Vacuum cleaner

Abstract

A vacuum cleaner (1, fig.1) comprising a dirt separator 400 with a filter assembly 405 and a drive assembly 450 for dislodging dirt and regenerating a filter 410 of the filter assembly by agitating, m

Description

BACKGROUND

[0001] Vacuum cleaners may comprise one or more dirt separators to separate dirt from an airflow drawn through the vacuum cleaner. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Figure lisa perspective view of a vacuum cleaner;

[0003] Figure 2 is a perspective view of the vacuum cleaner wherein a bin body forming part of the vacuum cleaner has been omitted;

[0004] Figure 3 is a side view of the vacuum cleaner;

[0005] Figure 4 is a top view of the vacuum cleaner;

[0006] Figure 5 is a bottom view of the vacuum cleaner;

[0007] Figure 6 is a rear view of the vacuum cleaner;

[0008] Figure 7 is a front view of the vacuum cleaner;

[0009] Figure 8 is an exploded view of the vacuum cleaner;

[0010] Figure 9 is an exploded view of a bin assembly of the vacuum cleaner;

[0011] Figure 10 is a perspective view of the bin body of the bin assembly;

[0012] Figure 11 is another perspective view of the bin body of the bin assembly;

[0013] Figure 12 is a side view of the bin body of the bin assembly;

[0014] Figure 13 is a sectional slice through the bin body of the bin assembly of Figure 12 in the plane A-A;

[0015] Figure 14 is a sectional slice through the bin body of the bin assembly of Figure 12 in the plane B-B;

[0016] Figure 15 is a side view of the bin assembly, where a bin base is in a closed position;

[0017] Figure 16 is a side view of the bin assembly, where the bin base is in an open position;

[0018] Figure 17 is an exploded view of the bin base;

[0019] Figure 18 is another exploded view of the bin base;

[0020] Figure 19 is a cross sectional view of the bin assembly and a dirt separator assembly of the vacuum cleaner, with an inlet valve member in a closed position;

[0021] Figure 20 is a cross sectional view of the bin assembly and the dirt separator assembly, with the inlet valve member in an open position;

[0022] Figure 21 is a perspective view of a bin-open assembly of the vacuum cleaner;

[0023] Figure 22 is a perspective view of a dirt separator assembly of the vacuum cleaner;

[0024] Figure 23 is an exploded view of the dirt separator assembly;

[0025] Figure 24 is a front view of a primary dirt separator of the dirt separator assembly;

[0026] Figure 25 is a top plan view of the primary dirt separator;

[0027] Figure 26 is a front perspective view of the primary dirt separator;

[0028] Figure 27 is a front perspective view of the primary dirt separator;

[0029] Figure 28 is a sectional slice through the bin body and the dirt separator assembly in the plane A-A as shown in Figure 20;

[0030] Figure 29 is a perspective view of a section of the bin body and the dirt separator assembly, the section represented by box B in Figure 20;

[0031] Figure 30 is a front perspective view of the base of dirt separator assembly;

[0032] Figure 31 is a rear perspective view of the base of dirt separator assembly;

[0033] Figure 32 is a front view of the base of the dirt separator assembly;

[0034] Figure 33 is a rear view of the base of the dirt separator assembly;

[0035] Figure 34 is a side view of the base of the dirt separator assembly;

[0036] Figure 35 is an exploded view of the base and a secondary dirt separator of the dirt separator assembly;

[0037] Figure 36 is a rear perspective view of the secondary dirt separator;

[0038] Figure 37 is a side view of the secondary dirt separator;

[0039] Figure 38 is a perspective view of a filter of the secondary dirt separator;

[0040] Figure 39 is a front view of the filter;

[0041] Figure 40 is a front perspective view of a front cap of the secondary dirt separator;

[0042] Figure 41 is a rear perspective view of the front cap;

[0043] Figure 42 is a side view of the front cap;

[0044] Figure 43 is a front perspective view of a rear cap of the secondary dirt separator;

[0045] Figure 44 is a rear perspective view of the rear cap;

[0046] Figure 45 is a side view of the rear cap;

[0047] Figure 46 is a front perspective view of a bridge of the secondary dirt separator;

[0048] Figure 47 is a rear perspective view of the bridge;

[0049] Figure 48 is a front perspective view of a regenerative drive assembly of the secondary dirt separator;

[0050] Figure 49 is a top view of the regenerative drive assembly;

[0051] Figure 50 is an exploded view of the regenerative drive assembly;

[0052] Figure 51 is a sectional slice through the regenerative drive assembly in the plane A-A as shown in Figure 49;

[0053] Figure 52 illustrates an eccentric path generated by the regenerative drive assembly;

[0054] Figure 53 is a front perspective view a compaction assembly of the vacuum cleaner;

[0055] Figure 54 is an exploded view from a front perspective of the compaction assembly;

[0056] Figure 55 is an exploded view from a rear perspective of the compaction assembly;

[0057] Figure 56A is a side view of a compaction handle of the compaction assembly;

[0058] Figure 56B is a side view of another embodiment of a compaction handle;

[0059] Figure 57 is a schematic cross-sectional view of a suction motor of the vacuum cleaner;

[0060] Figure 58 is a front perspective view of a housing and handle assembly of the vacuum cleaner;

[0061] Figure 59 is a side view of the housing and handle assembly;

[0062] Figure 60 is a perspective view of a first vertical section through the housing and handle assembly;

[0063] Figure 61 is a perspective view of a second vertical section through the housing and handle assembly;

[0064] Figure 62 is a sectional slice through the housing and handle assembly in the plane A-A as shown in Figure 59;

[0065] Figure 63 is a sectional slice through the housing and handle assembly in the plane B-B as shown in Figure 59;

[0066] Figure 64 is a cross-sectional side view through a centre of the vacuum cleaner;

[0067] Figure 65 is a perspective view of a post-motor filter assembly of the vacuum cleaner;

[0068] Figure 66 is another perspective view of the post-motor filter assembly;

[0069] Figure 67 is a cross-sectional view through the bin assembly and the dirt separator assembly, illustrating an airflow path through the dirt separator assembly;

[0070] Figure 68 is a front perspective view of the dirt separator assembly, illustrating part of an airflow path through the dirt separator assembly; and

[0071] Figure 69 is a cross-sectional plan view through the vacuum cleaner, illustrating an airflow path through the housing and handle assembly, the suction motor, and the post-motor filter assembly. DETAILED DESCRIPTION

[0072] A vacuum cleaner 1 is illustrated in Figure 1. The vacuum cleaner 1 comprises a bin assembly 100, a dirt separator assembly 200, a compaction assembly 300, a suction motor 500, a housing and handle assembly 600 and a battery assembly 800.

[0073] The vacuum cleaner 1 may function as a handheld vacuum. In another embodiment, the vacuum cleaner 1 may also include a wand and a cleanerhead that are attachable to the vacuum cleaner 1 to function as a stick vacuum cleaner.

[0074] Bin Assembly

[0075] The bin assembly 100 is shown in Figures 9 to 21. The bin assembly 100 comprises a bin base 102, a bin body 110, and a bin closure clasp 112.

[0076] The bin body 110 comprises a bin case 174, a bin hinge portion 175, a pair of runner guide rails 176, a pair of separator guide rails 177, first and second channels 178,179 and a bin base hook 188. In this example, the bin case 174, the bin hinge portion 175, the runner guide rails 176, the pair of separator guide rails 177, the channels 178,179, and the bin base hook 188 are all integrally formed. In other examples, some of the parts may be separately provided.

[0077] The bin case 174 is transparent and has a first end 181, a second end 182 and a side wall 183 extending between the first end 181 and the second end 182. A bin central axis 185 extends centrally through the bin case 174, between the first end 181 and the second end 182. In a plane normal to the bin central axis 185, the bin case 174 has a cross-sectional shape that is generally cylindrical in form. A bottom 186 of the bin case 174 has a recess to accommodate a bin-open assembly, described below in more detail.

[0078] The bin case 174 comprises a pair of openings 184 located towards a second end 182 of the bin case 174. In this example, the openings 184 are located on an upper side of the bin case 174 and are disposed on opposite sides. When the bin assembly 100 is attached to the dirt separator assembly 200, the openings 184 of the bin case 174 receive corresponding bin-release catches 252. A user is then able to release and remove the bin assembly 100 by depressing the bin-release catches 252.

[0079] The bin hinge portion 175 is located at the first end 181 of the bin case 174 and defines a second half of a hinged connection between the bin base 102 and the bin body 110. More particularly, the bin hinge portion 175 and the base hinge portion 124 are held together by a hinge pin 114 to define the hinged connection. The bin hinge portion 175 is located on an upper side of the bin case 174 when the vacuum cleaner 1 is positioned in a horizontal orientation as shown in Figure 3.

[0080] A pair of separator guide rails 177 are located on an inner surface of the side wall 183 of the bin case 174. The separator guide rails 177 are generally elongate and linear in form, and extend along an interior surface of the bin case 174 in a direction substantially parallel to the bin central axis 185. The separator guide rails 177 are integrally formed with the bin case 174 as part of a same moulding process. The separator guide rails 177 are disposed on opposite sides of the interior surface of the bin case 174.

[0081] The separator guide rails 177 extend between the first 181 and second 182 ends of the bin case 174. The bin case 174 is slidably attached to the dirt separator assembly 200 via the separator guide rails 177 and guide surfaces 253 of the dirt separator assembly 200.

[0082] Bin-open guide rails 176 are located on an outer surface of the bin case 174. In this example, the guide rails 176 are located on the bottom side of the bin case 174 and extend along a major length of the bin case 174. The guide rails 176 are used to slidably receive the bin-open assembly 350. The bin-open assembly 350 will be described below in more detail.

[0083] Channels 178,179 are located at the first end 181 of the bin case 174 on opposite sides of the bin hinge portion 175. Each of the channels 178,179 is formed by a pair of parallel projections or tracks that extend partly around the bin case 174. As will be explained below, the channels 178,179 receive and retain the bin closure clasp 112.

[0084] The bin base 102 is moveable relative to the bin body 110 about the hinge axis 123. The bin base 102 is moveable between a closed position, shown in Figure 15 where the bin base 102 is normal to the bin central axis 185, and an open position, shown in Figure 16 where the bin base 102 is substantially parallel to the bin central axis 185. In this example, the bin assembly 100 comprises a torsion spring 115 that surrounds the hinge pin 114 and biases the bin base 102 to the open position.

[0085] The bin base hook 188 extends from the first end 181 of the bin case 174. When the bin base 102 is in the closed position, the bin base hook 188 extends through a bin hook aperture in the base plate 116.

[0086] The bin closure clasp 112 comprises first and second clasps 190,192 and an extension spring 193. Each of the clasps 190,192 is generally arcuate or C-shaped and is seated within a respective channel 178,179 of the bin body 110. Each clasp 190,192 is attached at a first end to the bin body 110. In this example, the first end of each clasp 190,192 is attached to the bin hinge portion 175 of the bin body 110. Each clasp body 190,192 is then attached at a second opposite end to the extension spring 193. The extension spring 193 therefore extends between the two clasps 190,192. The extension spring biases the second ends of the claps 190,192 together. As a result, the clasps 190,192 clamp around the first end 181 of the bin body 110.

[0087] The width of each clasp 190,192 is such that the clasps 190,192 extend beyond the first end 181 ofthe bin body 110. Each clasp 190,192 comprises a pair of projections 194,195 provided on the inner surface of the arcuate portion of the clasp 190,192. The clasps 190,192 are retained within a respective channel 178,179 of the bin body 110 by the projections or tracks in channel 178,179. Movement of the clasps 190,192 in an axial direction (i.e., in a direction parallel to the bin central axis 185) is then opposed by the tracks of the channel 178,179 of the bin body 110. In particular, axial movement of each clasp 190,192 in a first direction (to the left in Figure 15) causes the first proj ection 194 of the clasp 190,192 to abut against the track in channel 178,179 of the bin body 110, and axial movement of each clasp 190,192 in a second opposite direction (to the right in Figure 15) causes the second projection 195 of the clasp 190,192 to abut against the track in channel 178,179 ofthe bin body 110.

[0088] The second projection 195 of each clasp 190,192 is provided on that part of the clasp 190,192 that extends beyond the first end 181 of the bin body 110. The second projections 195 of the clasps 190,192 then engage with a pair of projections 128 on the bin base 102 when the bin base 102 is in the closed position. Figure 16 shows just one of the pair of projections 128, which engages with the second clasp 192. A corresponding projection 128 is provided on the opposite side of the bin base 102 and can be seen in figure 17.

[0089] The bin base 102 comprises a base plate 116, a bin base cover 104, a base nozzle 118 and inlet valve assembly 144.

