Vacuum cleaner

Abstract

A vacuum cleaner comprising a separation system, a suction motor for generating an air flow through the separation system, a motor housing for housing the suction motor, and a battery assembly for supplying power to the suction motor, wherein the battery assembly is removably connected to the motor housing such that a first portion thereof is located within the motor housing.

Description

Technical Field

[0001] A vacuum cleaner generates an air flow by a suction generating device, and sucks dirt from the surface of the object to be cleaned with the air flow. Before being discharged from the vacuum cleaner, this air flow undergoes one or more separation stages to separate dirt from the air flow. Some vacuum cleaners are so-called "handheld types", and the user can hold the main unit of the vacuum cleaner by hand during use, and it is assumed that the user holds it by hand. Also, some vacuum cleaners are battery-powered and can be used without having to plug the power cord into an outlet.

Summary of the Invention

[0002] A first aspect of the present disclosure is a vacuum cleaner including a separation system, a suction motor for generating an air flow through the separation system, a motor housing for housing the suction motor, and a battery assembly for supplying power to the suction motor, wherein the battery assembly is removably connected to the motor housing such that a first portion of the battery assembly is located within the motor housing.

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

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

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

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

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

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

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

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

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

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

[0013] According to an embodiment of the first aspect of the present disclosure, the vacuum cleaner further includes a pole-structured main unit including a separation system, a suction motor, and a battery assembly. The outer sleeve of the battery assembly defines the handle of the vacuum cleaner.

[0014] According to an embodiment of the first aspect of the present disclosure, the separation system is a non-cyclone separation system. The separation system includes a chamber having an air inlet and a filter disposed within the chamber for filtering the airflow from the air inlet. The major surface of the filter extends in a direction parallel to the direction of the bulk airflow into the chamber. The separation system includes an elongated bin body having a central axis, and the direction of the bulk airflow is parallel to the central axis.

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

[0016] According to an embodiment of the second aspect of the present disclosure, the cleaner head includes four brush bars located within the cleaner head housing. Each brush bar is substantially frustoconical.

[0017] According to an embodiment of the second aspect of the present disclosure, each of the brush bars is rotatable about its respective brush bar axis, and when the cleaner head is positioned on the horizontal surface to be cleaned and the common central axis is oriented in a direction perpendicular to the horizontal surface to be cleaned, each brush bar axis forms an oblique angle with respect to the common central axis and / or forms an oblique angle with respect to the horizontal surface to be cleaned.

[0018] According to an embodiment of the second aspect of the present disclosure, with the common central axis oriented in a direction perpendicular to the horizontal plane on which the cleaner head is disposed, the cleaner head housing has a generally rectangular shape when viewed in the direction along the common central axis, and the common central axis is perpendicular to and intersects the short-axis central axis of the cleaner head housing. At least two brush bars are arranged to be located on opposite sides of the short-axis central axis.

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

[0020] According to an embodiment of the second aspect of the present disclosure, with the common central axis oriented perpendicular to the horizontal plane on which the cleaner head is disposed, the cleaner head housing has a generally rectangular shape when viewed in the direction along the common central axis, the common central axis is perpendicular to the longitudinal-axis central axis of the cleaner head housing, and is spaced apart from the longitudinal-axis central axis of the cleaner head housing.

[0021] According to an embodiment of the second aspect of the present disclosure, the cleaner head includes a bias mechanism for displacing the neck portion in a predetermined orientation with respect to the cleaner head housing. In a state where the cleaner head is positioned on the horizontal surface to be cleaned, the bias mechanism is configured to displace the neck portion such that a common central axis extends substantially perpendicular to the horizontal surface to be cleaned. Further, in a state where the cleaner head is positioned on the horizontal surface to be cleaned and the main unit is separated from the cleaner head, the bias mechanism is configured to displace the neck portion such that the central axis of the neck portion extends substantially perpendicular to the horizontal surface to be cleaned.

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

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

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

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

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

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

[0028] According to an embodiment of the second aspect of the present disclosure, the neck portion is movably attached to the cleaner head housing. The neck portion includes first and second arms pivotally connected to the cleaner head housing. The neck portion includes a tubular body, and in a state where a common central axis is oriented in a direction perpendicular to a horizontal plane in which the cleaner head is disposed, the common central axis is parallel to the central axis of the cleaner head and is spaced from the central axis of the cleaner head, the first and second arms form an oblique angle with respect to the tubular body.

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

[0030] According to an embodiment of the third aspect of the present disclosure, the control circuit board is disposed downstream of the suction motor. The control circuit board is disposed such that an air flow downstream of the suction motor during use is divided by a plane having opposing first and second sides defined by the control circuit board to form a Y-shaped air flow.

[0031] According to an embodiment of the third aspect of the present disclosure, a suction motor and a control circuit board are housed within a common chassis. The suction motor is flexibly mounted within the common chassis, and the control circuit board is rigidly mounted within the common chassis. The suction motor is housed within a first portion of the common chassis, the control circuit board is housed within a second portion of the common chassis, and the second portion of the common chassis is fluidly separated from the first portion of the common chassis. There is no airflow filter disposed between the suction motor and the control circuit board.

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

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

[0034] According to an embodiment of the third aspect of the present disclosure, the vacuum cleaner includes a motor housing in which the suction motor and the control circuit board are disposed, the motor housing includes first and second airflow outlets, and the first and second airflow outlets are disposed in a plane having opposing sides defined by the control circuit board. The common chassis is disposed within the motor housing, and the first and second airflow paths are each in fluid communication with one of the first and second airflow outlets.

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

[0036] According to an embodiment of the third aspect of the present disclosure, the vacuum cleaner includes a battery assembly including a plurality of battery cells arranged in a row, the control circuit board has a generally rectangular cross-sectional shape, and the long axis of the control circuit board extends in a direction parallel to the row of battery cells.

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

[0038] According to an embodiment of the third aspect of the present disclosure, the separation system includes an air inlet, the control circuit board has a generally rectangular cross-sectional shape, and the long axis of the control circuit board extends in a direction parallel to the direction of the bulk air flow passing through the air inlet.

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

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

[0041] According to an embodiment of the third aspect of the present disclosure, the vacuum cleaner includes a user interface including a user interface circuit board, and the user interface circuit board defines an additional plane that is substantially rotated 90 degrees with respect to the plane defined by the control circuit board.

[0042] According to an embodiment of the third aspect of the present disclosure, the separation system includes a bin body, a suction motor and a circuit board are housed in a motor housing, the vacuum cleaner includes a battery assembly including a battery housing, the bin body, the motor housing and the battery housing are coupled to each other to define a main unit of the vacuum cleaner, the control circuit board has a generally rectangular cross-sectional shape, and the major axis of the control circuit board extends in a direction parallel to the longitudinal central axis of the main unit. The bin body, the motor housing, and the battery housing are each an elongated tube, and at least two of the bin body, the motor housing, and the battery housing have the same maximum width.

Brief Description of the Drawings

[0043]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Figure 24

Figure 25

Figure 26

Figure 27

Figure 28

Figure 29

Figure 30

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

Figure 36

Figure 37

Figure 38

Figure 39

Figure 40

Figure 41

Figure 42

Figure 43

Figure 44

Figure 45

Figure 46

Figure 47

Figure 48

Figure 49

Embodiments for Carrying Out the Invention

[0044] Figures 1 and 2 show vacuum cleaners 10 without and with a dock.

[0045] The vacuum cleaner 10 includes a main unit 12 and a cleaner head 3000. The vacuum cleaner 10 is a so-called "handheld type" vacuum cleaner that can be supported by hand by the user during use and is battery-powered. As shown in Figure 2, a dock 4000 for storage when the vacuum cleaner 10 is not in use may be provided.

[0046] In Figures 3 and 4, the main unit 12 is shown alone and includes a separation system 100, a motor assembly 1000, and a battery assembly 2000.

[0047] The separation system 100 is shown in Figures 5 to 22 and includes a bin assembly 102, a filter assembly 200, and a core 300.

[0048] The bin assembly 102 includes a bin body 108, a first connection cuff 110, a second connection cuff 112, a wiper 114, and a bin interlock member 115.

[0049] The bin body 108 is elongated and generally cylindrical, and includes a first end 116, a second end 118, and a pair of guide rails 120. The bin body 108 is hollow, and the internal space of the bin body 108 defines the waste collection chamber 122 of the separation system 100. When the filter assembly 200 is attached to the core 300 and located within the bin body 108, the waste collection chamber 122 has a substantially constant cross-sectional area in the region corresponding to the filter assembly 200. The bin body 108 has an outer diameter of about 38 mm, but diameters in the range of 35 mm to 50 mm, or other diameters, are also contemplated. The bin body 108 has an axial length of about 38 cm as measured in a direction substantially parallel to the bin central axis B of the bin body 108. Accordingly, the ratio of the diameter of the bin body 108 to the axial length of the bin body 108 is 0.01 (i.e., 38 / 3800). In other words, the diameter of the bin body 108 is about 1% of the axial length of the bin body 108. The bin body 108 is formed of a plastic material and is generally transparent. However, those skilled in the art will recognize that using materials other than plastic will not depart from this technology. The bin body 108 defines the separator housing of the separation system 100.

[0050] The guide rails 120 are generally elongated and linear, and extend along the inner surface of the bin body 108 in a direction substantially parallel to the bin central axis B of the bin body 108. The guide rails 120 are formed integrally with the bin body 108 as part of the same molding process. The guide rails 120 are arranged diametrically opposite to each other and are in a common plane with the bin central axis B of the bin body 108.

[0051] The guide rail 120 extends between the first end 116 and the second end 118 of the bin body 108. The guide rail 120 is spaced a certain length in a direction parallel to the bin central axis B from the outer periphery of the first end 116 of the bin body 108. This length is determined by the dimensions of the valve assembly 304 to accommodate the valve assembly 304 to be movable between the open position and the closed position. Therefore, each guide rail 120 has an axial length of about 30 cm as measured in a direction parallel to the bin central axis B. Each guide rail 120 has a radial spread such that the guide rail protrudes about 5 mm into the dust collection chamber 122. The bin body 108 is slidably attached to the core 300 via the guide rail 120 and the guide surface 332 of the core 300.

[0052] The first connecting cuff 110 is located at the first end 116 of the bin body 108 and is shaped and dimensioned such that the free end 3030 of the neck portion 3004 of the cleaner head 3000 is received within the first connecting cuff 110. The first connecting cuff 110 includes a curved portion 124 and an engaging lip 142 that are shaped and dimensioned to selectively engage with the cleaner head catch 3040 of the neck portion 3004 of the cleaner head 3000, as will be described in more detail below. Further, the first connecting cuff 110 has a circular cross-sectional shape when viewed in a plane perpendicular to the bin central axis B. The end 130 of the first connecting cuff 110 is proximal to the bin body 108 and has a circular cross-sectional shape when viewed in a plane perpendicular to the bin central axis B. The curved portion 124 has a diameter of about 38 mm, but diameters in the range of 35 mm to 50 mm, or other diameters, are also contemplated.

[0053] When the bin body 108 is disposed around the core 300, a plane 126 is provided that is shaped and dimensioned to be located below the electrical connection portion 318 of the core 300. A gap 136 is provided between the bottom surface of the core 300 and the bin body 108. The gap 136 is provided such that the free end 3030 of the neck portion 3004 of the cleaner head 3000 is received within the gap 136, as will be described in more detail below.

[0054] The first connection cuff 110 partially defines the air flow inlet 140 of the separation system 100.

[0055] The second connection cuff 112 is located at the second end 118 of the bin body 108 and has a generally cylindrical hollow shape. The outer diameter of the second connection cuff is about 38 mm, although diameters in the range of 35 mm to 50 mm, or other diameters, are also contemplated. The second connection cuff 112 includes a bin catch receiving portion 144 and two internal ribs 146.

[0056] The bin catch receiving portion 144 is located on the bin body 108 on the side opposite the engaging lip 142 of the first connection cuff 110. The bin catch receiving portion 144 includes a latching member 148 that is shaped and dimensioned to engage the bin catch 1040 of the motor housing 1002 of the motor assembly 1000, as will be described in more detail below. The bin catch receiving portion 144 takes a different form from the engaging lip 142 of the first connection cuff 110.

[0057] The internal ribs 146 are formed on the inner surface of the second connection cuff 112 and are spaced apart diametrically opposite each other in a plane common with the bin central axis B. The internal ribs 146 extend along the length direction of the second connection cuff 112 and are arranged such that the internal ribs 146 are substantially continuous with the guide rails 120 at the second end 118 of the bin body 108.

[0058] Wiper 114 is shown in FIGS. 8 and 9 and includes a first portion 154 and a second portion 152 fixed by screw 156. Another screw 155 is provided to fix the wiper 114 to the second connection cuff 112. The first portion 154 includes a curved exposed wiping blade 151 shaped and dimensioned to substantially correspond to the primary mesh 202 of the filter assembly 200. The first portion 154 further includes a mounting surface 153. The second portion 152 includes a wall 157 having a generally semi-circular cross-sectional shape when viewed in a plane orthogonal to the bin central axis B. The second portion 152 further includes a mounting surface 149. Screw 156 is provided to fix the first portion 154 and the second portion 152 together via their respective mounting surfaces 153 and 149. The wiper 114 is formed of rubber or other material suitable for the surface of the primary mesh 202.

