

[0291] 26. A vacuum cleaner according to any preceding clause, wherein the neck is movably mounted to the cleaning head housing.

[0292] 27. The vacuum cleaner of clause 26, wherein the neck comprises first and second arms pivotally connected to the cleaning head housing.

[0293] 28. A vacuum cleaner according to clause 27, wherein the neck comprises a tubular body and the first and second arms are inclined relative to the tubular body so that the common central axis is vertically positioned relative to a horizontal surface on which the cleaning head is located, and the common central axis is parallel to and spaced apart from the central cleaning head axis.

[0294] In another embodiment of the present disclosure, a vacuum cleaner may be provided with the following provisions.

[0295] 1. A vacuum cleaner comprising: a separation system, a suction motor for generating an airflow through the separation system, and a control circuit for controlling the suction motor, wherein the control circuit is mounted on a control circuit board, and the control circuit board defines a plane extending in a direction parallel to a rotation axis of the suction motor.

[0296] 2. The vacuum cleaner according to clause 1, wherein the control circuit board is located downstream of the suction motor.

[0297] 3. A vacuum cleaner according to clause 1 or 2, wherein the control circuit board is positioned so that in use the airflow downstream of the suction motor is split at first and second opposite sides of a plane defined by the control circuit board, forming a Y-shaped airflow.

[0298] 4. A vacuum cleaner according to any of the preceding clauses, wherein the suction motor and the control circuit board are housed in a common chassis.

[0299] 5. A vacuum cleaner according to clause 4, wherein the suction motor is soft mounted in the common chassis and the control circuit board is hard mounted in the common chassis.

[0300] 6. A vacuum cleaner according to clause 4 or 5, wherein the suction motor is accommodated in a first part of the common chassis, the control circuit board is accommodated in a second part of the common chassis, and the second part of the common chassis is fluidly isolated from the first part of the common chassis.

[0301] 7. The vacuum cleaner according to clause 6, wherein no air flow filter is provided between the suction motor and the control circuit board.

[0302] 8. A vacuum cleaner according to clause 6 or 7, wherein the electrical cable extends between the second part of the common chassis and the first part of the common chassis, and the second part of the common chassis comprises a sealing member through which the electrical cable extends.

[0303] 9. A vacuum cleaner according to any of clauses 6 to 8, wherein the second portion of the common chassis at least partially defines the first and second airflow paths downstream of the suction motor.

[0304] 10. A vacuum cleaner according to any of clauses 4 to 9, wherein the common chassis comprises a first chassis half and a second chassis half, and the first chassis half and the second chassis half are separate components which, when combined together, define the common chassis.

[0305] 11. A vacuum cleaner according to any of the preceding clauses, wherein the vacuum cleaner comprises a motor housing, a suction motor and a control circuit board are located in the motor housing, the motor housing comprises a first and a second air flow outlet, and the first and second air flow outlets are located on opposite sides of a plane defined by the control circuit board.

[0306] 12. A vacuum cleaner as claimed in claim 11 when dependent on clause 9, wherein the common chassis is located within the motor housing and the first and second airflow paths are in fluid communication with respective ones of the first and second airflow outlets.

[0307] 13. A vacuum cleaner according to any preceding clause, wherein the control circuit board has a generally rectangular cross-sectional shape, and wherein a major axis of the control circuit board extends in a direction parallel to the rotational axis of the suction motor.

[0308] 14. The vacuum cleaner according to clause 13, wherein the smaller dimension of the control circuit board substantially corresponds to the outer diameter of the suction motor.

[0309] 15. A vacuum cleaner according to clause 14, wherein the smaller dimension of the control circuit board is less than 38 mm.

[0310] 16. A vacuum cleaner according to any of the preceding clauses, wherein the vacuum cleaner comprises a battery assembly, the battery assembly comprises a plurality of battery cells arranged in rows, the control circuit board has a substantially rectangular cross-sectional shape, and the main axis of the control circuit board extends in a direction parallel to the battery cell rows.

[0311] 17. The vacuum cleaner according to any of the preceding clauses, wherein the separation system comprises a central separation system axis, the control circuit board has a generally rectangular cross-sectional shape, and the main axis of the control circuit board extends in a direction parallel to the central separation system axis.

[0312] 18. A vacuum cleaner according to any of the preceding clauses, wherein the separation system comprises an airflow inlet, the control circuit board has a generally rectangular cross-sectional shape, and a major axis of the control circuit board extends in a direction parallel to a bulk airflow direction through the airflow inlet.

[0313] 19. A vacuum cleaner according to any of the preceding clauses, wherein the vacuum cleaner includes a battery assembly, and a power connection circuit board connected to the battery assembly and configured to supply power from the battery assembly to a suction motor, wherein the power connection circuit board defines another plane orthogonal to the plane defined by the control circuit board.

[0314] 20. The vacuum cleaner according to clause 19, wherein the power connection circuit board and the control circuit board together define a T-shaped structure.

[0315] 21. A vacuum cleaner as claimed in clause 13 or 14 when dependent on any one of claims 6 to 9, wherein the power connection plate is housed within the third portion of the common chassis and the second portion of the common chassis is located between the first and third portions of the common chassis.

[0316] 22. The vacuum cleaner according to any of the preceding clauses, wherein the vacuum cleaner comprises an acoustic foam downstream of the suction motor.

[0317] 23. A vacuum cleaner according to any of the preceding clauses, wherein the vacuum cleaner comprises a radiator downstream of the suction motor, the radiator being positioned to direct the air flow downstream of the suction motor.

[0318] 24. The vacuum cleaner according to clause 23, wherein the heat sink comprises a first heat sink member located on a first side of the rotation axis of the suction motor, and a second heat sink member located on a second opposite side of the rotation axis of the suction motor.