[0090] The base plate 116 is generally circular in form, and comprises a base plate aperture 122 and a base hinge portion 124. The base plate aperture 122 is shaped and dimensioned to receive an electrical connector 238 that extends from an end of the dirt separator assembly 200. The base hinge portion 124 defines a first half of a hinged connection between the bin base 102 and the bin body 110. The base hinge portion 124 is located on an upper side of the base plate 116 when the vacuum cleaner 1 is positioned in a horizontal orientation as shown in figure 3. The base hinge portion 124 defines a hinge axis 123.

[0091] A lower region of the base plate 116 comprises a bin pushrod engaging member 125 extending from the base plate 116 such that the bin pushrod engaging member 125 extends below the bin body 110 when the bin base 102 is in a closed position.

[0092] The base nozzle 118 extends through the base plate 116, and comprises a major portion that extends from a first side of the base plate 116 in a direction away from the bin body 110. The base nozzle 118 is hollow in form and comprises an airflow inlet 134 at one end, through which airflow enters the interior of the bin assembly 100 during use, when the bin base 102 is in a closed position. In some examples, the base nozzle 118 may be omitted, and the airflow inlet 134 may be defined by an aperture formed in the bin base 102. The base nozzle 118 has a generally round cross-sectional profile when viewed in a plane orthogonal to the nozzle central axis 119 of the base nozzle 118. The nozzle central axis 119 of the base nozzle 118 defines a central axis along which airflow enters the bin assembly 100 during use, which is discussed further below.

[0093] The inlet valve assembly 144 is attached to the base plate 116. The inlet valve assembly 144 is attached to a second side of the base plate 116 at a location above the base nozzle 118.

[0094] The inlet valve assembly 144 comprises an inlet valve member 146 and an inlet valve guard 150. The inlet valve member 146 is attached to the inlet valve guard 150 by a rubber hinge such that the inlet valve member 146 is movable relative to the inlet valve guard 150. More particularly, the inlet valve member pivots, via the rubber hinge, between a closed position in which the airflow inlet 134 is obstructed by inlet valve member 146, shown in Figure 19, and an open position in which the airflow inlet 134 is unobstructed by the inlet valve member 146, shown in Figure 20.

[0095] The inlet valve member 146 is shaped such that, when in the open position, the inlet valve member 146 shapes the airflow entering the bin body 110 through the airflow inlet 134. More particularly, the inlet valve member 146 shapes the airflow such that the profile of the airflow better corresponds to a surface of a primary filter 204 of the primary dirt separator 210, as described below in more detail. To this end, the inlet valve member 146 is downwardly convex in shape. The depth of the convex surface of the inlet valve member 146 increases from a first, upstream end of the inlet valve member 146, which attached to the rubber hinge, to a second, downstream end. When in the open position, the inlet valve member 146 is spaced radially from the nozzle central axis 119 of the base nozzle 118. The convex surface of the inlet valve member 146 projects towards the nozzle central axis 119, and the depth of the convex surface increases from the upstream end to the downstream end; this is perhaps best seen in Figure 20. Consequently, the radial distance between upstream end of the inlet valve member 146 and the nozzle central axis 119 of the base nozzle 118 is greater than the radial distance between downstream end and the nozzle central axis 119. When the inlet valve member 146 is in the open position, the inlet valve member 146 deflects the upper part of the airflow 110 in a downward direction, and thus the airflow entering the bin chamber 105 does so as a generally U-shaped column of air.

[0096] The rubber hinge 148 links both the inlet valve member 146 and the inlet valve guard 150 together. The rubber hinge 148 enables movement of the inlet valve member 146 relative to the inlet valve guard 150 from the closed position to the open position. By employing a rubber hinge, the force required to move the inlet valve member 146 to the open position is relatively low. As a result, the inlet valve member 146 moves to the open position in response to relatively low flow rates moving through the base nozzle 118. More accurately, the inlet valve member 146 moves in response to suction generated by the suction motor 500. This suction creates a pressure difference across the inlet valve member 146, which in turn causes air on the upstream side of the inlet valve member 146 to push and move the inlet valve member 146 to the open position. The inlet valve member 146 pivots about a horizontal axis. The inlet valve member 146 therefore moves to the open position in an upward direction. When the suction is removed, the inlet valve member 146 returns to the closed position under the force of gravity. The inlet valve member 146 may therefore be said to be biased to the closed position, and moves to the open position in response to suction generated by the suction motor 500. In this example, the rubber hinge is formed of rubber or latex, but other materials capable of providing a low hinge torque may be used.

[0097] The inlet valve guard 150 is shaped as a concave hood that overlies the inlet valve member 146. The inlet valve guard 150 has an abutment portion which engage with corresponding abutment portion on the inlet valve member 146, when the inlet valve member 146 is in the open position. This limits the rotation of the inlet valve member 146 to prevent over-rotation of the inlet valve member 146, which might otherwise cause the inlet valve member 146 to become jammed within the inlet valve guard 150.

[0098] When the inlet valve member 146 is in the closed position, as shown in Figure 19, the inlet valve member 146 abuts an inlet valve stop provided at the inlet. This then prevents the inlet valve member 146 from potentially jamming within the base nozzle 118 when returning to the closed position.

[0099] The bin base cover 104 covers the base plate 116 and comprises a first opening 1702 through which the electrical connector 238 projects, as can be seen in Figures 17 and 18.

[0100] The bin base 102 comprises a pair of projections 128 each of which extends circumferentially around a part only of the base plate 116 of the bin base 102. Likewise, the second projection 195 of each clasp 190,192 extends circumferentially around a part only of the clasp 190,192. When the bin base 102 is in the closed position, as shown in Figure 15, the second projection 195 of the first clasp 190 engages with one of the pair of projections 128 of the bin base 102, and the second projection 195 of the second clasp 192 engages with the other of the pair of projections 128. As a result, movement of the bin base 102 from the closed position to the open position is prevented.

[0101] The bin closure clasp 112 has a contracted configuration and an expanded configuration. The bin closure clasp 112 is shown in the contracted configuration in Figures 9 and 15. When the bin base 102 is in the closed position and the bin closure clasp 112 is in the contracted configuration, the bin closure clasp 112 retains the bin base 102 in the closed position. In order to release the bin base 102 from the closed position, the bin closure clasp 112 is moved to the expanded configuration.

[0102] In order to move the bin closure clasp 112 to the expanded configuration, a bin pushrod 356, forming part of the bin-open assembly 350 and described below in more detail, is pushed in the direction of the bin base 102. The end of the bin pushrod 356 projects into a gap between the two clasps 190,192. The end of the bin pushrod 356 is wedge-shaped. Consequently, as the bin pushrod 356 is pushed towards the bin base 102, the bin pushrod 356 engages and pushes apart the two clasps 190,192 against the biasing force of the extension spring 193. As the clasps 190,192 are pushed apart, each clasp 190,192 flexes or pivots outwardly about the first end that is attached to the bin body 110. As the clasps 190,192 pivot, the second projections 195 of the clasps 190,192 disengage or clear the projections 128 of the bin base 102. As a result, the bin base 102 is no longer retained by the bin closure clasp 112 and is free to move to the open position.

[0103] The first projections 194 of the clasp 190,192 and the tracks 198,199 of the bin body 110 have a greater circumferential extension. Consequently, whilst the second projections 195 of the clasps 190,192 disengage the projections 128 of the bin base 102, the first projections 194 continue to engage the projections 199 of the bin body 110. Asa result, each clasp 190,192 continues to be retained within the channels 178,179 of the bin body 110.

[0104] The clasps 190,192 of the bin closure clasp 112 are moved apart in the expanded configuration. More particularly, the second ends of the clasps 190,192 are moved apart, whilst the first ends of the clasps 190,192 remain positionally fixed. In moving apart, the clasps 190,192 effectively expand in an outward direction away from the bin body 110 and the bin base 102. The clasps 190,192 can perhaps be thought collectively as a band or c-clip that surrounds an end the bin body 110 and the bin base 102. The diameter of this band or c-clip then expands in the expanded configuration and contracts in the contracted configuration. The clasps 190,192 may therefore be said to have a first equivalent diameter in the contracted configuration and a second, larger equivalent diameter in the second configuration.

[0105] The projections 128 of the bin base 102 are ramped. When the bin closure clasp 112 is in the contracted configuration and the bin base 102 is moved from the open position to the closed position, the ramped faces of the projections 128 contact the second projections 195 of the clasps 190,192. As the bin base 102 continues to be moved to the closed position, the second projections 195 of the clasps 190,192 ride up the ramped faces of the projections 128 of the bin base 102. This causes the clasps 190,192 to pivot outwardly about the first ends that are attached to the bin body 110. The two clasps 190,192 are therefore pushed apart, with the push force used to move the bin base 102 acting in opposition to the biasing force of the extension spring 193. Finally, as the bin base 102 completes the move to the closed position, the second projections 195 of the clasps 190,192 ride over the top of the projections 128 of the bin base 102. The biasing force of the extension spring 193 then causes the two clasps 190,192 to snap down over the projections 128 of the bin base 102. As a result, the bin base 102 is again retained in the closed position by the bin closure clasp 112. The ramped faces of the projections 128 of the bin base 102 therefore enable the bin closure clasp 112 to move from the contracted configuration to the expanded configuration during closure of the bin base 102.

[0106] The bin base 102 and the bin body 110 together define an internal chamber 105 of the bin assembly 100. The dirt separator assembly 200 is located within this internal chamber 105. As described below in more detail, the dirt separator assembly 200 comprises a primary dirt separator 210, a secondary dirt separator 400 and a base 250. Part of the internal chamber 105 of the bin assembly 100 serves as a primary chamber 209 within which the primary dirt separator 210 is located. The base 250 comprises a secondary chamber 249 within which part of the secondary dirt separator 400 (namely the filter assembly 410) is located. In use, airflow enters the primary chamber 209 via the airflow inlet 134. Dirt entrained in the airflow is then separated by the primary dirt separator 210 and retained within the primary chamber 209. The airflow then flows into the secondary chamber 249 whereupon the secondary dirt separator 400 separates dirt from the airflow. The primary chamber 209 and the secondary chamber 249are closed by the bin base 102. Dirt separated by the dirt separator assembly 200 and retained within the primary and secondary chambers 209, 249 can then be emptied by moving the bin base 102 to the open position.

[0107] The bin-open assembly 350 is provided at the bottom of the bin case 174 and is coupled to the runner guide rails 176. The bin-open assembly 350 is operable to open the bin base 102. The bin-open assembly 350 comprises a bin pushrod 356, a compression spring 358, and a handle portion 372.

[0108] The bin pushrod 356 is elongate in form and is attached at one end to the handle portion 372. In this example, the bin pushrod 356 and the handle portion 372 are integrally formed. The opposite end of the bin pushrod 356 is wedge-shaped and engages with the bin closure clasp 112 when opening the bin assembly 100. The handle portion 372 projects downwardly from an end of the bin pushrod 356 and is generally semi-circular in shape. The bin pushrod 356 is slidably mounted to the runner guide rails 176. The bin pushrod 356 is moveable between a retracted position and an extended position. The compression spring 358 is attached to both the bin pushrod 356 and a fixture 366 at a location along the runner guide rails and acts to bias the bin pushrod 356 to the retracted position. The bin pushrod 356 is moved to the extended position by gripping the handle portion 372 and pushing the bin pushrod 356 in the direction of the bin base 102. In response, the wedge-shaped end of the bin pushrod 356 engages the bin closure clasp 112 to move the bin closure clasp to the expanded configuration and thus release the bin base 102 from the closed position. Further movement of the bin pushrod 356 then causes the end of the bin pushrod 356 to push the bin pushrod engaging member 125 of the bin base 102 in a direction away from the bin body 110, and thus move the bin base 102 from the closed position to the open position. The bin pushrod 356 may therefore be regarded as bin opening mechanism which, when actuated, causes the bin closure clasp 112 to release the bin base 102 and then push the bin base 102 from the closed position.

[0109] The base plate 116 comprises a magnet housing 117. A magnet is provided in the magnet housing 117 and a corresponding proximity sensor 259 is provided at the base 250 of the dirt separator assembly 200. In this example, the proximity sensor 259 is a reed switch to detect the bin base 102 moving from the closed position to the open position. However, one skilled in the art will recognise that other proximity sensors, such as a Hall-effect sensor, may alternatively be used. The function of the proximity sensor is described below.

[0110] Dirt Separator Assembly

[0111] The dirt separator assembly 200 is illustrated in Figures 22 to 52 and comprises a primary dirt separator 210, a secondary dirt separator 400 and a base 250.

[0112] The primary dirt separator 210 comprises a core 202, a primary filter 204, first and second auxiliary filters 206, 208, and a dirt detection assembly 215. The primary dirt separator 210 is a non-cyclonic separator, as will be described in more detail hereinafter.