[0059] As schematically shown in FIG. 10, the bin interlock member 115 includes a first engaging end 158 and a second engaging end 1581 opposite the first engaging end 158. The bin interlock member 115 is formed of an elastically deformable material and is fixed to the core 300 such that the first engaging end 158 and the second engaging end 1581 float freely. The first engaging end 158 defines an angled contact surface for contacting the free end 3030 of the neck portion 3004 of the cleaner head 3000. When the cleaner head 3000 is inserted into the first connection cuff 110, the engaging lip 142 engages the cleaner head catch 3040 of the neck portion 3004, and at the same time, the free end 3030 of the neck portion 3004 of the cleaner head 3000 engages the first engaging end 158. As a result, the second engaging end 1581 moves toward the bin body 108 and abuts against the recess 1151 of the bin body to pivot the bin interlock member 115 to prevent further movement of the bin body. When no force is applied, the first engaging end 158 of the bin interlock member 115 is generally adapted to fit into the gap 136 between the core 300 and the bin body 108, but the second engaging end 1581 does not contact the bin body 108.

[0060] The filter assembly 200 is shown in FIGS. 11 to 15 and includes a primary mesh 202, a carrier 204, a cage 206, and a filter medium 208. The carrier 204 includes an upper tray 2041 and a lower tray 2042. Considering the nature of the filter assembly 200, the separation system 100 may be regarded as a non-cyclone separation system. The primary mesh 202 and the filter medium 208 can be regarded as including first and second separation mechanisms, respectively.

[0061] The filter assembly 200 is composed of a primary mesh 202 and a filter medium 208. The primary mesh 202 performs separation at the primary level and captures particles of 350 μm or more. This corresponds to approximately 70% of the dust. On the other hand, the filter medium 208 captures all particles less than 350 μm. Most of this dust remains between the primary mesh 202 and the filter medium 208. For reasons of hygiene and product safety, it is necessary to prevent the user from being exposed to this captured dust during the filtering process. It has also been found that the filter medium 208 being washed independently of the primary mesh 202 during the washing process is important for the performance over the life of the filter. This ensures more effective washing and shorter drying times. Therefore, the primary mesh 202 and the filter medium 208 are individually fixed by the upper tray 2041 and the lower tray 2042 with a predetermined clearance provided between the upper and lower trays in order to capture as many dust particles of a size less than 350 μm as possible between the primary mesh 202 and the filter medium 208. In one embodiment, the predetermined clearance is about 1.5 mm. The clearance between the upper tray 2041 and the lower tray 2042 minimizes the dust that appears on the surrounding components during the filtering step in order to completely confine the fine particles. Even if the filter assembly is subjected to intense movement or rotated upside down, most of the dust remains confined between the upper tray 2041 and the lower tray 2042.

[0062] The upper tray 2041 and the lower tray 2042 are fixed to each other during normal use and during the filter assembly removal process, but can be separated when removed from the vacuum cleaner body.

[0063] The primary mesh 202 functions to filter coarse dust from the airflow during use, and thus can be called a filter, or in fact, sometimes called a coarse filter. In some embodiments, the primary mesh 202 is referred to as the first filter. The primary mesh 202 is formed of a metal such as aluminum or other metallic materials and includes through-holes distributed along the length direction of the primary mesh 202. Each through-hole has a chamfered edge and a diameter of about 350 μm. Therefore, dust particles larger than 350 μm in size cannot pass through the primary mesh 202. That is, most dust particles will be captured in the dust chamber defined between the primary mesh 202 and the bin body 108.

[0064] The primary mesh 202 generally has a U-shaped cross-sectional shape when viewed in a plane perpendicular to the longitudinal separator axis S. In other words, the primary mesh 202 generally has a U-shaped cross-sectional shape when viewed along the length direction of the primary mesh 202. The curvature of the primary mesh 202 is such that the free ends of the U-shaped cross-sectional shape face each other so as to be separated from each other, and the primary mesh 202 has a relatively shallow curvature. The primary mesh 202 has an axial length of about 28 cm measured in a direction parallel to the longitudinal separator axis S. The valleys formed by the upstream surface of the primary mesh 202 form an airflow path for the bulk airflow from the airflow inlet. The upstream surface of the primary mesh 202 may sometimes also be referred to as the primary surface.

[0065] The upper tray 2041 includes a first end wall 214 and a second end wall 216, a first edge wall 218 and a second edge wall 220, and seven cross members 222. The first end wall 214 and the second end wall 216 each have a curved upper surface, and this curved upper surface is defined in shape and dimensions such that the primary mesh 202 is positioned thereon. The first end wall 214 and the second end wall 216 each have a certain area located below the primary mesh 202. The first end wall 214 includes an end wall clip 224 that corresponds to the first end wall 214 and is defined in shape and dimensions to engage with an end wall lip 246 of the first end wall 234 of the lower tray 2042. The second end wall 216 is defined in shape and dimensions to abut against a core connection portion 248 of the lower tray 2042. When the upper tray and the lower tray are slidably coupled, the end wall clip 224 engages with the end wall lip 246, is inserted together into a corresponding groove provided in the core 300, and is further moved so that the core connection portion 248 engages with a positioning channel 311 of the core 300, thereby locking the filter assembly to the core 300.

[0066] The first edge wall 218 and the second edge wall 220 extend outwardly from the first end wall 214 and the second end wall 216, and define a track 226 that is defined in shape and dimensions to be slidably received within a track channel 254 of the lower tray 2042, where the track channel 254 corresponds to the track 226. The first edge wall 218 and the second edge wall 220 have a curved length of approximately 31 mm in the axial direction, and thus have the same axial extent as the primary mesh 202.

[0067] Each of the cross members 222 extends between the first edge wall 218 and the second edge wall 220 and is curved to correspond to the curvature of the primary mesh 202. The cross members 222 are arranged at equal intervals along the axial length from the first end wall 218 to the second end wall 220 and define a support surface on which the primary mesh 202 rests. Each cross member 222 is located below the primary mesh 202. The cross members 222 serve to divide the primary mesh 202 into eight sub-areas.

[0068] The cage 206 is curved about an axis substantially parallel to the longitudinal separator axis S, and when viewed in a plane orthogonal to the longitudinal separator axis S, the cage 206 has a generally U-shaped cross-sectional shape. The cage 206 is positioned below the upper tray 2041 and above the filter medium 208, and is shaped and dimensioned accordingly. The width of the cage 206 corresponds to the filter medium 208 when measured in a direction orthogonal to the longitudinal separator axis S. The cage 206 includes a repeating pattern of cutouts 228, and the pattern is repeated along the length of the filter medium 208.

[0069] The filter medium 208 is any form of filter medium commonly used in vacuum cleaners, and includes a filter medium body 230 and filter wings 232. The width of the filter medium body 230 is approximately 30 mm when measured in a first direction orthogonal to the longitudinal separator axis S, and the width is sized such that the filter medium body 230 can be accommodated within the filter medium chamber 244 of the lower tray 2042. The filter medium body 230 has a thickness measured in a second direction orthogonal to the longitudinal separator axis S and also orthogonal to the first direction, and the thickness is sized such that the filter medium body 230 can be accommodated within the filter medium chamber 244 of the lower tray 2042.

[0070] The filter wings 232 extend from a side opposite to the upper end of the filter medium body 230, and each filter wing 232 extends from the filter medium body 230. The filter wings 232 extend axially from the ends of the filter medium body 230. The filter wings 232 are shaped and dimensioned to overlap a part of the upper rim 242 of the lower tray 2042, and are shaped and dimensioned to be positioned between the track channels 254 of the lower tray 2042. Although the filter medium body 230 and the filter wings 232 are slightly curved about the longitudinal separator axis S, the filter medium 208 has a generally T-shaped cross-sectional shape when viewed in a plane orthogonal to the longitudinal separator axis S.

[0071] The lower tray 2042 includes a first end wall 234, a second end wall 236, side walls 238 extending between the first end 234 and the second end 236, three cross members 240 extending between the side walls 238, and an upper rim 242.

[0072] The first end wall 234 and the second end wall 236 each have a width in a direction perpendicular to the longitudinal separator axis S. The side walls 238 each have a length in a direction parallel to the longitudinal separator axis S. The first end wall 234, the second end wall 236, the side walls 238, and the cross members 240 together define a filter media chamber 244. The filter media chamber 244 is sized and shaped to receive the filter media body 230 of the filter media 208.

[0073] The upper rim 242 is formed on the upper surfaces of the first end wall 234, the second end wall 236, and the side walls 238, and extends downward from and outwardly beyond the first end wall 234, the second end wall 236, and the side walls 238. A first portion of the upper rim 242 corresponding to the first end wall 234 defines an end wall lip 246 to removably engage the end wall clip 224 of the first end wall 214 of the mesh carrier 204. A second portion of the upper rim 242, opposite the first portion and corresponding to the second end wall 236, includes a core connection portion 248.

[0074] The filter media 208 is inserted into the filter media chamber 244 and welded to the filter media chamber 244 using ultrasonic welding. Thereafter, the cage 206 is placed over the filter media 208 and further welded to the lower tray 2042 by ultrasonic welding, surrounding the filter media 208 between the lower tray 2042 and the cage 206. In particular, the cage 206 is welded to the upper rim 242 of the lower tray 2042.

[0075] The core connection portion 248 includes a positioning projection 250 and an upright wall 252. The positioning projection 250 is defined to have a shape and dimensions such that it can be received within the positioning channel 311 of the core 300. The positioning projection 250 has a different shape from the end wall clip 224, whereby the end wall clip 224 cannot be positioned within the positioning channel 311. Thus, the filter assembly 200 is asymmetric with respect to an axis orthogonal to the longitudinal separator axis S, and may define a structure for error prevention. The upright wall 252 has a height in a direction orthogonal to the longitudinal separator axis S, and in a state where the filter assembly 200 is assembled, the upright wall 252 is substantially continuous with the second end wall 216 of the mesh carrier 204.

[0076] The portion of the upper rim 242 corresponding to the side wall 238 includes a track channel 254 defined to have a shape and dimensions for slidably receiving the tracks 226 of the first edge wall 218 and the second edge wall 220 of the mesh carrier 204.

[0077] FIG. 13 shows another embodiment of the lower tray 2042. Here, when viewed in a plane orthogonal to the longitudinal separator axis S, the filter medium 208 is a corrugated medium filter and has a rectangular cross-sectional shape.

[0078] The filter medium 208 may be a hygroscopic medium. In that case, when the hygroscopic medium gets wet, the filter medium expands beyond or through the openings of the cage 206, causing interference between the lower tray 2042 and the upper tray 2041. As a result, it is prevented from attaching or inserting a wet or moist filter to the core 300. In other words, when the hygroscopic medium is wet, the hygroscopic medium expands through the openings of the cage, and the lower tray 2042 cannot be slidably coupled to the upper tray 2041. Further, a hydrochromic indicator can be applied to the surface of the filter medium 208 so that a user can visually confirm whether the filter medium is wet or dry. For example, a hydrochromic indicator can be applied to the bottom surface of the filter medium 208, and when the filter medium 208 is wet, the hydrochromic indicator may appear through the portion defined by the three cross members 240.

[0079] The core 300 is shown in FIGS. 16 to 33, and the core 300 includes a core body 302 and a valve assembly 304.

[0080] The core body 302 has an elongated shape and includes a first end 306, a second end 308, an exhaust channel 310, an auxiliary mesh 312, an exhaust duct 314, a wiring accommodation channel 316, and an electrical connection portion 318. The auxiliary mesh 312 can be regarded as a third separation mechanism. FIG. 16 shows the core 300 with the auxiliary mesh 312, and FIG. 17 shows the core 300 without the auxiliary mesh 312.

[0081] When measured in a direction parallel to the longitudinal central axis C of the core body 302, the maximum axial length between the valve assembly 304 and the second end 308 is approximately 33 cm. Such a length substantially corresponds to the length of the bottle assembly 102. The core body 302 has a maximum width of less than 38 mm when measured in a first direction orthogonal to the longitudinal central axis C of the core body 302. The core body 302 has a maximum height of approximately 21 mm when measured in a second direction orthogonal to the longitudinal central axis C of the core body 302 and also orthogonal to the first direction. The dimensions of the core body 302 are such that the core body 302 can be selectively accommodated within the bottle assembly 102.

[0082] On the side of the first end 306 of the core body 302, a valve mounting channel 320 and a lamp 322 are arranged. The valve mounting channel 320 is shaped and dimensioned to receive the valve base 340 of the valve assembly 304. The valve mounting channel 320 extends across the entire width of the core body 302 and is formed to define half of a double-tail joint. The lower surface of the valve mounting channel 320 includes a positioning recess 321, and this positioning recess 321 is shaped and dimensioned to receive a positioning projection 350 corresponding to the positioning recess 321 on the valve base 340 of the valve assembly 304. The lamp 322 stands upright with respect to the valve mounting channel 320 and includes a notch 324. The notch 324 is generally U-shaped, and the curvature of the notch 324 substantially corresponds to the curvature of the primary mesh 204 of the filter assembly 200. The lamp 322 is arranged at a distance from the valve mounting channel 320 in a direction measured parallel to the longitudinal central axis C of the core body 302. This distance provides a clearance for the valve assembly 304 to move between the open position and the closed position.

[0083] The second end 308 of the core body 302 includes a planar wall 309 and a positioning channel 311. The planar wall 309 stands upright from the same side as the lamp 322 of the core body 302 and extends in a direction perpendicular to the longitudinal central axis C of the core body 302. The positioning channel 311 is located on the side of the planar wall 309 facing the lamp 322 and extends upward in a direction perpendicular to the longitudinal central axis C of the core body 302. The positioning channel 311 is defined by two opposing walls 313, and the free ends of the opposing walls 313 are inclined toward each other. The positioning channel 311 is shaped and dimensioned to receive the positioning protrusion 250 of the core connection portion 248 of the filter assembly 200.