[0319] 25. The vacuum cleaner of any of the preceding clauses, wherein the vacuum cleaner comprises a user interface comprising a user interface circuit board, and the user interface circuit board defines a further plane rotated by substantially 90 degrees relative to the plane defined by the control circuit board.

[0320] 26. A vacuum cleaner according to any of the preceding clauses, wherein the separation system includes a bin body, the suction motor and the circuit board are housed in a motor housing, and the vacuum cleaner includes a battery assembly, the battery assembly includes a battery housing, the bin body, the motor housing and the battery housing are connected together to define a main unit of the vacuum cleaner, the control circuit board has a substantially rectangular cross-sectional shape, and the main axis of the control circuit board extends in a direction parallel to the central longitudinal axis of the main unit.

[0321] 27. The vacuum cleaner of clause 26, wherein each of the bin body, the motor housing and the battery housing is an elongated tube, and at least two of the bin body, the motor housing and the battery housing have the same maximum width.

[0322] It should be understood that any feature described with respect to any one example may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other example, or in combination with any combination of any other example. In addition, equivalents and modifications not described above may also be adopted without departing from the scope of the appended claims.

Claims

1. A vacuum cleaner comprising: Separation system; a suction motor for generating airflow through the separation system; a motor housing accommodating a suction motor; as well as A battery assembly for powering a suction motor; wherein, The battery assembly is releasably connected to the motor housing such that a first portion of the battery assembly is located within the motor housing.

2. The vacuum cleaner according to claim 1, wherein: The motor housing includes an opening configured to receive a first portion of the battery assembly.

3. The vacuum cleaner according to claim 2, wherein: The first portion of the battery assembly includes an interface portion configured to prevent the battery assembly from rotating within the motor housing opening.

4. The vacuum cleaner according to claim 3, wherein: The opening includes a planar interior surface, and the interface portion is planar and is located below the planar interior surface.

5. A vacuum cleaner according to any preceding claim, wherein: The motor housing includes a battery latch mechanism configured to releasably engage the battery assembly.

6. The vacuum cleaner according to claim 5, wherein: The first portion of the battery assembly includes a locating recess configured to releasably engage the battery locking mechanism.

7. A vacuum cleaner according to any preceding claim, wherein: The battery assembly also includes a plurality of battery cells, and at least one battery cell is located within the first portion of the battery assembly.

8. The vacuum cleaner according to claim 7, wherein: The battery assembly also includes a second portion that accommodates at least one battery cell.

9. The vacuum cleaner of claim 8, further comprising a battery management system having a planar battery circuit board located within the second portion of the battery assembly.

10. The vacuum cleaner according to claim 9, wherein: The plurality of battery cells are aligned along a common axis and parallel to the plane of the battery circuit board.

11. The vacuum cleaner according to claim 9 or 10, wherein: The plurality of battery cells are four battery cells, and the battery circuit board covers three battery cells located in the second portion of the battery assembly.

12. The vacuum cleaner according to claim 11, wherein The battery assembly includes an inner sleeve that is an elongated tube having a central axis, wherein a common axis of the plurality of battery cells is parallel to the central axis.

13. A vacuum cleaner according to any one of claims 8 to 12, wherein: The second portion is located outside the motor housing.

14. The vacuum cleaner according to claim 13, wherein: The second portion and the motor housing each include an outer surface that defines at least a portion of an outer surface of a main unit of the vacuum cleaner.

15. A vacuum cleaner according to any preceding claim, wherein The vacuum cleaner has a central longitudinal axis, and the separation system, suction motor and battery assembly are aligned along the central longitudinal axis.

16. The vacuum cleaner according to claim 15, wherein The suction motor has an axis of rotation coaxial with the central longitudinal axis.

17. A vacuum cleaner according to claim 15 or 16, wherein: The battery assembly has a central axis coaxial with the central longitudinal axis.

18. A vacuum cleaner according to any preceding claim, wherein The separation system includes a cartridge body, and the battery assembly includes a battery housing, the cartridge body, the motor housing, and the battery housing being coupled together to define a main unit of the vacuum cleaner.

19. The vacuum cleaner according to claim 18, wherein The cartridge body, the motor housing and the battery housing are each an elongated tubular portion.

20. A vacuum cleaner according to claims 15 to 17, wherein The battery assembly is separable from the motor housing in a direction parallel to the central longitudinal axis.

21. A vacuum cleaner according to claim 18 or 19, wherein The battery housing includes an outer sleeve formed at least in part from a non-slip material.

22. The vacuum cleaner of any preceding claim, further comprising a cleaning head assembly fluidly connected to the separation system.

23. The vacuum cleaner according to claim 22, wherein: The cleaning head assembly includes at least two brush bars, each of which is conical.

24. The vacuum cleaner according to claim 23, wherein The at least two brush strips are four brush strips arranged in two pairs.

25. A vacuum cleaner according to any preceding claim, wherein The separation system has a length to diameter ratio of at least 0.

01.

26. A vacuum cleaner according to any preceding claim, further comprising a main unit which is a wand structure comprising the separation system, suction motor and battery assembly.

27. The vacuum cleaner according to claim 21, wherein The outer sleeve of the battery assembly defines a handle for the vacuum cleaner.

28. A vacuum cleaner according to any preceding claim, wherein The separation system is a non-cyclonic separation system.

29. The vacuum cleaner according to claim 28, wherein The separation system includes a chamber having an air flow inlet; and a filter disposed in the chamber for filtering the air flow from the air flow inlet.

30. The vacuum cleaner according to claim 29, wherein The major surface of the filter extends parallel to the direction of bulk air flow into the chamber.

31. The vacuum cleaner of claim 31, wherein: The separation system includes an elongated bin body having a central axis, and the bulk gas flow direction is parallel to the central axis.

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