[0113] The base 250 comprises a first base portion 212, a second base portion 214 and a third base portion 216. The first base portion 212 is located within the bin case 174 of the bin assembly 100, the second base portion 214 closes the open end of the bin assembly 100, and the third base portion 216 closes an open end of the first base portion 212.

[0114] The core 202 of the primary dirt separator 210 comprises a generally U-shaped centre portion and a pair of wings 219, 220 that extend outwardly from the U-shaped. The cross-sectional shape of the core 202 is substantially uniform along its length. The core 202 may be thought of as comprising a first shoulder 217 and a second shoulder 218, each of which has an inner bottom surface that arc towards each other to form the U-shaped channel of the core 202, and an outer bottom surface that extend towards the bin case 274 to form the wings 219, 220. The U-shaped channel defines an inner channel 228 which acts as an airflow channel that extends along the length of the core 202. The peak of the shoulders 217, 218, the wings 219, 220 and the bin case 274 defines an outer channel 230, described further below.

[0115] The cross-sectional profile of the core 202 may also be said to comprise a concave portion formed between two uprights (i.e., the shoulders 217, 218) and two flat portions (i.e., the wings 219, 220) formed outside of the two uprights. The concave portion defines a trough (i.e., the inner channel 228) that extends along the length of the core 202.

[0116] When positioned within the bin assembly 100, a part of the internal chamber 105 of the bin assembly serves as a primary chamber 209. The primary chamber 209 is that part of the internal chamber 105 that extends between the primary dirt separator 210 and the bin assembly 100. The primary chamber 209 therefore comprises the inner channel 228 that extends along the U-shaped portion of the core 202, and an outer channel 230 that extends along each of the wings 219, 220 of the core 202 and over the U-shaped portion. As shown in Figure 24, the cross-sectional shape of the inner channel 228 resembles a heraldic shield while the outer channel 230 resembles a C-shape. In combination, the cross-sectional shape of the inner and outer channels resembles the shape of a mushroom or an umbrella.

[0117] The core 202 is positioned within the bin assembly 100 and extends from the first end 181 to the second end 182 of the bin body 110. The core 202 extends in a direction parallel to the nozzle central axis 119 of the base nozzle 118. The core 202 includes a centre portion that is generally U-shaped in cross-section in a plane normal to the nozzle central axis 119 and a left and right side portions that are planar and disposed opposite one another.

[0118] The first core portion 212 extends partly around the nozzle central axis 119 of the base nozzle 118; this can be seen in Figure 24, which shows the location of the nozzle central axis 119. The first and second shoulders 217, 218 may be said to extend upwardly on opposite sides of the nozzle central axis 119. The inner channel 228 of the core 202 then extends parallel to the nozzle central axis 119. Moreover, the nozzle central axis 119 extends through the inner channel 228.

[0119] The core 202 has a first end 222 proximal the bin base 102 and thus proximal the airflow inlet 134 defined by the base nozzle 118, and a second end 224 distal the bin base 102 and thus distal the airflow inlet 134. This core may be formed of metal, plastic or any other suitable material.

[0120] The centre portion of the core 202 has an opening that defines a primary outlet and is covered by the primary filter 204. Each of the left and right side portions (i.e., the wings) 219, 220 has an opening that defines an auxiliary outlet and is covered by respective first 204 and second 206 auxiliary filters. A primary outlet passage 226 is defined between the primary filter 204 and the base 250, a first auxiliary outlet passage 234 is defined between the first auxiliary filter 206 and the base 250, and a second auxiliary outlet passage 236 is defined between the second auxiliary filter 208 and the base 250.

[0121] The inner channel 228 is located at inner regions of the first 217 and second 218 shoulders of the core 202, and overlies the primary filter 204. The primary filter 204 is shaped according to the profile of the U-shaped center portion of the core 202.

[0122] The outer channel 230 is located above the inner channer and the outer regions of the first 127 and second 218 shoulders of the core 202, and is positioned to overlie the first 206 and second 208 auxiliary filters respectively. The first 206 and second 208 auxiliary filters are generally planar and shaped according to the left and right side portions of the core 202. The primary filter 204 covers an opening or inlet of the primary outlet passage 226. Airflow entering the primary chamber 209 flows along the inner channel 228 in a first direction and over the primary filter 204. A first portion of the airflow then passes through the primary filter 204 and flows along the primary outlet passage 226 in a second direction, opposite to the first direction. The first portion of the airflow flows along the primary outlet passage 226 and into a secondary chamber 249, within which the secondary dirt separator 400 is located. A second portion of the airflow, on reaching the closed end of the inner channel 228, leaves the inner channel 228 and enters the outer channel 230. The second portion of the airflow then passes through the first 206 and second 208 auxiliary filters and flows along the first auxiliary outlet passage 234 and second auxiliary outlet passage 236 respectively in the second direction. The second portion of the airflow flows along the auxiliary outlet passages 234, 236 and into the secondary chamber 249. The first and second airflows then combine and move through the secondary chamber 249 in the first direction.

[0123] In this example, the primary outlet passage 226, the first auxiliary outlet passage 234 and the second auxiliary outlet passage 236 are not isolated from one another. Instead, the core 202 comprises a plurality of openings 240, 242 that serve to link the primary outlet passage 226 to the auxiliary outlet passages 234, 236. The primary outlet passage 226 is therefore in fluid communication with each of the auxiliary outlet passages 234, 236 via the openings 240, 242. The first and second auxiliary outlet passages 234, 236 are located on opposite sides of the primary outlet passage 226.

[0124] The first portion is between 55% and 75% of the airflow, and thus the second portion is between 25% and 45% of the airflow. In this particular example, the first portion is around 60% of the airflow while the second portion is around 40% of the airflow.

[0125] Each of the auxiliary filters 206,208 and primary filter 204 comprises a mesh. The auxiliary filters 206,208 and primary filter 204 are attached to the core 202. In this example, the core 202 is overmoulded onto the primary and auxiliary filters 204, 206, 208, which comprise interlock features (e.g., tabs, folds, holes) to aid the attachment of the core 202 to the filters 204, 206, 208.

[0126] The mesh of the primary and auxiliary filters 204, 206, 208 are formed of metal or any other suitable materials such as plastic. The holes of the mesh have a hole size of between 0.2 mm and 0.5 mm, and the mesh has an open area of between 20% and 35%. The auxiliary filters 206,208 have a combined total open area that is less than the total open area of the primary filter 204.

[0127] The primary filter 204 comprises a notch at one end, which accommodates the dirt detection assembly 215.

[0128] The dirt detection assembly 215 comprises an impact area which forms part of the core 202, a piezoelectric acoustic sensor, a pressure plate, a spring, a cap, and a dirt detection assembly circuit board. The impact area is formed as part of the surface of the core 202. The impact plate area is shaped and dimensioned to fit within the notch of the primary filter 204, whilst also extending out of the notch 272 towards the airflow inlet 134. Thus the primary filter 204 extends partly along the sides of the impact area 280. The piezoelectric acoustic sensor, the pressure plate, the spring, and the cap, underlie the impact area, and are located within the looming passage 232 of the first base portion 212, along with the dirt detection assembly circuit board. Components of the dirt detection assembly 215 can enable dirt impacting on the impact area 280 to be detected. In some examples, the suction motor 500 may be controlled in response to the dirt that is detected. Additionally or alternatively, information regarding the dirt that is detected may be displayed on a user display of the vacuum cleaner 1. In an alternative embodiment, a separate impact plate may form the impact area. The impact plate may be mounted to an upper surface of the first core portion by a vibration isolating component. One skilled in the art will recognise that other types of dirt sensing device may be used.

[0129] A first extension 227 extends from the first wing 219 forming a first groove 221 to receive one of the separator guide rails 177. A second extension 229 extends from the second wing 220 forming a second groove 223 to receive the other separator guide rail 177. The first and second extensions 227, 229 extend from respective ends of the wings 219, 220 that are distal from the first and second shoulders 217, 218.

[0130] The first base portion 212 comprises a secondary dirt separator housing 241 that defines a secondary chamber 249 within which a part of the secondary dirt separator 400 is located. The secondary dirt separator housing 214 comprises a top wall 245, a front end 246, a rear end 247, and a side wall 248.

[0131] The top wall 245 comprises a first coupling 263, a second coupling 264, a first divider 265, and a second divider 267. In this example, the first and second couplings 263, 264 and the first and second extensions 227, 229 comprise interlock features to attach the core 202 to the base 250. First and second dividers 265, 267 also include interlock features to further attach the core 202 to the base 250. First and second dividers 265, 267 together with and first and second extensions 227 and 229 also act as a divider to define the first and second auxiliary outlet passages 234,236.

[0132] A looming passage 232 is defined at the top wall 245 of the base 250 and is hollow in form and houses the electrical harness, the dirt detection assembly 215 and a circuit board. In order to better illustrate the looming passage, the electrical harness and components of the dirt detection assembly 215 have been omitted from Figures 23 and 29. The looming passage 232 is located between the primary outlet passage 226 and the top wall 245, and underlie generally below the U-shaped cross-section of the core 202. The looming passage 232 extends along the full length of the core 202. An end of the looming passage 232 at the front end 246 of the secondary separator housing 241 is closed by the electrical connector 238, which couples with a corresponding electrical connector of a wand that is attached to the vacuum cleaner 1 to provide both power and communication signals from the vacuum cleaner 1 to the wand and the cleanerhead that are connected to the vacuum cleaner 1. The rear end 247 of the secondary separator housing 241 connects to the second base portion 214. The dirt detection assembly 215 is located between the circuit board and the electrical connector 238.

[0133] The side wall 248 extends between the front end 246 to the rear end 247 and underlies the top wall 245. The side wall 248 is shaped according to the bin case 174. In this example, the side wall 248 has a semi-ellipse shape in a plane normal to the nozzle central axis 119.

[0134] The looming passage 232 may also be considered as being defined between the primary dirt separator 210 and the secondary dirt separator 400, or being surrounding by the primary dirt separator 210 and the secondary dirt separator 400.

[0135] The second base portion 214 is generally cylindrical in shape and comprises a side wall 243 and an end wall 244. The second base portion 214 is located at the rear end 247 of the secondary separator housing 241, with the end wall 244 abutting the rear end 247. In this example, the second base portion 214 is formed integrally with the first base portion 212.

[0136] The end wall 244 closes an end of the inner channel 220 and outer channel 230 of the core 202. The inner channel 220 is therefore open at the first end 222 of the core 202 and closed by the end wall 244 at the second end 224 of the core 202.

[0137] The second base portion 214 comprises an annular channel and a catch recess formed on an outside of the side wall 243. The bin body seal 251 is seated in the annular channel, and the bin release catch 252 is seated in the catch recess. The second base portion 214 further comprises an outlet plenum 255 located behind the end wall 244. The outlet plenum 255 is in fluid communication with the secondary chamber 249 of the secondary separator housing 241 and serves as an outlet for the secondary dirt separator 400.

[0138] The outlet plenum is generally cylindrical in shape (e.g., puck shaped) and is located behind the end wall 244 when the vacuum cleaner 1 is positioned in a horizontal orientation as shown in Figure 3. The outlet plenum is in fluid communication with an upstream plenum 605 of the housing and handle assembly 600.

[0139] The secondary dirt separator 400 is illustrated in Figures 35 to 52, and comprises a filter assembly 405 and a regenerative drive assembly 450. The filter assembly 405 comprises a filter 410, a front cap 420, a rear cap 430, and a bridge 440. The secondary dirt separator 400 is a non-cyclonic separator, as will be discussed in more detail hereinafter.

[0140] The filter 410 is defined by an elongate element comprising a wall that extends along a filter axis 411 between open front 416 and open rear 417 of the elongate element. The wall forms a closed loop on a plane transverse to the filter axis 411 to enclose an interior volume 415. The filter 410 therefore wraps around and encloses the filter axis 411. The filter axis 411 represents a central longitudinal axis of the filter 410 which is parallel to the nozzle central axis 119.

[0141] The filter assembly 405 is located within the secondary chamber 249 and is therefore positioned below the primary dirt separator 210. The filter axis 411 is oriented parallel to the bin central axis 185.

[0142] The filter assembly 405 extends approximately the same length of the primary dirt separator 210 is located beneath the primary dirt separator 210. The open front 416 of the filter 410 is mounted to the front cap 420 while the open rear 417 of the filter 410 is mounted to the rear cap 430. A bridge 440 surrounds the outer surface of the filter 410 on a plane transverse to the filter axis 411. In this example, the bridge is centrally located between the open front 416 and open rear 417.

[0143] The front cap 420 is secured to the front end 246 of the first base portion 212 such that the remaining portion of the filter 410 is suspended within the secondary separator housing 241. Further details on the front cap 420 will be described below.