[0084] The exhaust channel 310 is formed on the upper surface of the core body 302 on the same side as the lamp 322 of the core body 302 and is located between the lamp 322 and the first end 306 of the core body 302. The lower surface of the exhaust channel 310 proximal to the second end 308 of the core body 302 defines a surface 326 inclined toward the exhaust duct 314. The exhaust channel 310 is shaped and dimensioned to receive a portion of the lower tray 2042 and the filter media body 230. The exhaust channel 310 is arranged to be located under the primary mesh 202. The exhaust channel 310 extends in a direction parallel to the direction in which the primary mesh 202 extends along the chamber 122. The direction in which the exhaust channel 310 extends is also parallel to the direction of the bulk air flow flowing into the separation system 100 through the air inlet 140. Further, the direction in which the primary mesh 202 extends in the chamber 122 is also parallel to the central handle axis of the outer sleeve 2018. In use, when measured in a direction parallel to the direction of the bulk air flow through the air inlet 140, the minimum distance between the air inlet 140 and the primary mesh 202 is about 5 mm, and in some embodiments, it may not exceed 10 mm.

[0085] The upper peripheral portion 328 of the exhaust channel 310 is formed and dimensioned to contact the upper rim 242 of the lower tray 2042 such that the upper rim 242 of the lower tray 2042 is supported by the upper peripheral portion 328 of the exhaust channel 310. The lower tray 2042, the filter media body 230, the auxiliary mesh 312, and the exhaust channel 310 together function to partially define the air flow outlet 330 of the separation system 100.

[0086] The guide surface 332 located outside the side edge of the upper peripheral portion 328 of the exhaust channel 310 is shaped and dimensioned to slidably receive the guide rail 120 of the bin body 108 of the bin assembly 102 thereon.

[0087] The auxiliary mesh 312 functions as a filter, or is actually also called a fine filter, to filter fine dust from the air flow during use. The auxiliary mesh 312 also functions to prevent dust from falling from the separator cartridge 200 into the exhaust channel 310 when the separator cartridge 200 is removed from the exhaust channel 310, as will be described in more detail below.

[0088] The auxiliary mesh 312 is formed of a metal such as aluminum and includes through holes evenly arranged along the length direction of the auxiliary mesh 312. Each through hole has a chamfered edge. The auxiliary mesh 312 has an axial length corresponding to the notch for accommodating the filter assembly 200 when measured in a direction parallel to the longitudinal central axis C of the core body 302. The auxiliary mesh 312 has a width corresponding to the notch for accommodating the filter assembly 200 when measured in a direction orthogonal to the longitudinal central axis C of the core body 302. The auxiliary mesh 312 is received in the exhaust channel 310 and is shaped and dimensioned such that the auxiliary mesh 312 can be positioned below the filter assembly 200. The cross-sectional shape of the auxiliary mesh 312 when viewed along the direction in which the auxiliary mesh 312 extends is generally different from the cross-sectional shape of the primary mesh 202. For example, the auxiliary mesh 312 may have a substantially flat cross-sectional shape.

[0089] The auxiliary mesh 312 is mounted in the exhaust channel 310. The auxiliary mesh 312 is arranged to be positioned below the primary mesh 202.

[0090] The exhaust duct 314 is located at the second end 308 of the core body 302 and is in fluid communication with the exhaust channel 310. Thus, the exhaust duct 314 can also be regarded as forming part of the air flow outlet 330 of the separation system 100. The exhaust duct 314 has a maximum cross-sectional area larger than the maximum cross-sectional area defined between the lower tray 2042 and the bottom of the exhaust duct 314 when viewed in a plane orthogonal to the longitudinal central axis C. The distal end of the exhaust duct 314 remote from the exhaust duct 314 is open.

[0091] The wiring accommodation channel 316 extends from the first end 306 to the second end 308 of the core body 302 and is located below the exhaust channel 310 and the exhaust duct 314. The wiring accommodation channel 316 is a hollow chamber that accommodates the electrical connection portions extending from the motor assembly 1000 and the battery assembly 2000, as will be described in more detail below.

[0092] The electrical connection part 318 extends outward from the first end part 306 of the core body 302 in a direction away from the valve assembly 304. The electrical connection part 318 is at a relatively high position with respect to the lower side wall of the core body 302 that defines the outer side wall of the wiring accommodation channel 316. As will be described in more detail below, the electrical connection part 318 is received in the bin assembly 102 and is shaped and dimensioned to removably engage with a cleaner head electrical connection part 3036 corresponding to the electrical connection part 318 at the cleaner head 3000.

[0093] The electrical connection part 318 houses three terminal connection parts 336, and the lower surface of the electrical connection part 318 located under the valve mounting channel 320 defines a contact surface 338 for selectively engaging the engaging end part 158 of the bin interlock member 115. A silicone film 3181 is provided at one end of the electrical connection part 318 facing the electrical connection part 3036. The silicone film 3181 is provided with a notch in the shape of "o" or "+" for inserting a terminal. Thereby, dust is prevented from entering the electrical connection part 318.

[0094] The valve assembly 304 is shown in FIGS. 14 to 16 and includes a valve base 340, a flexible member 342, and a rigid member 344.

[0095] The valve base 340 is relatively rigid. The valve base 340 has an elongated shape and is formed and dimensioned to be slidably received in the valve mounting groove 320. The valve base 340 is formed together with the valve mounting groove 320 and has a cross-sectional T-shaped structure. The valve base 340 has a width that spreads over substantially all of the width of the core body 302 when positioned in the valve mounting groove 320 when measured in a direction orthogonal to the longitudinal central axis C of the core body 302.

[0096] The valve base 340 clamps the flexible member 342, holds the flexible member 342 in an upright state, and forms a T-shaped valve assembly 304 as a whole. Additional fixing means are provided for fixing the flexible member 342 to the valve base 340. At least two keying openings are provided in the valve base, and these keying openings are shaped and dimensioned to receive a predetermined amount of flexible material that forms the flexible member 342 as part of an overmolding process and act to fix the flexible member 342 to the valve base 340. A predetermined amount of flexible material that forms the flexible member 342 and extends through the keying openings forms positioning protrusions 350. These positioning protrusions 350 extend away from the lower surface of the valve base 340 and are shaped and dimensioned to be received within the positioning recesses 321 of the valve mounting channel 320. The height of the positioning protrusions 350 is such that sufficient force can be applied to the valve assembly 304 in a direction along the valve base 340 to remove the positioning protrusions 350 from the positioning recesses 321 without damaging the positioning protrusions 350. The positioning protrusions 350 are located substantially centrally along the valve base 340.

[0097] The flexible member 342 is formed of silicone. The flexible member 342 is overmolded on the valve base 340 and has a generally semi-circular cross-sectional shape.

[0098] The rigid member 344 includes a body 356, a first contact portion 358, and a second contact portion 360. The body 356 has a generally semi-circular cross-sectional shape, and the first contact portion 358 and the second contact portion 360 have generally square or rectangular cross-sectional shapes. The first contact portion 358 and the second contact portion 360 extend generally radially outward from the body 356 in a region of the straight portion of the body 356, extend beyond the flexible member 342, and clamp the ends of the flexible member 342. The upstream surface of the body 356 includes three molding protrusions 362 that extend through the opening of the flexible member 342.

[0099] The rigid member 344 is embedded within the flexible member 342 as part of an overmolding process that forms the flexible member 342. The rigid member 344 is partially embedded within the flexible member 342 such that the downstream face of the rigid member 344 is exposed. The flexible member 342 extends substantially over the entire perimeter of the body 356 of the rigid member 344 and defines a seal lip 364.

[0100] The flexible member 342 and the rigid member 344 together define a valve member 366 of the valve assembly 304, and the valve member 366 has an upstream face 368 and a downstream face 370. The upstream face 368 is defined by the flexible member 342, the first contact portion 358 and the second contact portion 360 of the rigid member 344, and the formed protrusion 362 of the rigid member 344. The downstream face 370 is defined by the seal lip 364 of the flexible member 342, the body 356 of the rigid member 344, the first contact portion 358 and the second contact portion 360 of the rigid member 344.

[0101] The rigid member 344 is embedded within the flexible member 342 such that the flexible material of the flexible member 342 is positioned between the valve base 340 and the rigid member 344, and such flexible material has a predetermined height between the valve base 340 and the rigid member 344. This portion of the flexible material substantially defines a living hinge 372 that allows the flexible member 342, and thus the valve member 366, to move relative to the valve base 340. The valve base 340 substantially defines a hinge axis that allows the valve member 366 to rotate.

[0102] The receiving channel 354 extends linearly across the upper surface 352 of the valve base 340 and receives a predetermined amount of flexible material that forms the flexible member 342 as part of the overmolding process. The height of the receiving channel 354 is selected to allow movement of a predetermined amount of the flexible member 342, as will be described in more detail below. The receiving channel 354 is offset from the center of the valve base 340 and is positioned closer to the upstream end of the valve assembly 304 than to the downstream end of the valve assembly 304. It will be understood that the terms "upstream" and "downstream" as used herein are provided in relation to the airflow through the operating vacuum cleaner 10.

[0103] Considering the nature of the offset of the receiving channel 354 that extends linearly across the upper surface 352 of the valve base 340 and the height of the flexible material that defines the living hinge 372, the valve member 366 can rotate asymmetrically to different extents around the valve base. The valve member 366 can rotate in the downstream direction such that the downstream surface 370 defines a minimum angle of about 40° with respect to an axis parallel to the longitudinal central axis C of the core body 302. Although a minimum angle of about 40° is shown in FIG. 17, one of ordinary skill in the art will recognize that other angles can be implemented without departing from the art. The valve member 366 can rotate in the upstream direction such that the upstream surface 368 is positioned substantially parallel to the longitudinal central axis C of the core body 302. Further operation of the valve assembly 304 will be described in more detail below.

[0104] The motor assembly 1000 is shown in FIGS. 24 through 33 and includes a motor housing 1002, a suction motor 1004, a motor mount 1006, a motor control circuit board 1008, power terminals 1010, an electronics chassis 1012, a first heat shield 1014 and a second heat shield 1016, a first sound-absorbing foam insert 1018 and a second sound-absorbing foam insert 1020, a user interface assembly 1024, and a housing insert 1026.

[0105] The motor housing 1002 is generally in the shape of an elongated hollow cylinder and includes a first end 1028, a second end 1030, a bin catch receiving opening 1032, a user interface opening 1034, a first air flow outlet 1036 and a second air flow outlet 1038, and a battery catch receiving opening 1039.

[0106] The motor housing 1002 has a diameter of about 38 mm, although diameters in the range of 35 mm to 50 mm are also contemplated. The housing is about 0.7 mm thick when measured radially with respect to the longitudinal axis MH of the motor housing and is formed of cold rolled aluminum.

[0107] The bin catch receiving opening 1032 is formed around the first end 1028 of the motor housing 1002 and is shaped and dimensioned to receive a part of the bin catch 1040. The bin catch 1040 is elastically pivotally attached to the first end 1028 of the motor housing 1002 and is shaped and dimensioned to selectively engage with the latching member 148 of the bin catch receiving portion 144 of the bin body 108.

[0108] The user interface opening 1034 is formed towards the second end 1030 of the motor housing 1002 and is shaped and dimensioned such that the LCD screen 1100, the power button 1108, and the mode button 1110 of the user interface assembly 1024 are visible through the user interface opening 1034. The user interface opening 1034 is located on the same side of the motor housing 1002 as the bin catch receiving opening 1032.

[0109] The first air flow outlet 1036 and the second air flow outlet 1038 are arranged opposite to each other on the cylindrical surface of the motor housing 1002 such that the corresponding points of the first air flow outlet 1036 and the second air flow outlet 1038 are separated from each other by approximately 180 degrees with respect to the circumferential direction of the motor housing 1002. The central regions of the first air flow outlet 1036 and the second air flow outlet 1038 are respectively arranged at positions rotated by approximately 90 degrees in the circumferential direction of the motor housing 1002 with respect to the ink catch receiving opening and the user interface opening 1034. The first air flow outlet 1036 and the second air flow outlet 1038 are arranged approximately in the middle along the longitudinal axis direction of the motor housing 1002 when measured in a direction parallel to the longitudinal axis MH of the motor housing.

[0110] The first air flow outlet 1036 and the second air flow outlet 1038 are each formed by a series of slots formed in the motor housing 1002.

[0111] The battery catch receiving opening 1039 is arranged toward the second end 1030 of the motor housing 1002 and is arranged on the motor housing 1002 on the side opposite to the user interface opening 1034. The battery catch receiving opening 1039 is arranged along the motor housing 1002 so as to be generally positioned between the user interface opening 1034 and the first air flow outlet 1036 and the second air flow outlet 1038 in a direction parallel to the longitudinal axis MH of the motor housing. The battery catch receiving opening 1039 is defined in a shape and dimension for receiving the battery catch mechanism 1022.

[0112] The suction motor 1004 is schematically shown in FIG. 29 and includes a stator assembly 1042, a rotor assembly 1044, and a housing assembly 1046.

[0113] The stator assembly 1042 includes a stator core 1048 and a winding 1050 wound around the stator core 1048. It will be understood that a number of different arrangements of the stator assembly are envisioned. The rotor assembly 1044 includes a shaft 1052, a permanent magnet 1054 attached to the shaft 1052, and an impeller 1056 attached to the shaft 1052. The shaft 1052 defines the axis of rotation R of the suction motor 1004. The impeller 1056 is attached to the shaft 1052 downstream of the permanent magnet 1054 such that the suction motor 1004 is an outlet cooling motor. The impeller 1056 is a mixed flow impeller.