[0144] The filter 410 is approximately the same length of the primary dirt separator 210, such that the bin case 174 is divided by a plane parallel to the bin central axis 185 to define an upper chamber or primary chamber 209 for the primary dirt separator 210 and a lower chamber or secondary chamber 249 for the secondary dirt separator 400. The regenerative drive assembly 450 is located below the filter 410 with a portion extending beyond the open rear 417 of the filter 410 and into a space between the filter 410 and the suction motor 500, as will be described in more detail later.

[0145] The filter 410 is arranged within the secondary chamber 249 of the secondary separator housing 241, beneath the primary outlet passage 226, first and second auxiliary outlet passages 234, 236, and is shaped to complement the shape of the secondary chamber 249. The shape of the wall of the filter 410 in transverse cross-section is substantially uniform along the length of the filter 410, and includes upper and lower arcuate portions that each curve around a common axis, which axis therefore defines a centre of curvature for the arcuate portions in a given transverse slice of the filter 410. It follows that the wall of the filter 410 has two distinct radii of curvature corresponding to the upper and lower arcuate portions. The arcuate portions are connected at each end by side portions, so that the enclosed cross-section defines part of an annulus. Accordingly, the filter 410 is generally U-shaped, or semi-ellipse shaped in a plane transverse to the filter axis 411. The filter 410 may therefore be said to be shaped to define an interior volume 415 having a hollow U-shaped, or semi-elliptical tube.

[0146] In this example, the wall of the filter 410 has a composite structure, being composed of a layer of filter media and reinforcement strings 413. The reinforcement strings 413 are threaded to the fold lines 48 of the outer circumference of the filter media. In this example, the reinforcement strings 413 are threaded on opposing ends of the filter media and at the center of the filter media.

[0147] The filter 410 is configured as a surface loading filter. This means that the filter 410 is configured such that substantially all collected debris and particles accumulates on the surface of the filter media, and as such is particularly suitable for regenerating where accumulated dirt and debris may be agitated off the filter media. However, surface loading filters tend to block more quickly than depth loading filters and hence typically to require regeneration more frequently.

[0148] The filter media is formed as a sheet of suitable filter material such as PTFE (polytetrafluoroethylene) and is typically fragile. Hence, the reinforcement strings 413 acts as a frame to provide additional strength. The filter media itself is known and so is not described further here. In another embodiment, scrim may be added to the filter media to act as a frame or backing liner to provide additional strength.

[0149] The filter 410 is corrugated or pleated, in that the filter 410 is folded into a series of pleats 419 defined by folds 418. The pleats 419 extend continuously around the wall of the filter 410, resulting in the sawtooth-like profile that is shown in Figure 39. The pleats 419 serve to increase the surface area of the filter 410 to improve filtration performance while lowering resistance to fluid flow and the associated losses. It is noted that in other examples the filter 410 may be nonpleated or may be pleated or corrugated in other ways. For example, the filter 410 may be more gently corrugated to produce a sinusoidal-like profile that provides a similar effect to the sharp-edged folds 419 of the present example.

[0150] Each pleat 419 is deeper than it is wide. In this respect, in this example, the depth of each pleat is approximately four times the width.

[0151] Each pleat 419 extends the entire length of the filter 410 from a front end 416 to a rear end 417 of the filter 410. Each fold line 418 is straight and extends parallel to the filter axis 411. Consequently, each of the pleats 419 extends longitudinally in a direction parallel to the filter axis 411. The pleats 419 surround and enclose the filter axis 411.

[0152] The front end 416 of the filter 410 has a boundary defined by the edge of the filter 410 and is open to provide access to the interior volume 415 of the filter 410 and thereby serve as an inlet to receive airflow from the primary dirt separator 210. The open front end 416 therefore defines a filter inlet. When the filter assembly 400 is mounted within the secondary chamber 249, the filter inlet is positioned to receive a flow of air discharged from the primary dirt separator 210. The rear end417 ofthe filter 410 is closed by the rearcap430. Air entering the interior volume 415 enclosed by the filter 410 through the filter inlet therefore cannot exit through the rear end of the filter 410, and is instead forced to exit outwardly through the filter 410.

[0153] The front cap 420 supports the front end 416 of the filter 410 and the rear cap 430 supports the rear end 417 of the filter 410. The front and rear caps 420, 430 are both compliant, for reasons that shall become clear later. The desired compliancy may be achieved through the selection of a suitably resilient material for the mounts, for example.

[0154] The front cap 420 comprises a generally flat, plate-like element having an outer edge corresponding to the shape of the filter 410 but with a generally constant offset, and an opening of a size and shape corresponding to the filter inlet 427. A protruding lip 421 extends around the edge of the opening to provide a means to guide dirt and debris trapped within the filter 410 to evacuate out of the bin body 110. A seal 422 is provided around the outer perimeter of the front cap 420 to seal the front cap against the front of the secondary separator housing 241. This ensures that airflow from the primary dirt separator 210 is directed into the filter inlet. The secondary separator housing 241 has a movement restriction member 423 in the form of protrusion extending from the inner surface of the secondary separator housing 241 proximate the front end 246. Figure 30 illustrates one movement restriction member 423. However, additional movement restriction members may be provided around the inner circumference of the secondary separator housing 241. When the secondary dirt separator 400 is inserted into the secondary separator housing 241, the rear surface of the front cap 420 abuts the movement restriction member 423. Subsequent assembling of the third base portion 216 to the first base portion 212 clamps the front cap 420 between the third base portion 216 and the movement restriction member 423. This means that only the front cap 420 is fixedly mounted to the front end of the secondary separator housing 241 with the remaining part of the filter assembly 405 suspended in the space within the secondary separator housing 241. In order words, the filter assembly 405 is cantilevered where the front end of the filter assembly 405 is anchored by the third base portion 216 and the movement restriction means 423 with the remaining portion of the filter assembly 405 suspended or unsupported within the secondary separator housing 241. Essentially, a first end of the filter assembly 405 (i.e. the front cap 420) is held stationary, and a rear end of the filter assembly 405 or a midsection of the filter assembly 405 located between the front end and the rear end is suspended within the secondary separator housing 241.

[0155] Essentially, a first part of the filter assembly which is the front cap 420 is held stationary and the regenerative drive assembly 450 is operable to move a second part of the filter assembly comprising the filter 410, bridge 440 and end cap 430 around a closed path.

[0156] The front cap 420 further comprises a handle 425 to allow a user to assemble or disassemble the filter 410 into / out of the secondary separator housing 241.

[0157] The rear cap 430 comprises a generally flat inner surface 431 and having an outer edge 433 corresponding to the shape of the filter 410 that closes the open rear of the filter 410. Outer surface 432 of the rear cap 430 comprises a pocket 434 for housing a magnet, and a knob 435 extending along the filter axis 411. When installed in the secondary separator housing 241, the knob 435 extends into a space defined by the bracket 436 in the secondary separator housing 241. The bracket 436 has a dimension that is bigger than the knob 435 with a function to limit the rotation of the filter 410 when regenerating the filter 410. This means that when installed in the secondary separator housing 241, the knob 435 is not in contact with the bracket 426. When regenerating the filter 410, there is a possibility where the closed path may extend wider than usual and hence the filter 410 may knock on the inner surface of the secondary separator housing 241. Thus, the bracket 436 is to limit the filter 410 from knocking onto the inner surface of the secondary separator housing 241. In another example, the knob 435 may be omitted and the regenerative drive assembly 450 operates in a controlled manner to prevent or limit the filter 410 from knocking the inner surface of the secondary separator housing 241.

[0158] The magnet is provided in the pocket 434 and a corresponding proximity sensor 437 is provided at the base 250 of the dirt separator assembly 200. In this example, the proximity sensor 437 is a Hall-effect sensor to detect presence of the filter 410. However, one skilled in the art will recognise that other proximity sensor such as using reed switch may be implemented without departing from the art. The function of the proximity sensor will be described below.

[0159] The bridge 440 comprises an element 441. The element 441 includes upper 442 and lower 443 arcuate portions that each curve around a common axis, which axis therefore defines a centre of curvature for the arcuate portions in a given transverse slice of the bridge 440. The arcuate portions are connected at each end by side portions, so that the enclosed cross-section defines part of an annulus. Accordingly, the element 441 surrounds the outer surface of the filter 410 on a plane transverse to the filter axis 411 and is located between the front cap 420 and rear cap 430. Element 441 wraps around the filter 410 and is adhesively coupled to the filter 410. Hence, movement of the element 441 causes corresponding movement of the filter 410.

[0160] The bridge 440 comprises a hub 444 extending from a surface of the element 441. In this example, hub 444 extends from an outer surface at the midpoint of the lower arcuate portion 443. The hub 444 defines a through opening 445 having a bushing to receive a drive shaft 446. Specifically, the through opening 445 has wider dimension at the rear of the hub tapering to the bushing or midpoint of the hub 444 to guide the drive shaft 446 into through opening 445 and into the bushing.

[0161] The regenerative drive assembly 450 is configured to regenerate the filter assembly 405. More specifically, the regenerative drive assembly 450 is configured to wobble, agitate or otherwise shake the filter assembly 405 to deform the filter 410 elastically such that the pleats 419 of the filter 410 knock against each other, and thereby dislodge dirt from the filter 410 to prevent blinding of the filter 410, without significant manual intervention from the user. A single movement may be sufficient to regenerate the filter 410, or alternatively the regenerative drive assembly 450 may deliver a series of movements. In this example, the regenerative drive assembly 450 moves a part of the filter assembly 405 repeatedly around a closed path. In this example, the closed path is an eccentric path, such as an elliptical path.

[0162] The regenerative drive assembly 450 comprises a drive assembly and a transmission coupled to the drive assembly and to the filter assembly. The transmission comprises a drive shaft 446, an eccentric mass 455 mounted to the drive shaft 446, and a shaft coupling 454 mounted to the shaft of the motor 451. The drive assembly comprises a motor 451, a motor mounting 452 and a motor damper 453.

[0163] A first end of the drive shaft 446 is adapted to be inserted into the through opening 445 of the hub 444 while a second end, opposing the first end, is fixedly coupled to the shaft coupling 454. In this example, thread lines 457 are defined on the second end and the shaft coupling 454 to allow drive shaft 446 to be screwed to the shaft coupling 454.

[0164] The shaft coupling 454 is a barrel or a tube that receives the second end of the drive shaft 446 and an open end of the motor shaft. In this example, the shaft coupling 454 couples the drive shaft 446 to the motor shaft so that rotation of the motor shaft will correspondingly rotate the drive shaft 446.

[0165] The motor 451 is a conventional electric motor configured to rotate the motor shaft. Electric motors are well known and hence omitted for brevity. The motor 451 sits in the motor mounting 452 and motor damper 453 is provided between the motor 451 and motor mounting 452 to reduce vibration and acoustic.

[0166] Bracket 436 in the secondary separator housing 241 is aligned with the filter axis 411 and has a pair of extensions provided on opposing sides of the bracket 436. The extensions are integrally formed with the secondary separator housing 241 and define a space 459 therewithin that complement the outer shape of the motor mounting 452. Motor mounting 452 is fixedly secured within the space 459. A pair of projections 4521 extends from sides of the motor mounting 452. When the motor mounting 452 is secured within the space 459, the pair of projections 4521 aligns with threaded holes on the pair of extensions of the bracket 436 so that screws can be screwed through the projections 4521 and into the threaded holes on the pair of extensions, fixedly securing the motor mounting to the secondary separator housing 241.

[0167] The eccentric mass 455 is coupled to the drive shaft 446. In this example, the eccentric mass 455 is coupled closer to the first end than the second end of the draft shaft. The eccentric mass 455 is a weighted element that is coupled to the drive shaft 446 to generate an eccentric path 458, which is a two-dimensional path in a plane transverse to the filter axis. Hence, arranging the eccentric mass 455 closer to the first end will cause the first end of the drive shaft 446 to generate a wider eccentric path 458. In this example, the eccentric mass 455 has a semi-circular crosssection. Other shapes that may achieve uneven weight distribution to cause the first end of the drive shaft 446 to generate a two-dimensional path in a plane transverse to the filter axis could alternatively be implemented. For example, a cylindrical mass having a circular cross-section and an off-center hole for receiving the drive shaft 446 could be used to generate a two-dimensional path. In this example and as shown in Figure 52, the eccentric path 458 is a closed path or loop that is generally in the shape of an ellipse. Due to the imbalance in the weight of the eccentric mass 455, the eccentric path 458 is not fixed and travels with slight rotation as shown in the ellipses in dotted lines. These irregular paths cause the pleats 419 of the filter 410 to flap and agitate against one another dislodging dirt on the filter 410.

[0168] The motor 451 is connected to a power distribution unit and a controller is configured to operate the motor 451 at predetermined times, for example each time the vacuum cleaner 1 is activated or deactivated; when the proximity sensor 259 provided at the base 250 of the dirt separator assembly 200 detects the bin base 102 moving from the closed position to the open position; when proximity sensor of the compaction assembly 300 detects user activating compaction; or otherwise at regular intervals. The controller may also be configured to detect the loading state of the filter 410 and initiate a regeneration operation automatically when the loading exceeds a threshold level. Alternatively, or additionally, the controller may be operable in response to a user demand through a suitable user interface such as a button or triggering the compaction assembly 300.

[0169] By rotating the drive shaft 446 at high speed, the eccentric path 458 generated by the first end of the drive shaft 446 correspondingly moves the bridge along the eccentric path 458. Such rotation of the bridge along the eccentric path 458 causes the pleats 419 of the filter 410 to move. As the general shape of the eccentric path 458 is elliptical in shape, under high speed rotation, there is a sudden change of direction which causes the pleats 419 of the filter 410, due to their own inertia, to flap and agitate against each other dislodging accumulated dirt on the filter 410.

[0170] In this example, the regenerative drive assembly 450 moves the filter assembly 405 around the closed path a speed of around 18,000 rpm, which corresponds to an oscillating frequency of around 300 Hz. At this particular speed or frequency, the displacement or movement of the filter pleats 419 is at a maximum, which is to say that the filter pleats 419 vibrate or oscillate at a maximum amplitude. The filter assembly 405 may therefore be said to have a resonant speed or frequency around 18,000 rpm or 300 Hz. The resonant speed or frequency for the filter assembly will depend on many factors, such as that stiffness of the filter media, and the weight and position of the eccentric mass. Nevertheless, it is anticipated that resonance is likely to be observed for many arrangements at speeds of between 6,000 rpm and 54,000 rpm, corresponding to frequencies of between 100 Hz and 900 Hz.

[0171] By regenerating the filter assembly 405 to dislodge accumulated dirt and debris on the filter 410, the regenerative drive assembly 450 reduces blocking or blinding of the filter 410 and so regenerates the filter 410 by returning the filter 410 to a cleaner, less loaded state. This mitigates increase pressure consumption of the filter 410 due to such blocking or forming of caked dirt on the filter 410, and the associated detrimental impact on the performance of the vacuum cleaner 1. Regenerating the filter assembly 405 through the use of the regenerative drive assembly 450 may dispense with the need to provide for easy access to the filter assembly 405 for users, since manual regeneration of the filter assembly 405 may no longer be required.

[0172] When the bin base 102 is in the closed position, the base plate 116 closes and seals both ends of the primary and secondary chambers 209, 249 preventing the escape of dirt and debris that has been separated by the respective primary and secondary dirt separators 210,400. Moving the bin base 102 to the open position allows dirt and debris to be evacuated from the primary and secondary chambers 209,249 concurrently.

[0173] Compaction assembly

[0174] The compaction assembly 300 is illustrated in isolation in Figures 53 to 56B. The compaction assembly 300 may be considered to be a compaction mechanism. The compaction assembly 300 comprises a compaction plate 302, a wiping member 304, first 308 and second 310 compaction rods, compaction cover 306 and a compaction handle 312. The compaction assembly 300 or various components thereof may be considered to form a wiping mechanism, which in this case is configured to wipe an inner surface of the bin body 110, the primary filter 204 and the first 206 and second 208 auxiliary filters in response to a single actuation of the wiping mechanism. It is to be appreciated, though, that in other examples there may be a separate compaction assembly 300 and wiping mechanism.

[0175] The compaction plate 302 comprises a front plate 314, a wiper 316, and a rear plate 318. At least one of the plates of the compaction plate 302 may be considered to be a wiping mechanism and / or a compaction mechanism of the compaction assembly 300. The compaction plate 302 is slidably mounted within the primary chamber 209 and moves parallel to the nozzle central axis 119. The front plate 314 comprises a compaction body 320 and a front flange 324. The compaction body 320 has a generally flat surface with an outer perimeter shaped according to the primary chamber 209 formed between the primary dirt separator 200 and the bin body 110. As noted previously, the primary chamber 209 comprises the inner 228 and outer 230 channels.

[0176] The compaction body 320 is generally E-shaped in form, and is shaped and dimensioned to be slidably received within the primary chamber 209 of the primary dirt separator 200. The front flange 324 is generally arcuate in form, and curves about a top portion of the compaction body 320. The front flange 324 extends from the compaction body 320 such that the front flange 324 is located on an opposite side of the compaction plate 302 to the first 308 and second 310 compaction rods. The front flange 324 is integrally formed with the compaction body 320, and extends from the compaction body. In alternative embodiment, the front flange 324 may be omitted.

[0177] The wiper plate 316 has substantially the same form as the compaction body 320, and is sandwiched between the front plate 314 and the rear plate 318. The wiping member 304 is shaped and dimensioned to correspond to a periphery of the front plate 314. The wiping member 304 comprises a first outer perimeter portion 3161 arranged to engage with a sidewall portion of the bin body and a second outer perimeter portion 3162 arranged to engage with the primary dirt separator 210. The wiping member 304 is formed of a resiliently deformable material, such as rubber, and is mounted to the wiper plate 316 about the periphery of the wiper plate 316 such that a periphery of the wiping member 304 is angled toward the front plate 314. In other words, the wiping member 304 extends at an oblique angle from the periphery of the wiper plate 316 in a direction towards the bin base 102 such that the periphery of the wiping member 304 is abutting the respective surfaces to the cleaned. In this example, the wiping member 304 is mounted along the entire periphery of the wiper plate 216 but in other cases, the wiping member 304 may instead be mounted along part but not all of this periphery. In an alternative embodiment, the wiping member 304 may be mounted to the periphery of the front plate 312. In another alternative example, the wiping member 304 may be integrally formed as part of the wiper plate 316, and extend at an oblique angle from the periphery of the wiper plate 316 in a direction towards the bin base 102 such that the periphery of the wiping member 304 abuts respective surfaces to be cleaned.

[0178] The rear plate 318 has substantially the same form as the wiper plate 316. The rear plate 318 is located on an opposite side of the wiper plate 316 to the front plate 314. The rear plate 318 comprises a magnet 319. A corresponding proximity sensor 317 is provided on the front surface of the second base portion 214. In this example, the proximity sensor 317 is a reed switch to detect the compaction plate 302 moving out of the rest position. However, other proximity sensors, such as a Hall-effect sensor, may alternatively be implemented. The function of the proximity sensor will be described below.

[0179] Each of the rear plate 318, wiper plate 316 and front plate 314 includes rod receiving apertures, which are shaped and dimensioned to receive a corresponding one of the first 308 and second 310 compaction rods.

[0180] The first 308 and second 310 compaction rods are each generally cylindrical and elongate in form between a first end and a second end. The first 308 and second 310 compaction rods can be received within the rod receiving apertures of the rear plate 318 and through corresponding apertures in the wiper plate 316 and front plate 314. In some examples, the rod receiving apertures may be overmoulded with rubber bushings or seals to ensure that the first 308 and second 310 compaction rods are received within the rod receiving apertures with an interference or friction fit.

[0181] The compaction handle 303 comprises a base 331, a handle 332, first 334 and second 336 compaction handle connectors extending from opposing sides of the base 331, and a plunger 354 provided below the base 331. The handle 332 is generally semi-circular in form and extends upright from a rear edge of the base 331. In this example, a bend of about 100 degrees is formed between the handle 332 and the base 331. In another embodiment as shown in Figure 56B, the handle 332 is pivotally mounted to the rear edged of the base 331 where the handle 332 is pivotable between a rest position where a surface of the handle 332 is flush with the surface of the base 331 and an active position where the surface of the handle 332 is pivoted about 100 degrees from the surface of the base 331, forming a pop up handle.

[0182] The first 334 and second 336 compaction handle connectors are pipe-like shaped and are slidably mounted on ends of the first 308 and second 310 compaction rods. The plunger 354 provided below the base 331 together with the bump on the surface of the base cover acts as a movement restriction member, to prevent unintended activation of the compaction plate.

[0183] The compaction cover 306 comprises a base cover 341 and a top cover 342. Longitudinal sides of the base cover 341 and top cover 342 defines channels adapted to allow the first 308 and second 310 compaction rods to slide within. The top cover 342 has an elongate cutout defining a channel to allow the base 331 to move between a rest position and a compaction position. The base cover 341 includes the bump 343 extended from a surface of the base cover 341. In this example, the bump 343 acts as a restrictor to prevent the compaction handle 303 from movement.

[0184] The compaction assembly 300 is configured to wipe an inner surface of the bin body 110, the primary filter 204 and the first 206 and second 208 auxiliary filters and concurrently compact dirt and debris in the primary chamber 209 against the bin base 102. The compaction assembly 300 is moveable between a rest position, where the compaction plate 302 is proximal and / or abutting the second base portion 214, and a compaction position where the compaction plate is distal and spaced from the second base portion 214 and closer to the bin base 102. To compact dirt and / or wipe the filters in the primary separator, a user pushes the compaction handle 303 towards the base nozzle 116. The plunger 354 will ride over the bump 343 and travel towards the second base portion 214. Consequently, compaction plate 302, wiping member 304, first 308 and second 310 compaction rods move in tandem with the compaction handle 303 towards the bin base 102. Hence, the inner surface of the bin body 110, the primary filter 204 and the first 206 and second 208 auxiliary filters are wiped by the wiping member 304, and dirt and debris in the primary chamber 209 are compressed against the bin base 102 by the compaction plate 302 in a single actuation of the compaction handle 303. The rest position of the compaction plate 302 and compaction handle 303 may be a stowed position or a non-compacting position. The noncompacting position may be a position in which the compaction plate 302 has not been moved in order to compact dirt in the bin assembly. The non-compacting position may be the position of the compaction plate 302 in normal operation of the vacuum cleaner 1, i.e. when using the vacuum cleaner to clean a surface.

[0185] Suction Motor

[0186] The suction motor 500 comprises an electric motor 502, an impeller 504, and a diffuser 506. The electric motor 502 comprises a motor can, 505, a stator assembly 508, and a rotor assembly 510. One example of a motor may be the Dyson VI0 digital motor, produced and sold by Dyson Technology Limited at the filing date of the present application. Another example motor is that described in UK patent publication GB2608832A. In either case, such a stator assembly may comprise a single-phase stator assembly, although three-phase stator assemblies are also envisaged.

[0187] The stator assembly 508 comprises a stator core 512, and a winding 514 wound about the stator core 512. It will be appreciated that a number of different stator assembly arrangements are envisaged. The rotor assembly 510 comprises a shaft 516, and a permanent magnet 518 mounted to the shaft 516. The shaft 516 defines a rotational axis R of the electric motor 502.

[0188] The motor can 505 defines a casing for the electric motor 502, and houses the stator assembly 508 and the rotor assembly 510. The motor can 505 at least partly defines both an inlet passage for the electric motor 502 and an outlet passage for the electric motor 502, and in some examples at least partly acts as a shroud for the impeller 504.

[0189] The impeller 504 is mounted to the shaft 516 downstream of the permanent magnet 518, such that the electric motor 502 is an inlet-cooled motor. The impeller 504 is a mixed-flow impeller.

[0190] The diffuser 506 is located downstream of the impeller 504 and comprises a radial portion 520 and an axial portion 522. The radial portion 520 is in fluid communication with an outlet of the impeller 504 and extends in a direction substantially orthogonal to the shaft 516, and hence substantially orthogonal to the rotational axis R of the electric motor 502. The axial portion 522 is downstream of, and in fluid communication with, the radial portion 520. The axial portion 522 extends in a direction substantially parallel to the shaft 516, and hence substantially orthogonal to the rotational axis R of the electric motor 502. The axial portion 522 extends in a direction away from the impeller 504, toward an opposite end of the shaft 516 to the end of the shaft 516 to which the impeller 504 is mounted. A transition between the radial portion 520 and the axial portion 522 is smooth and curved in form. The radial portion 520 and the axial portion 522 are integrally formed, and collectively define an airflow outlet channel downstream of the impeller 504.

[0191] In this example, the diffuser 506 does not comprise vanes that extend into the radial portion 520, but has vanes that extend into the axial portion 522, although other examples where different arrangements of vanes are present are also envisaged. A controller 526 of the suction motor 500 is mounted to a control printed circuit board (PCB) of the vacuum cleaner 1.

[0192] Housing and Handle Assembly

[0193] The housing and handle assembly is illustrated in figures 58 to 64. The housing and handle assembly 600 comprises a main housing body 602 and a handle portion 700.

[0194] The main housing body 602 comprises an outer wall 608, an inner wall 610, an upstream plenum 605, a downstream plenum 607, a plurality of motor inlet passageways or first passageways 612, a motor bucket 614, plurality of motor outlet passageways or second passageways 616.