[0114] The housing assembly 1046 defines the casing of the suction motor 1004 and houses the stator assembly 1042 and the rotor assembly 1044. The housing assembly 1046 defines a diffuser stage 1058 located upstream of the impeller 1056, and the diffuser stage 1058 functions as an axial diffuser.

[0115] The motor mount 1006 is generally cylindrical and hollow. Thus, the motor mount 1006 functions as a soft mount for the suction motor 1004. The motor mount 1006 includes a first sealing lip 1060, a second sealing lip 1062, and a number of mounting pipettes 1064. The first sealing lip 1060 and the second sealing lip 1062 are respectively disposed near the respective peripheral portions of the free end of the motor mount 1006 and stand up from the outer surface of the motor mount 1006. The mounting pipettes 1064 are arranged as a number of columns composed of three mounting pipettes 134, and each column extends between the first seal lip 1060 and the second seal lip 1062 in a direction parallel to the rotation axis R of the suction motor 1004. The columns of the three mounting pipettes 134 are arranged closer to the first sealing lip 1060 due to the arrangement of the stator assembly 1042 in the housing. Basically, the columns of the three mounting pipettes 134 are arranged so as to surround the stator assembly 1042. The inner diameter of the motor mount 1006 is designed so that the motor mount 1006 fits snugly around the housing assembly 1046 of the suction motor 1004.

[0116] The motor control circuit board 1008 includes a first portion 1066 to which a control circuit is attached and a second portion 1068 to which power terminals 1010 are attached. The control circuit may include an inverter for the suction motor 1004 and one or more processors. The first portion 1066 is generally planar and is arranged such that an extension line of the rotation axis R of the suction motor 1004 extends within a plane defined by the motor control circuit board 1008. The first portion 1066 has a generally rectangular cross-sectional shape, and the shorter dimension of the first portion is less than 38 mm. In some embodiments, the shorter dimension of the first portion 1066 substantially corresponds to the outer diameter of the suction motor 1004. The second portion 1068 is generally planar and is arranged such that the second portion 1068 is substantially orthogonal to the first portion 1066. The first portion 1066 is electrically connected to the suction motor 1004 by a flexible cable 1070 of the harness assembly 1013. The motor control circuit board 1008 is firmly attached within the electronic device chassis 1012. The power terminals 1010 define an electrical connection for receiving power from the battery assembly 2000.

[0117] The electronic device chassis 1012 includes a first portion 1072 and a second portion 1074 that collectively define a motor receiving portion 1076, a printed circuit board (PCB) receiving portion 1078, and an electrical connection housing 1080. The motor receiving portion 1076 has a generally cylindrical and hollow shape and has opposing open ends. The motor receiving portion 1076 is sized and shaped to receive the suction motor 1004 and the motor mount 1006.

[0118] The PCB receiving portion 1078 is located between the motor receiving portion 1076 and the electrical connection housing 1080. The PCB receiving portion 1078 includes a casing having a shape and dimensions for receiving the first portion 1066 of the motor control circuit board 1008. The PCB receiving portion 1078 includes a notch 1082 that enables the flexible cable 1070 to extend between the motor receiving portion 1076 and the PCB receiving portion 1078, and thus enables it to extend between the suction motor 1004 and the motor control circuit board 1008. The peripheral portion of the notch portion 1082 includes a grommet 1084 through which the flexible cable 1070 extends. The PCB receiving portion 1078 is fluidly isolated from the motor receiving portion 1076. Thereby, an air flow filter can be prevented from existing between the suction motor 1004 and the motor control circuit board 1008. The width of the PCB receiving portion 1078 is narrow compared to the motor receiving portion 1076 and the electrical connection housing 1080 when measured in a direction orthogonal to the rotation axis R of the suction motor 1004. Thanks to such an arrangement of the PCB receiving portion 1078, the air flow from the suction motor 1004 is split into two paths and exhausted from the first air flow outlet 1036 and the second air flow outlet 1038, respectively. As a result, a Y-shaped air flow is formed between the inlet of the suction motor 1004 and the first air flow outlet 1036 and the second air flow outlet 1038.

[0119] The electrical connection housing 1080 is generally cylindrical and is disposed adjacent to the PCB receiving portion 1078 at the end of the electronic device chassis 1012 opposite to the motor receiving portion 1076. The transition between the PCB receiving portion 1078 and the electrical connection housing 1080 is smooth, and the electrical connection housing 1080 has a shape and dimensions substantially corresponding to the internal dimensions of the motor housing 1002. The electrical connection housing 1080 has a shape and dimensions for receiving the second portion 1068 of the motor control circuit board 1008, the power supply terminal 1010, and the communication connection portion 1086 of the harness assembly 1013.

[0120] The harness assembly includes a flexible cable 1070 and a communication connection part. A part of the flexible cable 1070 passes through the motor housing 1002, extends through the wiring accommodation channel 316, and is electrically connected to the electrical connection part 318 of the core 300. In some embodiments, the flexible cable 1070 includes a charging cable for transmitting power from the cleaner head to the battery assembly 2000, as will be described in more detail below. A part of the flexible cable 1070 is electrically connected to the suction motor 1004. The communication connection part includes pins for removably connecting to the battery assembly 2000 and is also connected to the motor control circuit board 1008.

[0121] The first heat shield 1014 and the second heat shield 1016 are substantially of the same shape and are formed of metal or any material to direct the airflow from the suction motor 1004 and discharge it from the first air outlet 1036 and the second air outlet 1038. The first heat shield 1014 and the second heat shield 1016 are shaped and dimensioned to be located on the side regions of the PCB receiving part 1078 of the electronic device chassis 1012 and function as heat sinks. The first heat shield 1014 and the second heat shield 1016 receive the first sound-absorbing foam insert 1018 and the second sound-absorbing foam insert 1020. The first heat shield 1014 and the second heat shield 1016 each include cutouts 10141 and 10161. For the sake of brevity, FIG. 18 shows only one side of a pair of heat shields, a pair of sound-absorbing foam inserts, and the first part of the electronic device chassis 1012.

[0122] The battery catch mechanism 1022 includes a catch insert 1090 and a catch member 1092. The catch insert 1090 is disposed within the motor housing 1002 in the region of the battery catch receiving opening 1039, and the catch member 1092 is elastically attached to the catch insert 1090. The catch member 1092 includes a hook 1094 having a shape and dimensions that removably engage with the positioning recess 2048 of the battery assembly 2000, as will be described in more detail below.

[0123] The user interface assembly 1024 is shown separately in FIG. 26 and includes an interface base 1096, an interface PCB 1098, an LCD screen 1100, a screen bracket 1102, a button bracket 1104, a button seal 1106, a power button 1108, a mode button 1110, and a window portion 1112.

[0124] The interface base 1096 is shaped and dimensioned to receive the interface PCB 1098 and is shaped and dimensioned to be located on the planar portion 10301 of the housing insert 1026. The interface PCB 1098 includes microswitches 1114 corresponding to the power button 1108 and the mode button 1110, and the LCD screen 1100 is attached to the interface PCB 1098. The screen bracket 1102 has a shape and dimensions such that it is located above the LCD screen 1100 and includes a through hole 1116 through which the LCD screen 1100 can be seen.

[0125] The button bracket 1104 is shaped and dimensioned to be located under the power button 1108 and the mode button 1110, and includes a through hole 1118 that allows the power button 1108 and the mode button 1110 to selectively contact their respective microswitches 1114 via the button seal 1106. The button seal 1106 is formed of silicone and is shaped and dimensioned to fit within the button bracket 1104 between the button bracket 1104 and the power button 1108 and the mode button 1110. A polyethylene terephthalate (PET) sheet is provided between the button seal 1106 and the microswitch 1114 to protect the button seal 1106 from being punctured by the microswitch 1114. The thickness of the PET sheet is approximately 0.10 mm.

[0126] The window portion 1112 is shaped and dimensioned to be located above the interface base 1096 such that the interface PCB 1098, the LCD screen 1100, the screen bracket 1102, the button bracket 1104, the button seal 1106, the power button 1108, and the mode button 1110 are located between the interface base 1096 and the window portion 1112. The window portion 1112 consists of an opening 1120 from which the LCD screen 1100, the power button 1108, and the mode button 1110 are visible and accessible to the user. A screen protector 1119 for protecting the LCD screen 1100 is provided between the window portion 1112 and the screen bracket 1102.

[0127] The housing insert 1026 is generally slender and hollow-shaped and has a shape and dimensions that are received within the second end portion 1030 of the motor housing 1002.

[0128] The housing insert 1026 has a first end 1122 and a second end 1124. The housing insert 1026 has an axial length of approximately 10 cm between the first end 1122 and the second end 1124 when measured in a direction parallel to the axis MH of the motor housing. Such a length approximately corresponds to a length slightly longer than that of one battery cell 2002 of the battery assembly 2000, as will be described in more detail below. The first end 1122 is open so that the power terminal 1010 and the communication connection can extend into the first end 1122. The inner surface 1123 of the first end 1122 has a shape and dimensions corresponding to the interface portion 2046 of the battery assembly 2000, as will be described in more detail below, and the upper inner surface of the first end 1122 has a shape substantially of a plane 10301. The second end 1124 is open, and the second end 1124 has a shape and dimensions for receiving the first sleeve portion 2042 of the battery assembly 2000. In one embodiment, the housing insert 1026 may be configured to receive a quarter or less of the length of the battery assembly 2000.

[0129] The upper outer surface 1126 of the housing insert 1026 between the first end 1122 and the second end 1124 is generally planar and is defined to have a shape and dimensions for receiving the interface base 1096 of the user interface assembly 1024. This arrangement suppresses the rotational movement of the battery assembly 2000 relative to the motor housing 1002. This is sometimes referred to as an anti-rotation mechanism.

[0130] The battery assembly 2000 is shown in FIGS. 28 to 32 and includes four battery cells 2002, a first cell cradle 2004 and a second cell cradle 2006, a cell chassis 2008, a power terminal 2010, a communication terminal 2012, a battery management system, an inner sleeve 2016 and an outer sleeve 2018. The inner sleeve 2016 and the outer sleeve 2018 together define the battery housing of the battery assembly 2000. The inner sleeve 2016 and the outer sleeve 2018 can be formed of a plastic material.

[0131] Each battery cell 2002 is a cylindrical lithium-ion battery cell. The outer diameter and the axial length of each battery cell 2002 are left to design choices and depend on the dimensions of the battery housing, the available space within the battery housing, and the battery capacity required to operate the vacuum cleaner. Each battery cell 2002 can be considered a rechargeable battery cell, or the combination of battery cells 2002 can be considered a rechargeable battery.

[0132] The first cell cradle 2004 and the second cell cradle 2006 each have substantially the same shape and include an upper cradle portion 2020 and a lower cradle portion 2022. The upper cradle portion 2020 and the lower cradle portion 2022 are each shaped to correspond to one of the upper half and the lower half of a pair of battery cells 2002 arranged linearly in a row. The battery cells 2002 are arranged in the first cell cradle 2004 and the second cell cradle 2006 and are provided with tabs for connecting the terminals of adjacent cells. When arranged in the first cell cradle 2004 and the second cell cradle 2006, the battery cells 2002 extend in a row along an axis parallel to the longitudinal battery housing axis BH.

[0133] The cell chassis 2008 is generally elongated and includes a first end 2024, a second end 2026, and a planar wall 2030. The first end 2024 of the cell chassis 2008 includes openings 2032 for receiving respective ones of the power terminals 2010 and the communication terminals. The first end 2024 and the second end 2026 of the cell chassis have a generally semi-circular cross-sectional shape when viewed in a direction parallel to the longitudinal battery housing axis BH.

[0134] The planar wall 2030 extends from the second end 2026 towards the first end 2024 but stops short of the first end 2024. The planar wall 2030 corresponds to a linear peripheral portion of the second end 2026. The planar wall 2030 is defined by a shape and dimensions such that it is located approximately below half of the battery circuit board 2036 of the battery management system 2014.

[0135] The first end 2024, the second end 2026, the curved wall 2028, and the planar wall 2030 together define a partially open chamber 2034. The partially open chamber 2034 is shaped and dimensioned to receive the first cell cradle 2004 and the second cell cradle 2006, and thus is shaped and dimensioned to receive four battery cells 2002.

[0136] The power terminals 2010 are disposed at the first end 2024 of the cell chassis 2008 and are in electrical communication with the battery cells 2002. The power terminals 2010 have a shape and dimensions such that they removably engage with the power terminals 1010 of the motor assembly 1000 and are adapted to selectively define an electrical connection between the battery assembly 2000 and the motor assembly 1000.

[0137] The communication terminals 2012 are disposed at the first end 2024 of the cell chassis 2008 and are communicatively coupled to the battery management system. The communication terminals 2012 have a shape and dimensions such that they removably engage with the communication connection portion 1086 of the harness assembly.

[0138] The battery management system includes a battery circuit board 2036 and a connection tab. The battery circuit board 2036 is generally planar and extends in a direction parallel to the battery housing axis BH having an axial length in the longitudinal direction. The battery circuit board 2036 extends partially along the length direction of the planar wall 2030 and is arranged such that the battery circuit board 2036 is located above three battery cells 2002 but not above one battery cell 2002. This means that the battery housing overlaps the motor housing in the central longitudinal access direction, and the overlap amount is about one-fourth of the length of the battery housing in the direction of the central longitudinal axis CL. The control circuit of the battery management system is attached to the battery circuit board 2036. The connection tab extends between the battery circuit board 2036 and the communication terminal 2012.

[0139] The battery cell 2002, the first cell cradle 2004, the second cell cradle 2006, the cell chassis 2008, the power terminal 2010, the communication terminal 2012, and the battery management system 2014 together define a battery sub-assembly.