[0195] The inner wall 610 is generally cylindrical in form, with the curvature generally matching the curvature of the outer wall 608.

[0196] The outer wall 608 is generally cylindrical in shape and defines an outer surface of the vacuum cleaner 1. The outer wall 608 comprises a step in outer diameter roughly at the midsection of the outer wall 608, such that a first end (front end) of the outer wall 608 is larger in diameter than a second opposite end (rear end). The first end of the outer wall 608 and the second end of the outer wall are open. When the housing and handle assembly 600 is attached to the dirt separator assembly 200, the first end of the outer wall 608 abuts and seals against the second base portion 214 of the dirt separator assembly 200. A seal or gasket (not shown) may be provided between the outer wall 608 and the second base portion 214 to provide a more effective seal. The second end of the outer wall 608 is closed by the post-motor filter assembly 604. In this example, the postmotor filter assembly 604 is removably attached to the outer wall 608 by means of bayonet-style fitting, in which projections provided on the post-motor filter assembly 604 mate with grooves provided around the outer wall 608.

[0197] The inner wall 610 is also generally cylindrical in shape, and is nested within the outer wall 608. The inner wall 610 is smaller than the outer wall 608, both in length and diameter. A first end (front end) of the inner wall 610 is closed by a motor cap 611, and a second opposite end (rear end) of the inner wall is open. The inner wall 620 and the motor cap 611 define a motor chamber 613 within which the motor bucket 614 and the suction motor 500 are housed.

[0198] The upstream plenum 605 is defined by the interior space bounded by the outer wall at the first end of the outer wall 608. The downstream plenum 607 is defined by the interior space bounded by the outer wall at the second end of the outer wall 608. Owing to the step in diameter of the outer wall, the upstream plenum 605 has a diameter (or equivalent diameter) that is greater than that of the downstream plenum 607. The inner wall 610 is positioned between the upstream plenum 605 and the downstream plenum 607. The upstream plenum is therefore positioned forward of the suction motor 500 and the downstream plenum is positioned rearward of the suction motor 500.

[0199] The motor inlet passageways 612 extend between the upstream plenum 605 and the downstream plenum 607. The motor inlet passageways 612 are defined by the outer wall 608, the inner wall 610, and a plurality of partitions 609 that extend between the outer wall 608 and the inner wall 610. In this example, the motor inlet passageways 612 comprise a three passageways that extend along a first side (e.g., left side) of the main housing body 602, and three passageways that extend along a second opposite side (e.g., right side) of the main housing body 602. Each of the motor inlet passageways 612 extends alongside the suction motor 500. In this example, each of the motor inlet passageways 612 is linear or straight and extends in a direction parallel to the rotational axis of the suction motor 500. As noted, the outer wall 608 has a step in diameter. The rear section of the outer wall 608 is therefore narrower than the front section. In order that the motor inlet passageways 612 are not unduly constricted by the step down in diameter, the outer wall 608 comprises a plurality of fingers 618 that extend along the narrow section of the outer wall 608. That is to say that the outer wall 608 is shaped to comprise a plurality of raised arcuate portions 618 that extend along the narrow section of the outer wall 608. Each finger or raised arcuate portion 618 corresponds to or bounds a respective motor inlet passageway 612.

[0200] The motor bucket 614 is generally cylindrical in shape, is hollow in form, and comprises a plurality of inlet apertures 626. The motor bucket 614 is positioned within the motor chamber 613 defined by the inner wall 610 and the motor cap 611. The motor bucket 614 is open at a first end (front end) and is closed at a second opposite end (rear end) by an end cap 634. In this example, a display screen and buttons for activating the vacuum cleaner are mounted to the end cap 634 of the motor bucket 614. The open end (front end) of the motor bucket 614 receives the suction motor 500. More particularly, the electric motor 502 is housed inside the motor bucket 614, whilst the impeller 504 and diffuser 506 are located outside the motor bucket 614. The closed end (rear end) of the motor bucket 614 extends beyond the motor chamber 613, and into the downstream plenum 607. Each of motor outlet passageways 616 extends between an aperture 619 in the inner wall 610 and an aperture 620 in the outer wall 610. Each of the motor outlet passageways 616 therefore fluidly connects the motor chamber 613 to the external environment. Each of the apertures 620 in the outer wall 608 may therefore be regarded as an exhaust outlet 620 through which airflow is discharged from the vacuum cleaner 1. Each of the exhaust outlets 620 is elongate in shape and is wider than it is tall. As a result, each of the exhaust outlets 620 resembles a slot. The exhaust outlets 620 are located generally midway along the length of the outer wall 608 (i.e., generally midway between the first or front end of the outer wall 608 and the second or rear end).

[0201] In extending from the inner wall 610 to the outer wall 610, the motor outlet passageways 616 extend across or traverse the motor inlet passageways 612. The motor inlet passageways 612 can be thought of as extending in a generally axial direction (i.e., in a direction parallel to the rotational axis of the suction motor 500) and the motor outlet passageways 616 can be thought of as extending in a generally radial direction (i.e., in a direction normal to the rotational axis). Each of the motor outlet passageways 616 and therefore each of the exhaust outlets 620 is located between a pair of adjacent motor inlet passageways 612. In this particular example, there are two motor outlet passageways 616 and therefore two exhaust outlets 620 between each pair of motor inlet passageways 612. Moreover, there are four exhaust outlets 620 on a first side (e.g., left side) of the main housing body 602, and four exhaust outlets 620 on a second, opposite side (e.g., right side) of the main housing body 602.

[0202] As described below in more detail, when the post-motor filter assembly 604 is attached to the main housing body 602, a filter 650 of the post-motor filter assembly 604 is positioned within the motor chamber 613. The post-motor filter assembly 604 comprises a pair of seals 652, 654 that seal against the inner wall 610 on either side (i.e., forward and rearward) of the motor outlet passageways 616. The post-motor filter assembly 604 also comprise a seal 656 that seals against the motor bucket 614. In use, when the suction motor 500 is powered on, airflow is drawn into and through the dirt separator assembly 200 by the suction motor 500. From the dirt separator assembly 200, the airflow is drawn into the upstream plenum 605, whereupon it divides and flows through the plurality of motor inlet passageways 612 and into the downstream plenum 607. Each of the motor inlet passageways 612 therefore carries a respective part of the airflow from the upstream plenum 605 to the downstream plenum 607. From the downstream plenum 607, the airflow enters the interior of the motor bucket 614 via the inlet apertures 626. The airflow is then drawn through the suction motor 505 and is expelled into the motor chamber 613. The airflow is then pushed by the suction motor 505 through the filter 650 of the post-motor filter assembly 604, through the motor outlet passageways 616, and is discharged from the vacuum cleaner 1 via the exhaust outlets 620.

[0203] The handle portion 700 comprises a main handle 702, a support strut 704, and a base 706.

[0204] The main handle 702 is integrally formed with, and projects downwardly from, the outer wall 608 of the main housing body 602. The main handle 702 extends from a first end 710 proximal to the outer wall 608, to a second end 712 distal to the outer wall 608. The main handle 702 is located beneath the suction motor 500 and is located rearward of the dirt separator assembly 200.

[0205] The main handle 702 is hollow in form, and houses electrical connections, alongside a battery terminal connection for connecting to a battery connector of the battery assembly 800, as will be described in further detail. The main handle body 702 is shaped and dimensioned to receive the battery connector within the main handle body 702.

[0206] The main handle body 702 is shaped and dimensioned to be grasped by a single hand of a user in use. The main handle body 702 is obliquely angled relative to the outer wall 608 of the main housing body 602. The main handle body 702 extends from the outer wall of the main housing body at a location between opposing housing outlets 620 so that when held, air exhausted out of the housing outlets 620 is away from user.

[0207] In this example, the main handle body 702 has a longitudinal axis 711 that intersects the suction motor 500. The longitudinal axis 711 intersects a plane normal to the filter axis 411 at an angle of no more than 30 degrees. In this example, the angle is between 10 degrees and 20 degrees.

[0208] The support strut 704, like the main handle 702, is integrally formed with, and projects downwardly from, the outer wall 608 of the main housing body 602. The support strut 704 projects from a front end of the outer wall 608, whereas the main handle 702 projects from a point roughly midway (i.e., between the front and rear ends) of the outer wall 608. The support strut 704 has a generally obround cross-sectional shape and extends in a direction generally parallel to the main handle 704. The support strut 704 has a first end 716 proximal to the outer wall 608 of the main housing body 602, and a second end 718 distal to the outer wall 608 of the main housing body 602.

[0209] The support strut 704 is spaced from the main handle 702. The spacing between the main handle 702 and the support strut 704 is substantially constant along a length of the main handle 702. The support strut 704 is positioned forward of the main handle 702, with the support strut 704 positioned closer to the dirt separator assembly 200.

[0210] The base 706 extends between the main handle 702 and the support strut 704, and comprises a hook or other coupling means for engaging with a corresponding catch of the battery assembly 800.

[0211] Battery Assembly

[0212] The battery assembly 800 is used to power the suction motor 500, the motor 451 of regenerative drive assembly 450, as well as all other electronic circuitry of the vacuum cleaner 1, such as the controllers, sensors and user display described below. The battery assembly 800 comprises a battery pack housing 802, battery cells 804, a connecting stem 812, and a battery pack release mechanism. The battery pack housing 802 is shaped and dimensioned to house the battery cells 804. The battery pack housing 802 and the battery cells 804 are located beneath the handle portion 700. A lower surface of the battery pack housing 802 is substantially planar in form. A front end of the battery pack housing 802 comprises a charge port 809 for receiving an electrical connector to recharge the battery cells 804. The connecting stem 812 projects upwardly from the rear of the battery pack housing 802. The connecting stem 821 is shaped to be received within the second end 712 of the main handle 702, and includes electrical terminals for connection to corresponding electrical terminals within the main handle 702.

[0213] The battery cells 804 are cylindrical Lithium ion cells.

[0214] Post-Motor Filter Assembly

[0215] The post-motor filter assembly 604 is shown in isolation in Figures 65 to 66. The postmotor filter assembly 604 comprises a cap 646, a frame 648, a filter 650, a first seal 652, a second seal 654, and a third seal 656. The post-motor filter assembly 604 is annular in form and partially surrounds the motor assembly 500.

[0216] The cap 646 has a diameter substantially corresponding to a diameter of the outer wall 608 of the main housing body 602. The end wall 662 is generally circular in form, and comprises a through-hole 664. The through-hole 664 is shaped and dimensioned to correspond substantially to a shape and dimension of the end cap. In one embodiment, a display screen is provided on the end cap 634 such that the display screen is visible through the through-hole 664 when the postmotor filter assembly 604 is mounted to the main housing body 602.

[0217] The frame 648 connects between the cap 646 and the filter 650. When attached to the main housing body of the vacuum cleaner 1, the frame 648 extends between the suction motor 500 and the end cap 634, while the filter 650 is aligned with the exhaust outlets 620.

[0218] Interlocking features are provided on the end cap 634 and the cap 646 to allow the postmotor filter assembly 604 to be releasably attached to the main housing body of the vacuum cleaner 1.

[0219] The filter 650 is formed of layers of filter media, including a layer of scrim or web material, a non-woven filter medium such as fleece, followed by a further layer of scrim or web material. An electrostatic filter medium could also be included if desired. The filter 650 is non-pleated in form. In another example, the filter is formed of a pleated HEPA-standard filter medium.

[0220] The first seal 652 and the second seal 654 are secured to the frame 648 at opposite ends of the filter 650. The first seal 652 projects radially outward from the frame 648, and the second seal 654 projects axially from an end of the frame 648. The third seal 656 is likewise secured to the frame 648 and projects radially inward. When the post-motor filter assembly 604 is attached to the housing and handle assembly 600, as illustrated for example in Figure 69, the first seal 652 and the second seal 654 abut and seal against the inner wall 610 of the main housing body 602. The two seals 652, 654 seal against the inner wall 610 on opposite sides (i.e., forward and rearward) of the motor outlet passageways 616. The third seal 656 abuts and seals against the motor bucket 614. More particularly, the third seal 656 seals against the motor bucket 614 at a position just forward of the inlet apertures 626. The first and third seals 652, 656 ensure that airflow entering the downstream plenum 607 is drawn into the motor bucket 614 via the inlet apertures 626, through the suction motor 500 and into the motor chamber 613. The first and second seals 652, 654 ensure that the airflow expelled into the motor chamber 613 passes through the filter 650 and into the motor outlet passages 616, from which the airflow is expelled from the vacuum cleaner 1 via the exhaust outlets 620.

[0221] Vacuum cleaner 1 includes one or more controllers communicatively connected to the battery, proximity sensors 259, 317, 437, suction motor 500, motor 451 and other sensing devices that may be incorporated to the vacuum cleaner 1. The controller is a microcontroller unit or a processing unit comprising a processor and a memory. Instructions are stored in the memory and executable by the processor to perform processes and methods as necessary to work the invention according to this disclosure. The controller is a well-known system and hence details of the controller are omitted for brevity.

[0222] A first controller is communicatively connected to the proximity sensor 259, the regenerative drive assembly 450 and filter loading sensor. The first controller is adapted to receive a signal from the proximity sensor 259 in response to detecting the bin base 102 moving from the closed position to the open position. In response to determining bin base 102 moving from the closed position to the open position, the first controller is adapted to activate the regenerative drive assembly to wobble, shake or agitate the filter assembly. Specifically, the first controller supply power to the motor 451 to activate regenerative drive assembly to regenerate the filter 410 of the secondary dirt separator 400. The first controller includes parameters store in the memory of the controller for activating the regenerative drive assembly. The parameter includes duration of each regenerative cycle, speed of rotation of the motor, intervals within each regenerative cycle, and frequency of each regenerative cycle. This means that the first controller for proximity sensor 259 is adapted to activate the regenerative drive assembly to wobble, shake or agitate the filter assembly based on one or more parameters including duration of each regenerative cycle, speed of rotation of the motor, intervals within each regenerative cycle, and frequency of each regenerative cycle. The parameter may be selected by a user or based on the filter loading value.

[0223] The first controller is also configured to detect the loading state of the filter 410 based on the filter loading sensor and initiate a regeneration operation automatically when the loading exceeds a threshold level. Alternatively, or additionally, the first controller may be operable in response to a user demand through a suitable user interface such as a button or triggering the compaction assembly 300.

[0224] The filter loading sensor may be provided in the vacuum cleaner 1 to determine the level of particles loaded on the filter 410. In one example, the filter loading sensor is a pressure sensor for determining the operating pressure of the suction motor or the speed of the suction motor and is communicatively connected to the controller. Determining the value of the filter loading based on the operating pressure of the motor or the speed of the motor may allow the filter loading to be determined reliably and accurately, based on an observable physical parameter which is correlated in a pre-determined manner with the value of the filter loading. Essentially, monitoring the operating pressure of the suction motor and / or the speed of the suction motor can reliably determine the level of particles loaded on the filter 410. Hence, the first controller is adapted to supply power to the motor 451 to activate regenerative drive assembly to regenerate the filter 410 of the secondary dirt separator 400 if the filter loading value is above a certain threshold. Particularly, the filter loading value is determined based on the operating pressure of the suction motor and / or the speed of the suction motor.

[0225] A second controller is communicatively connected to the proximity sensor 437, the regenerative drive assembly 450 and the power distribution unit of the suction motor. The second controller is adapted to receive a signal from the proximity sensor 437 in response to detecting presence or absence of the filter 410. In response to determining absence of the filter 410, the second controller is adapted to prevent user from powering up the suction motor 500 and motor 451.

[0226] A third controller is communicatively connected to the proximity sensor 317, power distribution unit of the suction motor and the regenerative drive assembly 450. The third controller is adapted to receive a signal from the proximity sensor 317 in response to detecting the compaction plate 302 is moving away from the rest position. In response to determining compaction plate 302 is moving away from the rest position, the third controller is adapted to reduce the power supply to the suction motor 500. In one example, the controller may be adapted to pulse the suction motor 500, i.e. repeatedly reducing and bring back power supply, as an alert to user. Additionally, in response to determining compaction plate 302 is moving away from the rest position, the third controller is adapted to activate the regenerative drive assembly to wobble, shake or agitate the filter assembly. If the compaction plate 302 is detected to be moving away from the rest position when the vacuum cleaner 1 is not activate, the third controller is adapted to prevent user from powering up the suction motor 500. If the compaction plate 302 is detected to be moving away from the rest position and the user attempts to activate the vacuum cleaner 1 by powering up the suction motor 500, the third controller is adapted to prevent powering up the suction motor 500 and present to the user an instruction on a display to move the compaction plate 302 to the rest position.

[0227] The vacuum cleaner 1 is shown in horizontal orientation in Figures 62.

[0228] With the vacuum cleaner 1 arranged horizontally, the bin central axis 185 and the nozzle central axis 119 extend horizontally. The bin central axis 185 and the nozzle central axis 119 are parallel to each other with an offset of about 5 mm to 10 mm, preferably 7mm. The bin assembly 100 extends annularly about the bin central axis 185 and, in this example, is coaxial with a central longitudinal axis or the rotational axis of the suction motor 500.

[0229] The primary dirt separator 210 and secondary dirt separator 400 are arranged within the bin assembly 100 such that bin central axis 185 is between the nozzle central axis 119 and the filter axis 411. Further, the filter assembly extends approximately the same length as the primary separator such that the secondary dirt separator 400 is beneath the primary dirt separator 210 or forming an up and down arrangement within the bin assembly 100. A primary chamber 209 is defined between the primary dirt separator 210 and bin assembly 100, within which dirt separated from the airflow by the primary dirt separator 210 may collect. In this example, the primary chamber 209 comprises the inner channel 228 and the outer channel 230. A secondary chamber 249 is defined by a housing 241 of the secondary dirt separator 400. Conceivably, the secondary chamber 249 may be used to collect dirt separated from the airflow by the secondary dirt separator 400. For example, with the bin base 102 in the closed position, the regenerative drive assembly 450 may agitate the filter assembly 405 causing dirt to become dislodged, whereupon it may collect in the secondary chamber 209. However, at least in this example, the expectation is that filter assembly 405 is agitated only when the bin base 102 is open, such that any dirt dislodged from the filter assembly 405 is immediately evacuated from the secondary chamber 249.

[0230] The bin assembly 100 comprises the bin body 110 that surrounds the primary dirt separator 210 and the filter assembly of the secondary dirt separator 410 and the bin base 102 closes an end of the bin body 110 such that when the bin base 102 moves to the open position, the primary chamber 209 and the secondary chamber 249 are no longer closed by the bin base 102, and the dirt and debris contained therein may be emptied simultaneously.

[0231] The bin-open assembly 350 also known as the bin base actuator is positioned at the bottom of the bin assembly. Specifically, the bin base actuator is positioned at the bottom of the bin body. The compaction handle 303 is positioned rearward of the bin assembly and is positioned at the top of the main housing body. The handle portion 700 is rearward of the bin base actuator and below the compaction handle 303.

[0232] The longitudinal axis 711 of the handle intersect a plane normal to one of the nozzle axis 119, bin axis 185 and filter axis 411 at an angle of no more than 30 degrees, and wherein optionally the angle is between 10 degrees and 20 degrees.

[0233] During use of the vacuum cleaner 1, the vacuum cleaner 1 will typically be held with the base nozzle 118 directed downwards at an angle of about 45 degrees relative to the horizontal. In this orientation, the inner channel 228 formed by the first and second shoulders, primary filter 204, first 206 and second 208 auxiliary filters faces generally upwards.

[0234] A path of airflow through the vacuum cleaner 1 is illustrated schematically in Figures 67 to 69. Airflow passes through the base nozzle 118, and into the primary chamber 209 via the airflow inlet 134. The suction generated by the suction motor 500 within the primary chamber 209 causes the inlet valve member 146 to pivot from its closed position to its open position to enable airflow to enter the primary chamber 209 via the airflow inlet 134. A direction of airflow at the airflow inlet 134 is parallel to the nozzle central axis 119.

[0235] The inlet valve member 146 directs airflow leaving the airflow inlet 134 towards the dirt detection assembly 215, and toward the primary filter 204. The inlet valve member 146 shapes the airflow leaving the airflow inlet 134 to a general U-shape when viewed in a plane normal to the nozzle central axis 119. More specifically, the airflow shaped by the inlet valve member 146 has a cross-sectional shape, in a plane normal to the nozzle central axis 119 is generally U-shaped.

[0236] The dirt-laden airflow from the airflow inlet 134 hitting the dirt detection assembly 215 enables the piezoelectric acoustic sensor to sense a number and / or a size of particulate matter entrained within the airflow, and in some examples can enable a corresponding visualisation of number and / or size of particulate matter to be displayed to the user via the display screen provided at the end cap 634.

[0237] The airflow from the airflow inlet 134 flows along the inner channel 228 in a first direction generally parallel to the nozzle central axis 119. As the airflow flows along the inner channel 228 towards the second end 224, a first portion of the airflow passes through the primary filter 204, with the primary filter 204 acting to filter out relatively large dirt from the airflow. Such filtered dirt is collected within the primary chamber 209 of the bin assembly 100. Airflow that has passed through the primary filter 204 flows into the primary outlet passage 226 and flows in a second direction opposite to that of the first direction. Specifically, after airflow passes through the primary filter 204 and enters into the primary outlet passage 226, the airflow flows towards the bin base 102.

[0238] A second portion of the airflow (i.e., that portion which has not passed through the primary filter 204) remains within the primary chamber 209, and recirculates generally toward the airflow inlet 134 as a result of the arrangement of the first 217 and second 218 shoulders and the positioning of the first 206 and second 208 auxiliary filters and the end wall 244. Particularly, the second portion of the airflow, on reaching the closed end of the inner channel 228, is directed upwardly and flows over the first and second shoulders, leaving the inner channel 228 and entering the outer channel 230 due to the first and second shoulders. The second portion of the airflow flows towards base nozzle, and hence recirculates generally toward the airflow inlet 134. Such recirculation can, in some examples, draw dirt toward a lower region of the primary chamber 209 adjacent the airflow inlet 134, such that the primary chamber 209 fills with dirt in a direction from the first end 222 to the second end 224 of the primary chamber 209.

[0239] The second portion of the airflow then passes through the first 206 and second 208 auxiliary filters and flows along the first auxiliary outlet passage 234 and second auxiliary outlet passage 236 respectively and subsequently into the inlet of the secondary dirt separator 400. Airflow that has passed through the first 206 and second 208 auxiliary filters, flows along the first auxiliary outlet passage 234 and the second auxiliary outlet passage 236 in the second direction opposite to the first direction. Specifically, after airflow passes through the first 206 and second 208 auxiliary filters, the airflow flows along the first auxiliary outlet passage 234 and second auxiliary outlet passage 236 in a direction towards the bin base 102.

[0240] As the first auxiliary outlet passage 234 and second auxiliary outlet passage 236 are in fluid communication with the primary outlet passage 226 via the first 240 and second 242 linking passages located at the first end 222 airflows in the primary outlet passage 226, first auxiliary outlet passage 234 and second auxiliary outlet passage 236 will merge at the first 240 and second 242 linking passages before entering into the secondary dirt separator 400.

[0241] The first 206 and second 208 auxiliary filters, similar to the primary filter 204, act to filter out relatively large dirt from the airflow. Such filtered dirt is collected within the primary chamber 209. The split between the first and second portions of the airflow is about 60 / 40 where between 55% and 75% of the airflow flows over the primary filter 204, and between 25% and 45% of the airflow flows over the first 206 and second 208 auxiliary filters. In this particular example, about 60% of the airflow flows over the primary filter 204 while about 20% of the airflow flows over each of the first 206 and second 208 auxiliary filters.

[0242] Airflow from the primary dirt separator 210 is directed to the secondary dirt separator 400. The airflow enters the interior 415 of the filter assembly 405 via the filter inlet 427. The airflow flows along the filter assembly 405 in the first direction which is parallel to the filter axis 411. As the rear end of the filter assembly 405 is closed by the rear cap 430, the airflow entering the interior 415 of the filter assembly 405 passes outwardly through the filter 410. In passing through the filter 410, dirt within the airflow is trapped by the filter 410. The filter 410 therefore acts to filter relatively small dirt from the airflow. After passing through the filter 410, the airflow flows along the outer part of the secondary chamber 249 and into the outlet plenum 255. In this example, airflow enters the interior 415 of the filter assembly 405 via the filter inlet 427 and subsequently flows through the filter 410 and enters the outer part of the secondary chamber 249. This in-to-out airflow arrangement ensures that dirt trapped on the upstream surface of the filter 410 are released within the interior 415 when regenerating the filter assembly 405. In another example, the airflow may be reconfigured with an out-to-in airflow arrangement where airflow from the primary dirt separator 210 enters secondary dirt separator and flows along the outer part of the secondary chamber 249 and subsequently through the filter 410 and enters the interior 415 and into the outlet plenum 255. Further modification of the front cap and rear cap is necessary to allow such out-to-in arrangement. One possible modification is by reversing the arrangement of front cap with the rear cap. Noting that the bin case 174 is transparent, the in-to-out airflow arrangement is preferable since dirt is trapped within the filter 410 and the transparent bin will not appear dirty. Furthermore, the secondary chamber 249 is easier to maintain since filtered air enters the outer part of the secondary chamber 249.