[0140] The battery assembly 2000 further includes a shock absorber disposed between the battery assembly 2000 and the motor housing. The shock absorber includes a plunger 2011 and a spring 2013 for absorbing an impact received along the axial direction.

[0141] The inner sleeve 2016 includes a first sleeve portion 2042 and a second sleeve portion 2044. The first sleeve portion 2042 has a hollow shape and has a shape and dimensions for receiving a portion of the battery sub-assembly corresponding to the first end 2024 of the cell chassis. The portion of the battery sub-assembly 2040 received within the first sleeve portion 2042 corresponds to the portion corresponding to the first battery cell 2002 in the row of battery cells and corresponds to the region of the battery sub-assembly where the battery circuit board 2036 is not disposed.

[0142] The first sleeve portion 2042 includes an interface portion 2046, a positioning recess 2048, and an electrical connection opening 2050. The interface portion 2046 is generally planar and is shaped and dimensioned to be located beneath the planar inner surface 1123 of the housing insert 1024. The positioning recess 2048 is located on the side of the first sleeve portion 2042 opposite the interface portion 2046 and is shaped and dimensioned to removably engage with the hook 1094 of the battery catch mechanism 1022 to hold the battery assembly 2000 relative to the motor assembly 1000. The electrical connection opening 2050 is disposed at the end of the first sleeve portion 2042 distal from the second sleeve portion 2044 and has a shape and dimension that allows access to the corresponding one of the power terminal 2010 and the communication terminal 2012.

[0143] The second sleeve portion 2044 is generally cylindrical and has a hollow shape. The second sleeve portion 2044 is shaped and dimensioned to be received within the outer sleeve 2018. The end of the second sleeve portion 2044 distal from the first sleeve portion 2042 is open so that the battery sub-assembly 2040 can be inserted within the inner sleeve 2016.

[0144] The outer sleeve 2018 is generally cylindrical, has a hollow shape, and has a first end 2052 and a second end 2054. The outer sleeve 2018 has an axial length of approximately 24 cm between the first end 2052 and the second end 2056 when measured in a direction parallel to the longitudinal battery housing axis BH. The outer sleeve 2018 has an outer diameter of approximately 38 mm. Outer diameters in the range from 35 mm to 50 mm are also envisioned. The outer sleeve 2018 is formed of metal, plastic, or other materials and has sufficient internal space to receive the second sleeve portion 2044 of the inner sleeve 2016 and a part of the battery sub-assembly. The outer sleeve 2018 functions as the handle of the vacuum cleaner 10 during use. The outer sleeve 2018 may be at least partially covered with a non-slip material to prevent slipping against surfaces such as the wall where the main unit 12 may be disposed opposite thereto. Alternatively, the non-slip material may be provided around the second end 2054 of the outer sleeve 2018.

[0145] The first end 2052 of the outer sleeve 2018 is open and defines an opening for receiving the second sleeve portion 2044 of the inner sleeve 2016 and a part of the battery sub-assembly. The second end 2054 of the outer sleeve 2018 is closed and is generally hemispherical. A user indicator 2060 is provided through an opening 2051 located near the first end 2052 of the outer sleeve 2018, and the user indicator 2060 takes the form of a light source capable of lighting up to indicate to the user the state of the battery cell 2002.

[0146] The outer sleeve 2018 is fixed to the inner sleeve 2016 by screws or other suitable fasteners. When assembled, the battery assembly 2000 formed by the inner sleeve 2016 and the outer sleeve 2018 has an axial length of approximately 34 cm when measured in a direction parallel to the longitudinal battery housing axis BH. When the battery assembly 2000 is assembled together with the motor assembly 1000, the exposed portion of the battery assembly 2000 has an axial length of 24 cm when measured in a direction parallel to the longitudinal battery housing axis BH. This means that the insert 1026 has a length of approximately 10 cm to receive the inner sleeve 2016 when measured in a direction parallel to the longitudinal battery housing axis BH.

[0147] The cleaner head 3000 is schematically shown in FIGS. 38 to 41. The cleaner head 3000 includes a main cleaner head housing 3002 and a neck portion 3004.

[0148] The main cleaner head housing 3002 is generally hollow and includes an internal chamber 3006. The base 3008 of the main cleaner head housing 3002 constitutes an air flow inlet 3010. Four brush bars 3012 and four corresponding drive motors are disposed within the chamber 3006, and each drive motor is configured to drive the rotation of a corresponding brush bar 3012 within the internal chamber 3006. Each brush bar 3012 is generally frustoconical in shape and includes an outer surface made of nylon. Two pairs of brush bars 3012 are arranged.

[0149] The neck portion 3004 is composed of a rigid body 3016 and a flexible duct 3018. The rigid body 3016 includes a first connecting arm 3020, a second connecting arm 3022, a first tubular body 3024, and a second tubular body 3026. The first connecting arm 3020 and the second connecting arm 3022 are each pivotally attached to the main cleaner head housing 3002 and fixedly attached to the first tubular body 3024. The first cleaner head arm 3020 and the second cleaner head arm 3022 are each positioned approximately in the middle in the depth direction of the cleaner head 3000 when measured in a direction orthogonal to the central axis CC of the cleaner head, and each is pivotally attached to the main cleaner head housing 3002. The first cleaner head arm 3020 and the second cleaner head arm 3022 can rotate with respect to the main cleaner head housing about a first cleaner head rotation axis orthogonal to the central axis CC of the cleaner head. In some embodiments, a biasing mechanism is provided that biases the neck portion 3004 to a position where the central axis of the neck portion 3004 of the cleaner head 3000 is parallel to the central axis CC of the cleaner head. This means that the central axis of the separation system coincides with the central axis of the neck portion 3004 of the cleaner head 3000.

[0150] The first tubular body 3024 is substantially hollow in shape and stands up from the first connecting arm 3020 and the second connecting arm 3022. The first tubular body 3024 has a shape and dimensions for receiving a part of the flexible duct 3018.

[0151] The second tubular body 3026 includes a fixed end 3028, a free end 3030, first and second charging contacts 3032, a cleaner head electrical connection portion 3036, a positioning magnetic portion 3038, and a cleaner head catch 3040.

[0152] The fixed end 3028 is pivotally attached to the first tubular body 3026 such that the second tubular body 3026 can rotate relative to the first tubular body 3024 about a second cleaner head rotation axis that is orthogonal to both the first cleaner head rotation axis and the central axis CC of the cleaner head. The fixed end 3028 is shaped and dimensioned to receive a portion of the flexible duct 3018. The flexible duct 3018 terminates within the fixed end 3028 and is in fluid communication with the free end 3030 of the second tubular body 3026.

[0153] The free end 3030 is shaped and dimensioned to be received within the first coupling cuff 110 of the bin assembly 102 and is also shaped and dimensioned to selectively engage the engaging end 158 of the bin interlock member 115.

[0154] The first and second charging contacts 3032 are each disposed on the outer surface of the second tubular body 3026 and are disposed generally diametrically opposed. The first and second charging contacts 3032 are each disposed approximately 90 degrees of rotation from the cleaner head catch 3040 about the circumferential direction of the second tubular body 3026. When the second tubular body 3026 extends in a direction substantially parallel to the central axis CC of the cleaner head and the cleaner head 3000 is positioned on the horizontal surface HS to be cleaned, the first and second charging contacts 3032 are positioned at a height as viewed from the horizontal surface HS to be cleaned such that the first and second charging contacts 3032 are in electrical communication with the cleaner head electrical connection portion 3036 respectively. The first and second charging contacts 3032 are sometimes also referred to as charging connectors and may include spring-loaded contact pins in some embodiments.

[0155] The cleaner head electrical connection portion 3036 is shaped and dimensioned to engage the electrical connection portion 318 of the core body 302 to form an electrical connection. The cleaner head electrical connection portion 3036 is in electrical communication with the first and second charging contacts 3032 and further with the control circuit of the drive motor 3014.

[0156] The positioning magnetic part 3038 is embedded in the wall of the second tubular body 3026, and is located about 90 degrees apart from each of the first and second charging contacts 3032 in the outer peripheral direction of the second tubular body 3026. The positioning magnetic part 3038 is located on the same side as the cleaner head catch 3040 with respect to the second tubular body 3026, and the cleaner head catch 3040 is located closer to the free end 3030 than the positioning magnetic part 3038. In some embodiments, a plurality of positioning magnetic parts are provided. The positioning magnetic part can include a permanent magnet or a ferromagnetic material.

[0157] The cleaner head catch 3040 includes an elastically displaced hook for selectively engaging with the engaging lip 142 of the flat portion 126 of the first connecting cuff, and selectively holds the cleaner head 3000 with respect to the bin assembly 102.

[0158] The dock 4000 of the vacuum cleaner 10 is shown in FIGS. 42 to 44.

[0159] The dock 4000 includes a base 4002 and a holding arm 4004.

[0160] The base 4002 consists of a lower base body 4006 and an upper base body 4008. The lower base body 4006 has a generally elliptical cross-sectional shape, and the lower surface of the lower base body 4006 includes an anti-slip material for suppressing the slip of the lower base body 4006 with respect to the surface on which the lower base body 4006 is located during use. The upper base body 4008 is attached to the lower base body 4006 by complementary coupling means or screws. The upper base body 4008 has a dimension greater than the maximum dimension of the cleaner head 3000.

[0161] The upper base body 4008 has a generally elliptical cross-sectional shape, and the upper surface of the upper base body 4008 includes an arm receiving opening having a shape and dimension for receiving the first arm portion 4012 of the holding arm 4004. The arm receiving opening is arranged away from the center of the upper base body 4008 and towards a region of the upper base body 4008 having a minimum width.

[0162] The holding arm 4004 includes a first arm portion 4012, a charging port 4014, a battery receiving opening 4016, a second arm portion 4018, a third arm portion 4020, a positioning magnet 4022, a first spring-loaded charging contact 4024 and a second spring-loaded charging contact 4026, and a first tool storage portion 4028 and a second tool storage portion 4030.

[0163] The first arm portion 4012 is received in the arm receiving opening of the upper base body 4008 and stands up from the upper base body 4008 in a direction substantially perpendicular to the upper base body 4008. The first arm portion 4012 faces inward toward the central region of the upper base body 4008 and defines a cleaner head contact surface 4032 having a shape and dimensions that contact a part of the cleaner head 3000 when the cleaner head 3000 is held at a predetermined position on the dock 4000.

[0164] The charging port 4014 is disposed in a region of the first arm portion 4012 that faces outward toward the peripheral side of the upper base body 4008. The charging port 4014 has a shape and dimensions for receiving an electrical connector for connecting the charging port to an external power source such as a main power source and is electrically connected to the electrical connector.

[0165] The battery receiving opening 4016 is formed in a boundary region between the first arm portion 4012 and the second arm portion 4018 and is arranged such that the opening side of the battery receiving opening 4016 faces away from the upper base body 4008. The battery receiving opening 4016 has a shape and dimensions for receiving the first sleeve portion 2042 of the inner sleeve 2016 of the battery assembly 2000. The battery receiving opening 4016 houses an electrical connection portion so that the battery assembly 2000 can be connected to a power source for charging via the charging port 4014. In some embodiments, the battery receiving opening is omitted.

[0166] The second arm portion 4018 is integrally formed with the first arm portion 4012 and extends away from the first arm portion 4012 such that an angle of approximately 45 degrees is formed between the first arm portion 4012 and the second arm portion 4018. The second arm portion 4018 extends inwardly from the first arm portion 4012 toward the central axis D of the dock, but does not reach the central axis D of the dock.

[0167] The third arm portion 4020 is integrally formed with the second arm portion 4018 and extends away from the second arm portion 4018 such that the third arm portion 4020 extends in a direction substantially parallel to the first arm portion 4012.

[0168] The third arm portion 4020 is generally convex, and the arm insert 4034 is disposed within the curved recess defined by the third arm portion 4020. The arm insert 4034 has an internal curvature generally corresponding to the curvature of the second tubular body 3026 of the cleaner head 3000 and defines a cleaner head receiving channel 4035. It will be understood that the arm insert 4034 may also be seen to define a contact surface for contacting the second tubular body 3026 of the cleaner head 3000. The arm insert 4034 serves to hold the positioning magnet 4022 and the first spring-type charging contact 4024 and the second spring-type charging contact 4026 for the third arm portion 4020.

[0169] The positioning magnet 4022 is disposed on the third arm portion 4020 at a position somewhat higher than the upper base body 4008 such that it aligns with the positioning magnetic portion 3038 when the cleaner head is stationary on the dock 4000. The positioning magnet 4022 includes two magnets laminated to enhance magnetic strength.

[0170] The first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026 are electrically connected to the charging port 4014 by wiring extending through the first arm portion 4012, the second arm portion 4018, and the third arm portion 4020. The first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026 extend through openings formed in the arm insert 4034 so as to correspond to each other, and in this way, the contact surfaces of the first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026 are exposed. The first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026 are located at the same height as the positioning magnet 4022. The first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026 are each located about 90 degrees away from the positioning magnet 4022 in the outer circumferential direction of the third arm portion 4020, and the positioning magnet 4022 is located at the center between the first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026.

[0171] The first tool storage portion 4028 and the second tool storage portion 4030 are each substantially the same in form, and have a shape and dimensions for receiving a tool for attaching to the main unit 12 of the vacuum cleaner 10 so that the tool is held relative to the dock 4000. The first tool storage portion 4028 and the second tool storage portion 4030 extend from the side opposite to the cleaner head receiving channel 4035 with respect to the third arm portion 4020.

[0172] The main unit 12 is shown in the assembled cleaning configuration in FIG. 45, and the cleaner head 3000 is shown attached to the main unit 12 in the assembled cleaning configuration in FIG. 46. FIG. 47 is a front view of the vacuum cleaner 10 stationary on the dock 4000.

[0173] When the main unit 12 is assembled and in a cleaning configuration, the bin assembly 102 is arranged such that the bin central axis B of the bin body 108 is coaxial with the longitudinal central axis CL of the main unit 12. Accordingly, the bin body 108 extends annularly about the longitudinal central axis CL of the main unit 12. The filter assembly 200 and the core 300 are housed within the bin body 108, and the bin catch 1040 of the motor housing 1002 engages with the latching member 148 of the bin catch receiving portion 144 of the second connecting cuff 112 to hold the bin assembly 102 against the motor housing 1002. With the filter assembly 200 and the core 300 housed within the bin body 108, the dust collection chamber 122 of the separation system 100 occupies approximately 30% to 40% of the bin body 108 and has a self-compressing arrangement in which dust entering the dust collection chamber 122 is compressed against the wiper 114. This is because the filter assembly 200 is arranged parallel to the core 300 housed within the bin body 108 and the suction motor 1004 is arranged downstream of the separation system 100.

[0174] The core 300 is arranged within the bin assembly 102 such that the electrical connection portion 318 of the core 300 covers the inner surface 134 of the planar portion 126 of the first connecting cuff 110, and a gap 136 is defined between the inner surface 134 and the electrical connection portion 318. The valve member 366 of the valve assembly 304 engages with the valve seat 135 such that the valve member 366 closes the air flow inlet 140. The hinge axis H of the valve base 340 of the valve assembly extends in a direction orthogonal to the longitudinal central axis CL of the main unit 12.

[0175] The guide rails 120 of the bin body 108 are arranged such that the guide rails 120 extend in a direction substantially parallel to the longitudinal central axis CL of the main unit 12. The guide rails 120 are arranged on the guide surface 332 of the core body 302 of the core, and the guide rails 120 are arranged to be axially aligned with one of the corresponding first contact portion 358 and second contact portion 360 of the rigid member 344 of the valve assembly 304 in a direction parallel to the longitudinal central axis CL of the main unit 12.

[0176] The filter assembly 200 is arranged such that the positioning protrusion 250 of the core connection portion 248 is received within the positioning channel 311 of the core 300 proximal to the exhaust duct 314, and the end wall clip 224 and end wall lip 246 of the filter assembly are positioned distal from the exhaust duct 314. The upper rim 242 of the lower tray 2042 is supported on the upper peripheral portion 328 of the exhaust channel 310 of the core body 302 such that the lower region of the filter media body 230 is positioned within the exhaust channel 310. The lower tray 2042, the filter media body 230, and the exhaust channel 310 partially define the air flow outlet 330 of the separation system 100. The portion of the air flow outlet 330 defined by the exhaust channel 310 is disposed at a distance from the longitudinal central axis CL of the main unit 12. The filter assembly 200, and thus the primary mesh 202 and the filter media 208, act to divide the coarse debris collection chamber 122 and the exhaust channel 310.

[0177] The upstream face of the primary mesh 202 faces away from the longitudinal central axis CL of the main unit 12, and thus from the central axis B of the bin body 108. The primary mesh 202 and the filter media 208 are spaced apart from each other by approximately 1.4 mm in a direction orthogonal to the longitudinal central axis CL of the main unit 12, which can also be viewed in the lateral direction. The primary mesh 202 and the filter media 208 each have an elongated shape with parallel longitudinal axes, and overlap each other longitudinally. The parallel longitudinal axes of the primary mesh 202 and the filter media 208 are also parallel to the direction of the bulk air flow from the air flow inlet 140 to the separation system 100. The generally U-shaped cross-section of the primary mesh 202 is such that the trough provided by the upstream face of the primary mesh 202 forms an air flow channel for the air flowing from the air flow inlet 140 of the separation system 100.

[0178] The exhaust duct 314 of the core body 302 is in fluid communication with the motor housing 1002. The motor housing 1002 extends away from the bin body 108 in a direction along the longitudinal central axis CL of the main unit 12 and extends annularly around the longitudinal central axis CL of the main unit 12. The suction motor 1004 is disposed within the motor housing 1002 such that the impeller 1056 of the suction motor 1004 is positioned proximal to the exhaust duct 314 and the stator assembly 1042 of the suction motor 1004 is positioned downstream of the impeller 1056. The motor control circuit board 1008 is positioned downstream of the suction motor 1004 within the motor housing 1002, and a first portion 1066 of the motor control circuit board 1008 is positioned within the PCB receiving portion 1078 of the electronic equipment chassis 1012. The first portion 1066 of the motor control circuit board 1008 defines a plane extending in a direction parallel to the rotation axis R of the suction motor 1004, and the major axis of the first portion 1066 of the motor control circuit board 1008 extends in a direction parallel to the rotation axis R of the suction motor 1004. The major axis of the first portion 1066 of the motor control circuit board 1008 may be considered to extend in a direction parallel to the rows of the battery cells 2002 and in a direction parallel to the central axis of the separation system 100. The motor housing 1002, the PCB receiving portion 1078 of the electronic equipment chassis 1012, and the electrical connection housing 1080 of the electronic equipment chassis define a motor outlet passage within the motor housing 1002.

[0179] The first air flow outlet 1036 and the second air flow outlet 1038 are in fluid communication with the motor outlet passage 1079, and the first air flow outlet 1036 and the second air flow outlet 1038 are arranged such that air flows out of the motor housing 1002 in a direction substantially orthogonal to the longitudinal central axis CL of the main unit 12 that forms a Y-shaped air flow from the motor housing to the first air flow outlet 1036 and the second air flow outlet 1038. The LCD screen 1100, the power button 1108, and the mode button 1110 are arranged on the same side of the motor housing 1002 as the ink catch 1040 of the motor housing 1002, and the LCD screen 1100, the power button 1108, and the mode button 1110 face in a direction orthogonal to the longitudinal central axis CL of the main unit 12 and orthogonal to the direction in which air flows out of the motor housing 1002 through the first air flow outlet 1036 and the second air flow outlet 1038.

[0180] The battery assembly 2000 is arranged such that the longitudinal battery housing axis BH is coaxial with the longitudinal central axis CL of the main unit 12. The first sleeve portion 2042 of the inner sleeve 2016 of the battery assembly 2000 is arranged within the housing insert 1024 of the motor assembly 1000, and the interface portion 2046 of the first sleeve portion 2042 is below the planar inner surface 1123 of the housing insert 1024 and in contact with the planar inner surface 1123 of the housing insert 1024. The power terminals 2010 of the battery assembly 2000 are connected to the power terminals 1010 of the motor assembly 1000, enabling power exchange between the battery assembly 2000 and the components within the motor housing 1002. The communication terminals 2012 of the battery assembly 2000 are connected to the communication connection portion 1086 of the harness assembly 1013, enabling communication to be established between the battery assembly and the components within the motor housing 1002.

[0181] The positioning recess 2048 of the first sleeve portion 2042 engages with the hook 1094 of the battery catching mechanism 1022 of the motor assembly 1000, thereby holding the first sleeve portion 2042 within the housing insert 1024 and holding the battery assembly 2000 relative to the motor assembly 1000.

[0182] The outer sleeve 2018 extends away from the motor housing 1002 and away from the bin assembly 102 in a direction parallel to the longitudinal central axis CL of the main unit 12. The outer sleeve extends away from the motor housing 1002 by approximately 24 cm in the axial direction as measured in a direction parallel to the longitudinal central axis CL of the main unit 12, defining a handle by which the user can grip the main unit 12 to move the vacuum cleaner 10 relative to the surface to be cleaned. The rows of battery cells 2002 extend parallel to the longitudinal central axis CL of the main unit 12 but are offset from the longitudinal central axis CL of the main unit 12.

[0183] As can be seen from FIG. 45, in the assembled state of the main unit 12, the separation system 100, the motor assembly 1000, and the battery assembly 2000 are aligned along the longitudinal central axis CL of the main unit 12, and their central axes are shared. In an alternative example, it can be said that the components of the separation system 100, the motor assembly 1000, and the battery assembly 2000 are arranged in an aligned manner. The suction motor 1004 is disposed between the separation system 100 and the battery assembly 2000. The separation system 100, the suction motor 1004, and the battery assembly 2000 can also be seen as being aligned along the longitudinal central axis CL of the main unit 12. Similarly, the respective central axes of the separation system 100, the suction motor 1004, and the battery assembly 2000 can be seen as being coaxial with the longitudinal central axis CL of the main unit 12.

[0184] Each of the separation system 100, the motor assembly 1000, and the battery assembly is elongated and generally tubular such that the main unit 12 is an elongated tubular shape. By doing so, the main unit 12 forms a pole structure, or this structure is also known as a single tubular structure. The main unit 12 has an overall axial length of approximately 95 cm when measured in a direction parallel to the longitudinal central axis CL of the main unit 12. The separation system 100 occupies approximately 38 cm of the overall axial length of the main unit, corresponding to 40% of the overall axial length of the main unit 12. The motor assembly 1000 occupies 33 cm of the overall axial length of the main unit, corresponding to approximately 35% of the overall axial length of the main unit 12. The battery assembly 2000 occupies 24 cm of the overall axial length of the main unit, corresponding to approximately 25% of the overall axial length of the main unit 12. The length of the motor housing 1002 in the direction along the longitudinal central axis CL of the main unit 12 is shorter than the length of the bin body 108 in the direction along the longitudinal central axis CL of the main unit 12. When the separator housing, the motor housing 1002, and the battery housing are coupled together, they define the main unit 12 of the vacuum cleaner 10.

[0185] The length of the motor assembly 1000 is longer than the exposed portion of the battery assembly 2000. When disassembled, the battery assembly 2000 is slightly longer than the motor assembly 1000 by approximately 1 cm.

[0186] Each of the bottle body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 defines the outer surface of the main unit 12. The outer diameters of each of the bottle body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 are common at 38 mm, whereby the main unit 12 has a substantially constant outer diameter of 38 mm. In an alternative example, the main unit 12 has a maximum outer diameter, and one or more of the bottle body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 share a maximum outer diameter of 38 mm. In a further example, each of the bottle body 108, the motor housing 1002 of the motor assembly, and the outer sleeve 2018 of the battery assembly 2000 share a maximum outer diameter of 38 mm. The maximum outer diameter may be 50 mm or less.

[0187] The longitudinal central axis CL of the main unit 12 is disposed substantially perpendicular to the horizontal plane HS to be cleaned, and the end of the main unit 12 corresponding to the first connecting cuff 110 of the bin assembly 102 is disposed closer to the horizontal plane HS to be cleaned than the outer sleeve 2018 of the battery assembly 2000, and the motor assembly 1000 is disposed above the separation system 100. Such an orientation of the main unit 12 can be seen in FIG. 45.

[0188] The longitudinal central axis CL of the main unit 12 is disposed substantially perpendicular to the horizontal plane HS to be cleaned, and the end of the main unit 12 corresponding to the first connecting cuff 110 of the bin assembly 102 is disposed closer to the horizontal plane HS to be cleaned than the outer sleeve 2018 of the battery assembly 2000, and the battery assembly 2000 is disposed above the separation system 100. Such an orientation of the main unit 12 can be seen in FIG. 45.

[0189] The longitudinal central axis CL of the main unit 12 is disposed substantially perpendicular to the horizontal plane HS to be cleaned, and the end of the main unit 12 corresponding to the first connecting cuff 110 of the bin assembly 102 is disposed closer to the horizontal plane HS to be cleaned than the outer sleeve 2018 of the battery assembly 2000, and a part of the battery assembly 2000 is disposed above the motor assembly 1000. Such an orientation of the main unit 12 can be seen in FIG. 45.

[0190] When the cleaner head 3000 is connected to the main unit 12, the central axes of the main unit 12 and the neck portion 3004 of the cleaner head 3000 are common, and the central axis is the longitudinal central axis CL of the main unit 12.

[0191] With the common central axis positioned perpendicular to the horizontal plane HS on which the cleaner head 3000 is disposed, the main cleaner head housing 3002 has a generally rectangular shape when viewed in the direction along the common central axis, and the common central axis is orthogonal to and intersects the short-axis central axis of the main cleaner head housing 3002. A pair of brush bars 3012 are positioned on both sides such that the brush bars in each pair face each other with respect to the short-axis central axis.

[0192] With the cleaner head 3000 connected to the main unit 12, the cleaner head 3000 placed on the horizontal plane HS to be cleaned, and the longitudinal central axis CL of the main unit 12 disposed substantially perpendicular to the horizontal plane HS to be cleaned, the cleaner head central axis CC is parallel to the longitudinal central axis CL of the main unit 12 but is spaced apart from the longitudinal central axis CL of the main unit 12. The orthogonal distance between the central axis CC of the cleaner head and the longitudinal central axis CL of the main unit 12 is approximately 20 mm.

[0193] The cleaner head 3000 is connected to the main unit 12, the cleaner head 3000 is placed on the horizontal surface HS to be cleaned, and with the longitudinal central axis CL of the main unit 12 being arranged substantially perpendicular to the horizontal surface HS to be cleaned, as shown in FIG. 47, the rotation axis of each brush bar 3012 is inclined obliquely with respect to the longitudinal central axis CL of the main unit 12.