[0243] The outlet plenum 255 of the dirt separator assembly 200 and the upstream plenum 605 of the housing and handle and assembly 600 collectively form a single plenum. From this plenum, the airflow divides and flows along the motor inlet passageways 612 and into the downstream plenum 607. Airflow flows through the motor inlet passageways 612 in a rearward direction away from the airflow inlet 134, and hence away from the dirt separator assembly 200, in a direction substantially parallel to the nozzle central axis 119 and generally in the first direction. From the downstream plenum 607, the airflow enters the interior of the motor bucket 614 via the inlet apertures 626. The airflow is then drawn into the suction motor 505.

[0244] The impeller 504 draws the airflow through the electric motor 502 in a forward direction toward the airflow inlet 134, and toward the dirt separator assembly 200, in a direction substantially parallel to the nozzle central axis 119, i.e. generally in the second direction. Airflow passes through the impeller 504 and radially outwardly into the radial portion 520 of the diffuser 506, before turning and passing through the axial portion 522 of the diffuser 506. Airflow passes through the axial portion 522 of the diffuser 506 away from the airflow inlet 134, and away from the dirt separator assembly 200, in a rearward direction substantially parallel to the nozzle central axis 119 and generally in the first direction.

[0245] Airflow passes from the axial portion 522 of the diffuser 506 into the motor chamber 613. The airflow then flows through the filter 650 of the post-motor filter assembly 604, through the motor outlet passageways 616, and is discharged from the vacuum cleaner 1 via the exhaust outlets 620. The airflow flows through the motor outlet passageways 616 and is discharged from the exhaust outlets 620 in a direction substantially orthogonal to the nozzle central axis 119. The airflow through the vacuum cleaner 1 between the base nozzle and the exhaust outlets 620 are shown in Figures 62, 63 and 67 to 69.

[0246] In use of the vacuum cleaner 1, the primary chamber 209 of the bin assembly 100 fills with relatively coarse dirt. To extend a period of time for which the user can clean without needing to empty the bin assembly 100, the user can utilise the compaction assembly 300 to compact dirt contained within the primary chamber 209.

[0247] To utilise the compaction assembly 300, a user grasps the compaction handle 303 and slides the compaction handle 303 in a direction towards the base nozzle 118. Consequently, the compaction plate 302 slides within the bin body 110, with the first 308 and second 310 compaction rods sliding within the channels defined by the compaction cover 306. Particularly, the compaction plate 302 slides from the rest position where the compaction plate 302 abuts the end wall 244 of the second base portion 214, to the compaction position where the compaction plate 302 is away from the second base portion 214 and closer to the bin base 102.

[0248] As the compaction plate 302 slides within the bin body 110, the front plate 314 of the compaction assembly 300 acts to compact dirt contained within the primary chamber 209. Furthermore, as the compaction plate 302 slides within the bin body 110, the wiping member 304 is in contact with and wipes the inner surface of the bin body 110, the primary filter 204 and the first 206 and second 208 auxiliary filters. Hence, the wiping member 304 wipes dirt from the inner surface of the bin body 110, and upstream surfaces of the primary filter 204 and the first 206 and second 208 auxiliary filters. Thus, a single actuation of the compaction handle 303 wipes both the core 202 and the bin body 110. The compaction handle 303 may be considered to be a handle of the wiping mechanism, for actuating the wiping mechanism. Dirt wiped by the wiping member 304 is compacted by the front plate 314 of the compaction assembly 300. With the bin base 102 in the open configuration, at least part of the wiping mechanism (such as at least part of the wiping member 304) may be moveable from a position within the bin body 110 to a position beyond the end of the bin body 110, so as to aid in wiping dirt from the primary dirt collector 209.

[0249] Due to the proximity sensor 317, as the compaction plate 302 moves away from the rest position, the proximity sensor 317 detects the absence of the magnetic field generated by the magnet 319 of the compaction plate 302. Hence, in response to determining that the compaction plate 302 is moving away from the rest position, the controller is adapted to reduce the power supply to the suction motor 500. In one example, the controller may be adapted to pulse the suction motor 500, i.e. repeatedly reducing and bring back power supply, as an alert to user. If the compaction plate 302 is detected to be moving away from the rest position when the vacuum cleaner 1 is not activate, the controller may be adapted to prevent the user from powering up the suction motor 500.

[0250] Once a compaction action has been performed by the user, the user can retract the compaction plate 302 to its rest position by sliding the compaction handle 303 in a direction away from the airflow inlet 134, substantially parallel to the nozzle central axis 119.

[0251] A user may compact the dirt in the primary chamber 209 by repeatedly sliding the compaction handle 303.

[0252] When desired, the user can also empty dirt from the primary chamber 209 and the secondary chamber 249.

[0253] To move the bin base 102 to the open position, the user grasps the handle portion 372 of the bin pushrod 356 and applies a force to the handle portion 372 in a direction toward the bin base 102. This causes the bin pushrod 356 to slide within the runner guide rails 176 in a direction toward the bin base 102, substantially parallel to the nozzle central axis 119. As the bin pushrod 356 slides within runner guide rails 176, the wedge-shaped end of the bin pushrod 356 contacts the bin closure clasp 112, and more particularly the first 190 and second 192 clasps. The end of the bin pushrod 356 forces the first 190 and second 192 clasps apart. Thus, the first 190 and second 192 clasps no longer inhibit movement of the bin base 102 relative to the bin body 110.

[0254] As the user further continues to push the handle portion 372 of the bin pushrod 356, the end of the bin pushrod 356 contacts the bin pushrod engaging member 125 of the bin base 102. The bin pushrod 356 is thereby able to push the bin base 102 away from the bin body 110. Although the bin assembly 100 comprises a spring 115 that biases the bin base 102 to the open position, seals provided between the bin base 102 and the bin case 174 may mean that the bin base 102 does not automatically move to the open position when the bin closure clasp 112 moves to the expanded configuration. It is for this reason that the bin base 102 includes an engaging member 125 against which the bin pushrod 356 is able to contact and push. When the bin base 102 moves to the open position, the primary chamber 209 and the secondary chamber are no longer closed by the bin base 102, such that dirt and debris contained therein may be emptied simultaneously.

[0255] Due to the proximity sensor 259, as the bin base 102 moves from the closed position to the open position, the proximity sensor 259 detects the absence of the magnetic field generated by the magnet in the magnet housing 117. Hence, in response to determining bin base 102 is moving to the open position, the controller is adapted to supply power to the motor 451 to activate the regenerative drive assembly 450 to regenerate the filter assembly 405 of the secondary dirt separator 400. In another embodiment, the controller is adapted to cut off or reduce the power supply to the suction motor 500 before supplying power to the motor 451 to activate the regenerative drive assembly 450.

[0256] Regenerating the filter assembly 405 during bin emptying improves removal of the dirt collected on the upstream surface of the filter 410. This is because dirt collected on the upstream surface forms a cake-like structure that holds onto the upstream surface of the filter 410. Regenerating the filter 910 causes the pleats 419 to agitate against each other dislodging the dirt cake formed on the upstream surface of the filter 410. Regenerating the filter assembly 405 when the suction motor 500 is powered down prevents the dirt from being re-entrained into the airflow and back onto the filter 410. Hence, it is more effective to regenerate the filter assembly 405 when suction motor 500 is powered down or off.

[0257] In another example, the controller may be adapted to supply power to the motor 451 of the regenerative drive assembly 450 at certain intervals, duration, and / or in response to other events (e.g., a user input) to activate the regenerative drive assembly 450 to regenerate the filter 410.

[0258] It is to be understood that any feature described in relation to any one example may be used 5 alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the examples, or any combination of any other of the examples. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the accompanying claims.

Claims

1. A vacuum cleaner comprising a dirt separator, the dirt separator comprising a filter assembly for removing dirt from an airflow moving through the vacuum cleaner, and a regenerative drive assembly for agitating the filter assembly to dislodge dirt from the filter assembly, wherein the regenerative drive assembly agitates the filter assembly by moving at least part of the filter assembly repeatedly along a closed path.

2. The vacuum cleaner of claim 1, wherein the closed path extends in at least two dimensions.

3. The vacuum cleaner of claim 1 or 2, wherein the closed path is elliptical.

4. The vacuum cleaner of any one of the preceding claims, wherein a first part of the filterassembly is held stationary and the regenerative drive assembly agitates the filter assembly by moving a second part of the filter assembly around the closed path.

5. The vacuum cleaner of claim 4, wherein the first part is a first end of the filter assembly, and the second part is a second, opposite end of the filter assembly or a midsection of the filter assembly located between the first end and the second end.

6. The vacuum cleaner of claim 4 or 5, wherein the second end of the filter assembly is suspended.

7. The vacuum cleaner of any one of the preceding claims, wherein the filter assembly comprises a filter having pleats defined by fold lines that extend parallel to a filter axis, and the closed path extends in at least two dimensions normal to the filter axis, and wherein optionally the closed path lies in a plane normal to the filter axis.

8. The vacuum cleaner of any one of the preceding claims, wherein the filter assembly comprises a filter that curves around a filter axis, and the closed path extends in at least two dimensions normal to the filter axis, and wherein optionally the closed path lies in a plane normal to the filter axis.

9. The vacuum cleaner of claim 8, wherein the filter wraps around and encloses the filter axis.

10. The vacuum cleaner of any one of the preceding claims, wherein the filter assembly comprises a filter shaped as a hollow semi-elliptical tube.

11. The vacuum cleaner of claim any one of the preceding claims, wherein the regenerative drive assembly agitates the filter assembly by moving the at least part of the filter assembly repeatedly along the closed path at a frequency no less than 100 Hz and / or no greater than 900 Hz.

12. The vacuum cleaner of any one of the preceding claims, wherein the regenerative drive assembly comprises an electric motor and a transmission coupled to the electric motor and to the filter assembly, wherein the transmission comprises a drive shaft and an eccentric mass mounted to the drive shaft.

13. The vacuum cleaner of any one of the preceding claims, wherein the regenerative drive assembly comprises an electric motor and a transmission coupled to the electric motor and to the filter assembly, and the transmission comprises a drive shaft that extends beneath the filter assembly.

14. The vacuum cleaner of any one of the preceding claims, wherein the vacuum cleaner comprises a handle located rearward of the dirt separator.

15. The vacuum cleaner of any one of the preceding claims, wherein the vacuum cleaner comprises a handle that extends along a handle axis, the filter assembly comprises a filter that curves around a filter axis or is pleated with fold lines that extend parallel to the filter axis, and the handle axis intersects a plane normal to the filter axis at an angle of between 0 degrees and 30 degrees, and wherein optionally the angle is between 10 degrees and 20 degrees.

16. The vacuum cleaner of any one of the preceding claims, wherein the vacuum cleaner comprises a suction motor for generating the airflow through the vacuum cleaner, and the suction motor is located downstream of the dirt separator, and wherein optionally the suction motor is located rearward of the dirt separator.

17. The vacuum cleaner of claim 16, wherein the filter assembly comprises a filter that curves around a filter axis or is pleated with fold lines that extend parallel to the filter axis, and the filter axis is parallel to a rotational axis of the suction motor.

18. The vacuum cleaner of claim 17, wherein the closed path extends in at least two dimensions normal to the filter axis, and wherein optionally the closed path lies in a plane normal to the filter axis.

19. The vacuum cleaner of any one of claims 16 to 18, wherein the regenerative drive assembly comprises an electric motor, and the electric motor and the suction motor have rotational axes that are parallel.

20. The vacuum cleaner of any one of claims 16 to 19, wherein the regenerative drive assembly agitates the filter assembly only when the suction motor is powered off.

21. The vacuum cleaner of any one of the preceding claims, wherein the vacuum cleaner comprises a further dirt separator located upstream of the dirt separator, and wherein optionally the dirt separator is located beneath the further dirt separator.

22. The vacuum cleaner of claim 21, wherein the further dirt separator is a non-cyclonic dirt separator.

23. The vacuum cleaner of claim 21 or 22, wherein: the vacuum cleaner comprises a further chamber within which the further dirt separator is located; airflow enters the further chamber in a direction parallel to a central axis; airflow flows along the filter assembly in a direction parallel to a filter axis and / or the filter assembly comprises a filter that curves around a filter axis or is pleated with fold lines that extend parallel to a filter axis, and the filter axis is parallel to the central axis.

24. The vacuum cleaner of claim 23, wherein the closed path extends in at least two dimensions normal to the filter axis, and wherein optionally the closed path lies in a plane normal to the filter axis.

25. The vacuum cleaner of any one of claims 21 to 24, wherein the filter assembly is located within a chamber, the further dirt separator is located within a further chamber, and the vacuumcleaner comprises a bin having a bin base that closes an end of the chamber and an end of the further chamber, and wherein optionally the bin base is movable to simultaneously open the chamber and the further chamber.s

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