[0194] With the cleaner head 3000 connected to the main unit 12, the engaging end portion 158 of the bin interlock member 115 is biased upward by the free end 3030 of the neck portion 3004 of the cleaner head 3000, and the engaging end portion 158 of the bin interlock member 115 engages with the contact surface 338 of the electrical connection portion 318 to suppress the relative movement of the bin body 108 with respect to the core 300. The cleaner head catch 3040 of the neck portion 3004 of the cleaner head 3000 engages with the engaging lip 142 of the first connecting cuff 110 to hold the cleaner head 3000 with respect to the main unit 12.

[0195] During use, the user can turn on the power of the vacuum cleaner 10 by using the power button 1108, and the power is supplied from the battery assembly 2000 to the suction motor 1004. The vacuum cleaner 10 can operate in any one of a low power mode, a medium power mode, or a high power mode. When the vacuum cleaner 10 is first powered on, the vacuum cleaner operates in the medium power mode, and the user can toggle the mode button 1110 to switch the operation mode. Those skilled in the art will recognize that the default operation mode at power-on may be configured to be the low power mode or the high power mode, and the actual operation mode implemented is left as a design choice. The suction motor 1004 causes the impeller 1056 to rotate and generates an air flow through the main unit 12 and the cleaner head 3000.

[0196] The user can grip the outer sleeve 2018 of the battery assembly 2000 that defines the handle portion of the main unit 12, and by moving the arm, can operate the cleaner head 3000 on the surface to be cleaned. Electric power is supplied from the battery assembly 2000 to the cleaner head 3000 via the harness assembly 1013, the electrical connection portion 318 of the core 300, and the cleaner head electrical connection portion 3036 of the cleaner head 3000. The drive motor 3014 drives the rotation of the brush bar 3012 within the internal chamber 3006, and the brush bar 3012 acts to sweep the surface to be cleaned. The drive motor 3014 drives the rotation of the brush bar 3012 to rotate so that the dust on the surface is swept towards the central axis CC of the cleaner head.

[0197] The airflow path through the vacuum cleaner 10 is schematically shown in FIGS. 48 and 49. The airflow enters the cleaner head 3000 through the airflow inlet 3010 together with the entrained dust and the like. The airflow passes through the internal chamber 3006 and exits the cleaner head 3000 via the flexible duct 3018 and the free end 3030 of the second tubular body 3026 of the neck portion 3004.

[0198] The airflow passes through the separation system 100 via the first connection cuff 110 and flows through the airflow inlet 140. Due to the force of the airflow passing through the vacuum cleaner 10, the valve member 366 pivots from its closed position to its open position in the downstream direction, enabling the airflow to enter the internal space of the bin body 108 through the airflow inlet 140. The bulk direction of the airflow at the airflow inlet 140 is the direction away from the airflow inlet 140 and is substantially parallel to the longitudinal central axis CL of the main unit 12. The bulk direction of the airflow at the airflow inlet 140 is considered to be the direction from the bottom of the bin assembly 102 to the top of the bin assembly 102 when the longitudinal central axis CL of the main unit 12 is arranged substantially perpendicular to the horizontal cleaning plane HS and the end of the main unit 12 corresponding to the bin assembly 102 is arranged closer to the horizontal cleaning plane HS than the battery assembly 2000. With this arrangement, the dust is compressed against the wiper 114.

[0199] The airflow flowing through the bin body 108 flows on the primary mesh 202 of the separator cartridge 200 in a bulk direction generally parallel to the longitudinal central axis CL of the main unit 12. When the airflow flows over the primary mesh 202, the airflow passes through the through-holes of the primary mesh 202, and the primary mesh 202 acts to filter relatively large dust from the airflow. The dust filtered in this way is collected in the coarse dust collection chamber 122 defined by the bin body 108. The valve assembly 304 covers at least a part of the bottom of the chamber 122 such that the airflow inlet 140 to the separation system 100 is provided within the plane of the valve assembly 304. Thus, the airflow enters the chamber 122 at the valve assembly 304 and flows in the manner described above.

[0200] Next, the airflow that has passed through the primary mesh 202 flows over the filter medium 208 in a direction substantially perpendicular to the longitudinal central axis CL of the main unit 12 and passes through the filter medium 208. The filter medium 208 functions to filter dust from the airflow, and such dust is relatively fine compared to the dust filtered by the primary mesh 202. The filtered dust accumulates on the filter medium 208, and the airflow passes from the filter medium 208 toward the auxiliary mesh 312.

[0201] The airflow flows through the auxiliary mesh 312 in a direction substantially perpendicular to the longitudinal central axis CL of the main unit 12. The auxiliary mesh 312 may be the same as the primary mesh and functions to prevent dust from entering the exhaust channel 310 during removal of the filter assembly 200. In another embodiment, the auxiliary mesh 312 functions to filter dust from the airflow, and such dust is relatively fine compared to the dust filtered by the filter medium 208. The filtered dust accumulates on the auxiliary mesh 312, and the airflow passes from the auxiliary mesh 312 to the exhaust channel 310. The airflow passes through the exhaust channel 310, through the exhaust duct 314, exits the separation system 100, and enters the motor assembly 1000.

[0202] After passing through the impeller, the airflow passes through the diffuser stage 1058 in a bulk direction substantially parallel to the longitudinal central axis CL of the main unit 12. The airflow exits the diffuser stage 1058 and is split at the PCB receptacle 1078 of the electronics chassis 1012 of the motor assembly 1000. Thus, the airflow is located in a plane having opposing sides defined by the first portion 1066 of the motor control circuit board 1008. The airflow flows through the motor exit passage 1079 toward the first airflow outlet 1036 and the second airflow outlet 1038. Next, as shown in FIG. 49, the airflow exits the motor housing 1002 via the first airflow outlet 1036 and the second airflow outlet 1038, which form a Y-shaped airflow.

[0203] During use of the vacuum cleaner 10, the coarse dust collection chamber 122 becomes filled with dust. Therefore, the user may wish to empty the dust from the coarse dust collection chamber 122. To do so, the user must first remove the cleaner head 3000 from the main unit 12. The user can release the cleaner head catch 3040 of the neck portion 3004 of the cleaner head 3000 from engagement with the engagement lip 142 of the first connecting cuff 110 and slide the main unit 12 in a direction substantially parallel to the longitudinal central axis CL of the main unit 12 away from the cleaner head 3000.

[0204] With the free end 3030 of the neck portion 3004 of the cleaner head 3000 removed from the first connecting cuff 110, the free end 3030 of the neck portion 3004 no longer engages with the engaging end portion 158 of the bin interlock member 115, and the engaging end portion 158 of the bin interlock member 115 no longer engages with the contact surface 338 of the electrical connection portion 318 of the core 300. Therefore, the bin interlock member 115 no longer restricts the movement of the bin body 108 relative to the core 300.

[0205] The user can release the bin catch 1040 from engagement with the bin catch receiving portion 144 and, by gripping the bin body 108, slide the bin body 108 in a direction away from the motor assembly 1000. The bin body 108 slides in a direction substantially parallel to the longitudinal central axis CL of the main unit 12 and away from the motor assembly 1000. As the bin body 108 slides in a direction away from the motor assembly 1000, the guide rails 120 slide along the guide surfaces 332 of the main body 302 of the core, and the guide rails 120 each contact the first contact portion 358 and the second contact portion 360 of the rigid member 344 of the valve assembly 304.

[0206] As the bottle body 108 continues to slide, each of the guide rails 120 contacts the first contact portion 358 and the second contact portion 360 of the rigid member 344 of the valve assembly 304, and by this contact, the valve member 366 is pushed to the open upstream position and held at its open upstream position. In such a position, the valve member 366 is positioned substantially parallel to the longitudinal central axis CL of the main unit 12, and dust can pass through the valve member 366 and fall from the first connecting cuff 110 of the bottle assembly 102. When the bottle body 108 slides relative to the core 300, the wiping member 152 contacts the upstream surface of the primary mesh 202, wipes dust from the upstream surface of the primary mesh 202, and the dust can pass through the valve member 366 and fall from the first connecting cuff 110 of the bottle assembly 102.

[0207] The bottle body 108 is slid away from the motor assembly 1000 until the bottle assembly 102 is separated from the filter assembly 200 and the core 300 and no longer covers them. By doing so, the user can remove the filter assembly 200 from the core 300 by moving the filter assembly 200 away from the core 300 in a direction substantially orthogonal to the longitudinal central axis CL of the main unit 12. When the filter assembly 200 is removed from the core 300, the auxiliary mesh 312 can capture the dust falling from the separator cartridge 200, thereby suppressing large dust from gathering in the exhaust channel 310 of the core body 302.

[0208] When the filter assembly 200 is removed from the core 300, the user can separate the mesh carrier 204 from the upper tray 2041 and the lower tray 2042 by releasing the end wall clip 224 of the mesh carrier 204 from the end wall lip 246 of the lower filter frame 210 and sliding the mesh carrier 204 out of the upper tray 2041 and the lower tray 2042. Thus, the primary mesh 202 can be separated from the filter medium 208. Thereafter, the user can clean the upper tray 2041 having the primary mesh 202 and the lower tray 2042 having the filter medium 208 separately.

[0209] Optionally, the user can reassemble the filter assembly 200 and reinstall the filter assembly 200 onto the core body 302. In one embodiment where the hygroscopic filter medium 208 is used, if the filter medium 208 is still wet, the filter medium 208 swells beyond a cage that prevents the upper tray 2041 and the lower tray 2042 from being assembled together. The bin body 108 is slid back over the combined filter assembly 200 and the core 300 and can be reinstalled onto the main unit 12. The cleaner head 3000 can be reinstalled onto the main unit 12 so that the user can resume cleaning if necessary or so that the vacuum cleaner 10 can be stored when cleaning is complete.

[0210] To store the vacuum cleaner 10, the user 10 can position the vacuum cleaner 10 relative to the dock 4000. The dock 4000 stands independently on the horizontal surface to be cleaned. To position the vacuum cleaner 10 relative to the dock 4000, the cleaner head 3000 is disposed on the upper base body 4008 of the dock 4000 such that the main cleaner head housing 3002 abuts against the cleaner head contact surface 4032 of the first arm portion 4012 of the holding arm 4004. The second tubular body 3026 of the neck portion 3004 of the cleaner head 3000 is located within the cleaner head receiving channel 4035 in the third arm portion 4012, and the cleaner head 3000 is configured to contact the dock 4000 at two locations with a vertical spacing therebetween. The holding arm 4004 can also be regarded as partially surrounding the main cleaner head housing 3002 when the cleaner head 3000 is positioned on the dock 4000. Regarding the fact that the dock 4000 and the cleaner head 3000 are in contact at two locations, the contact portions of the dock 4000 can be regarded as the abutting portions of the dock, and such contact can function to maintain the vacuum cleaner 10 in a substantially upright position relative to the horizontal surface to be cleaned when the cleaner head 3000 is positioned on the dock 4000.

[0211] With the second tubular body 3026 of the neck portion 3004 of the cleaner head 3000 positioned within the cleaner head receiving channel 4035, the positioning magnet 4022 of the dock 4000 interacts with the positioning magnetic portion 3038 of the cleaner head 3000 to hold the cleaner head 3000, and thus more generally the vacuum cleaner 10, relative to the dock 4000. The posture of the vacuum cleaner 10 within the dock 4000 can be considered as an upright posture and / or a vertical posture. The first spring-loaded charging contact 4024 and the second spring-loaded charging contact 4026 of the dock 4000 are in contact with the first and second charging contacts 3032 of the second tubular body 3026 of the cleaner head 3000. Power is transmitted from the dock 4000 to the cleaner head 3000 and from the cleaner head 3000 via the main unit 12 to the battery assembly 2000 by a power source electrically connected to the charging port 4014 of the dock 4000, enabling the battery assembly 2000 to be recharged.

[0212] In parallel with the battery assembly 2000 charged via the cleaner head, an additional battery assembly can also be charged, and the additional battery assembly is disposed within the battery receiving opening 4016.

[0213] Also, it will be understood that the battery assembly 2000 can be charged via the battery receiving opening 4016 without the need to charge through the cleaner head 3000, whether when a portion of the vacuum cleaner 10 other than the cleaner head 3000 is held by the dock or when a portion of the vacuum cleaner 10 other than the cleaner head 3000 is at a position separated from the dock.

[0214] To remove the battery assembly 2000 from the motor housing 1002, the user can activate the battery catch mechanism 1022 to disengage the hook 1094 from engagement with the positioning recess 2048 of the battery assembly 2000, thereby enabling the battery assembly 2000 to slide relative to the motor assembly 1000. The user can grip the outer sleeve 2018 of the battery assembly 2000 and slide the battery assembly 2000 away from the motor assembly in a direction parallel to the longitudinal central axis CL of the main unit 12.

[0215] Alternative tools for the cleaner head 3000 can also be used interchangeably with the main unit 12, and such tools are connected to the main unit 12 in the same manner as described for the cleaner head 3000 above. It will be understood that such alternative tools may not necessarily include a charging function, but may include motor-driven components such as drive brush bars.

[0216] It will be understood that the separation system 100 may be considered to be a separator, dirt separator, dust separator, dirt separation system, or dust separation system in the context described herein.

[0217] In embodiments of the present disclosure, the vacuum cleaner may be provided in the aspects of the following clauses.

[0218] Clause 1. A vacuum cleaner comprising a main unit having a handle, a cleaner head housing, a neck portion for connecting to the main unit, the neck portion extending from the cleaner head housing, and a cleaner head including two or more brush bars disposed within the cleaner head housing, wherein the handle and the neck portion share a common central axis.

[0219] Clause 2. The vacuum cleaner according to Clause 1, wherein the cleaner head includes four brush bars disposed within the cleaner head housing.

[0220] The vacuum cleaner according to claim 1 or 2, wherein each of the brush bars is substantially a frustum of a cone.

[0221] The vacuum cleaner according to any one of claims 1 to 3, wherein each of the brush bars is rotatable about its respective brush bar axis, the cleaner head is located on the horizontal plane to be cleaned, and in a state where the common central axis faces a direction perpendicular to the horizontal plane to be cleaned, each brush bar axis forms an oblique angle with respect to the common central axis and / or forms an oblique angle with respect to the horizontal plane to be cleaned.

[0222] The vacuum cleaner according to any one of claims 1 to 4, wherein in a state where the common central axis faces a direction perpendicular to the horizontal plane on which the cleaner head is disposed, the cleaner head housing has a generally rectangular shape when viewed in the direction along the common central axis, and the common central axis is orthogonal to and intersects the central axis in the short side direction of the cleaner head housing.

[0223] The vacuum cleaner according to claim 5, wherein at least two brush bars are arranged so as to be located on both opposite sides of the central axis in the short side direction described above.

[0224] The vacuum cleaner according to any one of claims 1 to 6, wherein each brush bar includes an outer surface formed of nylon.

[0225] The vacuum cleaner according to any one of claims 1 to 7, wherein in a state where the common central axis faces a direction perpendicular to the horizontal plane on which the cleaner head is disposed, the cleaner head housing has a generally rectangular shape when viewed in the direction along the common central axis, the common central axis is orthogonal to the central axis in the longitudinal direction of the cleaner head housing, and is arranged at an interval from the central axis in the longitudinal direction of the cleaner head housing.

[0226] The vacuum cleaner according to any one of claims 1 to 8, wherein the cleaner head includes a bias mechanism for offsetting the neck portion in a predetermined direction with respect to the cleaner head housing.

[0227] Item 10. The cleaner according to item 9, wherein in a state where the cleaner head is located on the cleaning horizontal surface, the bias mechanism is configured to displace the neck portion such that a common central axis extends substantially perpendicular to the cleaning horizontal surface.

[0228] Item 11. The cleaner according to item 9 or 10, wherein in a state where the cleaner head is located on the cleaning horizontal surface and the main unit is separated from the cleaner head, the bias mechanism is configured to displace the neck portion such that the central axis of the neck portion extends substantially perpendicular to the cleaning horizontal surface.

[0229] Item 12. The cleaner according to any one of items 1 to 12, comprising a separation system, a suction motor for generating an air flow through the separation system, and a battery assembly for supplying power to the suction motor, wherein the separation system, the suction motor, and the battery assembly are aligned along a common central axis.

[0230] Item 13. The cleaner according to item 12, wherein the battery assembly defines a handle.

[0231] Item 14. The cleaner according to item 12 or 13, wherein the separation system is a non-cyclone separation system.

[0232] Item 15. The cleaner according to any one of items 12 to 14, wherein the separation system has a central axis that is coaxial with the common central axis.

[0233] Item 16. The cleaner according to any one of items 12 to 15, wherein the suction motor has a rotation axis that is coaxial with the common central axis.

[0234] Item 17. The cleaner according to any one of items 12 to 16, wherein the battery assembly has a central axis that is coaxial with the common central axis.

[0235] Item 18. The vacuum cleaner according to any one of Items 12 to 17, wherein the suction motor is disposed between the separation system and the battery assembly.

[0236] Item 19. The vacuum cleaner according to any one of Items 12 to 18, wherein the separation system includes an air inlet, and the direction of the bulk air flow through the air inlet is parallel to a common central axis.

[0237] Item 20. The vacuum cleaner according to any one of Items 12 to 19, wherein the separation system includes a bin body, the suction motor is housed in a motor housing, the battery assembly includes a battery housing, and the bin body, the motor housing, and the battery housing are coupled to each other to define a main unit of the vacuum cleaner.

[0238] Item 21. The vacuum cleaner according to Item 20, wherein the bin body, the motor housing, and the battery housing are each an elongated tubular portion.

[0239] Item 22. The vacuum cleaner according to Item 20 or Item 21, wherein the main unit has a maximum outer diameter, and one or more of the bin body, the motor housing, and the battery housing share the maximum outer diameter.

[0240] Item 23. The vacuum cleaner according to Item 22, wherein the maximum outer diameter is 50 mm or less.

[0241] Item 24. The vacuum cleaner according to Item 23, wherein the maximum outer diameter is 38 mm.

[0242] Item 25. The vacuum cleaner according to any one of Items 22 to 24, wherein two or more of the bin body, the motor housing, and the battery housing have the same maximum outer diameter.

[0243] Item 26. The vacuum cleaner according to any one of Items 1 to 25, wherein the neck portion is movably attached to the cleaner head housing.

[0244] Item 27. The cleaner according to item 26, comprising first and second arms with a neck portion pivotally connected to a cleaner head housing.

[0245] Item 28. The cleaner according to item 27, wherein the neck portion includes a tubular body, and in a state where a common central axis is oriented in a direction perpendicular to a horizontal plane on which the cleaner head is disposed, the common central axis is parallel to the central axis of the cleaner head and is spaced from the central axis of the cleaner head, and the first and second arms form an oblique angle with respect to the tubular body.

[0246] In another embodiment of the present disclosure, the cleaner may be provided in the aspects of the following items.

[0247] Item 1. A cleaner including a separation system, a suction motor for generating an air flow through the separation system, and a control circuit for controlling the suction motor, wherein the control circuit is mounted on a control circuit board, and the control circuit board defines a plane extending in a direction parallel to the rotation axis of the suction motor.

[0248] Item 2. The cleaner according to item 1, wherein the control circuit board is disposed downstream of the suction motor.

[0249] Item 3. The cleaner according to item 1 or 2, wherein the control circuit board is arranged such that, during use, the air flow downstream of the suction motor is divided by a plane having opposing first and second sides defined by the control circuit board to form a Y-shaped air flow.

[0250] Item 4. The cleaner according to any one of items 1 to 3, wherein the suction motor and the control circuit board are housed in a common chassis.

[0251] Item 5. The cleaner according to item 4, wherein the suction motor is flexibly mounted in the common chassis and the control circuit board is rigidly mounted in the common chassis.

[0252] Item 6. The suction motor is housed within a first portion of a common chassis, the control circuit board is housed within a second portion of the common chassis, and the second portion of the common chassis is fluidly separated from the first portion of the common chassis. The vacuum cleaner according to item 4 or item 5.

[0253] Item 7. The vacuum cleaner according to item 6, wherein an air flow filter is not disposed between the suction motor and the control circuit board.

[0254] Item 8. The vacuum cleaner according to item 6 or item 7, wherein an electrical cable extends between the second portion of the common chassis and the first portion of the common chassis, and the second portion of the common chassis includes a sealing member through which the electrical cable passes.

[0255] Item 9. The vacuum cleaner according to any one of items 6 to 8, wherein the second portion of the common chassis at least partially defines first and second air flow paths downstream of the suction motor.

[0256] Item 10. The vacuum cleaner according to any one of items 4 to 9, wherein the common chassis includes a first chassis half and a second chassis half, and the first chassis half and the second chassis half are separate components that define the common chassis when the two halves are joined together.

[0257] Item 11. The vacuum cleaner according to any one of items 1 to 10, wherein the vacuum cleaner includes a motor housing in which the suction motor and the control circuit board are disposed, and the motor housing includes first and second air flow outlets that are disposed in a plane having opposing sides defined by the control circuit board.

[0258] Item 12. The vacuum cleaner according to item 11, which is dependent on item 9, wherein the common chassis is disposed within the motor housing, and the first and second air flow paths are each in fluid communication with one of the first and second air flow outlets.

[0259] Item 13. The vacuum cleaner according to any one of Items 1 to 12, wherein the control circuit board has a generally rectangular cross-sectional shape, and the major axis of the control circuit board extends in a direction parallel to the rotation axis of the suction motor.

[0260] Item 14. The vacuum cleaner according to Item 13, wherein the minor axis dimension of the control circuit board substantially corresponds to the outer diameter of the suction motor.

[0261] Item 15. The vacuum cleaner according to Item 14, wherein the minor axis dimension of the control circuit board is less than 38 mm.

[0262] Item 16. The vacuum cleaner according to any one of Items 1 to 15, wherein the vacuum cleaner includes a battery assembly including a plurality of battery cells arranged in a row, the control circuit board has a generally rectangular cross-sectional shape, and the major axis of the control circuit board extends in a direction parallel to the row of battery cells.

[0263] Item 17. The vacuum cleaner according to any one of Items 1 to 17, wherein the separation system includes a central separation system axis, the control circuit board has a generally rectangular cross-sectional shape, and the major axis of the control circuit board extends in a direction parallel to the central separation system axis.

[0264] Item 18. The vacuum cleaner according to any one of Items 1 to 17, wherein the separation system includes an air flow inlet, the control circuit board has a generally rectangular cross-sectional shape, and the major axis of the control circuit board extends in a direction parallel to the direction of the bulk air flow passing through the air flow inlet.

[0265] Item 19. The vacuum cleaner according to any one of Items 1 to 19, wherein the vacuum cleaner includes a battery assembly and a power connection circuit board connected to the battery assembly and configured to supply power from the battery assembly to the suction motor, and the power connection circuit board defines a further plane orthogonal to the plane defined by the control circuit board.

[0266] Item 20. The vacuum cleaner according to Item 19, wherein the power connection circuit board and the control circuit board are combined to define a T-shaped structure.

[0267] Item 21. The power connection board is housed within a third portion of the common chassis, and the second portion of the common chassis is located between the first portion and the third portion of the common chassis. The vacuum cleaner according to item 13 or item 14, which is dependent on any one of items 6 to 9.

[0268] Item 22. The vacuum cleaner according to any one of items 1 to 21, including an acoustic foam disposed downstream of the suction motor.

[0269] Item 23. The vacuum cleaner according to any one of items 1 to 22, including a heat sink disposed downstream of the suction motor, and the heat sink is arranged to guide the air flow downstream of the suction motor.

[0270] Item 24. The vacuum cleaner according to item 23, wherein the heat sink includes a first heat sink member located on a first side of the rotation axis of the suction motor and a second heat sink member located on a second, opposite side of the rotation axis of the suction motor.

[0271] Item 25. The vacuum cleaner according to any one of items 1 to 24, including a user interface including a user interface circuit board, and the user interface circuit board defines an additional plane that is substantially rotated 90 degrees with respect to the plane defined by the control circuit board.

[0272] Item 26. The separation system includes a bin body, the suction motor and the circuit board are housed within a motor housing, the vacuum cleaner includes a battery assembly including a battery housing, the bin body, the motor housing and the battery housing are coupled to each other to define the main unit of the vacuum cleaner, the control circuit board has a generally rectangular cross-sectional shape, and the major axis of the control circuit board extends in a direction parallel to the longitudinal central axis of the main unit. The vacuum cleaner according to any one of items 1 to 25.

[0273] Item 27. The vacuum cleaner according to item 26, wherein the bin body, the motor housing, and the battery housing are each an elongated tube, and at least two of the bin body, the motor housing, and the battery housing have the same maximum width.

[0274] It should be understood that any feature described in relation to any embodiment can be used alone or in combination with any other feature described, and also in combination with one or more features of any other embodiment or any combination of one or more features of any other embodiment. Further, equivalents and modifications not described above may also be employed without departing from the scope of the appended claims.

Claims

1. A vacuum cleaner, comprising: a separation system; a suction motor for generating an air flow through the separation system; a motor housing for housing the suction motor; a battery assembly for supplying power to the suction motor, wherein the battery assembly is removably connected to the motor housing such that a first portion of the battery assembly is located within the motor housing.

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

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

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

5. The vacuum cleaner according to any one of claims 1 to 4, wherein the motor housing includes a battery catch mechanism configured to removably engage the battery assembly.

6. The vacuum cleaner according to claim 5, wherein the first portion of the battery assembly includes a positioning recess configured to removably engage the battery catch mechanism.

7. The vacuum cleaner according to any one of claims 1 to 6, wherein the battery assembly further includes a plurality of battery cells, and at least one battery cell is located within the first portion of the battery assembly.

8. The vacuum cleaner according to claim 7, wherein the battery assembly further includes a second portion for housing at least one battery cell.

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

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

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

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

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

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

15. The vacuum cleaner has a longitudinal central axis, and the separation system, the suction motor, and the battery assembly are aligned along the longitudinal central axis. The vacuum cleaner according to any one of claims 1 to 14.

16. The suction motor has a rotation axis that is coaxial with the longitudinal central axis. The vacuum cleaner according to claim 15.

17. The battery assembly has a central axis that is coaxial with the longitudinal central axis. The vacuum cleaner according to claim 15 or 16.

18. The separation system includes a bin body, the battery assembly includes a battery housing, and the bin body, the motor housing, and the battery housing are coupled to each other to define the main unit of the vacuum cleaner. The vacuum cleaner according to any one of claims 1 to 17.

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

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

21. The battery housing includes an outer sleeve formed at least partially from an anti-slip material. The vacuum cleaner according to claim 18 or 19.

22. The vacuum cleaner further includes a cleaner head assembly fluidly connected to the separation system. The vacuum cleaner according to any one of claims 1 to 21.

23. The cleaner head assembly according to claim 22, comprising at least two brush bars, each brush bar being conical.

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

25. The cleaner according to any one of claims 1 to 24, wherein the separation system has a length-to-diameter ratio of at least 0.

01.

26. The cleaner according to any one of claims 1 to 25, further comprising a main unit of a pole structure including the separation system, the suction motor, and the battery assembly.

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

28. The cleaner according to any one of claims 1 to 27, wherein the separation system is a non-cyclone separation system.

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

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

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

Images