Vacuum cleaner device, system, modular insert, and method of manufacture therefor

Abstract

A vacuum cleaner device comprises a collection tank portion and a suction head portion with a motor fan assembly configured to generate an airflow along an airflow path extending between a dirty air inlet and a clean air outlet. A separator plate is mountable between the collection tank portion and the suction head portion. The separator plate is configured to receive a first module insert or a second module insert.

Description

[0001] VACUUM CLEANER DEVICE, SYSTEM, MODULAR INSERT, AND METHOD OF MANUFACTURE THEREFOR

[0002] Field

[0003] The technology relates to the field of vacuum cleaner devices, specifically focusing on the design and manufacturing of modular vacuum cleaners with interchangeable components for various vacuum cleaner models.

[0004] Vacuum cleaners are essential tools for maintaining cleanliness in various environments, such as homes, offices, and workshops. There are numerous vacuum cleaner models available in the market, each designed to cater to specific cleaning needs and requirements. These models often differ in terms of their components, such as filters, motors, and valves, which are responsible for the overall performance and functionality of the vacuum cleaner.

[0005] One known vacuum cleaner system is disclosed in WO2012159124A1 , which describes a multi-functional cleaning and floor care system. This system includes a reservoir assembly and a wet / dry vacuum assembly. The reservoir assembly has a wheeled chassis and a reservoir defining an interior space for holding a fresh cleaning liquid, with its upper end defining an opening. The reservoir assembly further includes a spigot fluidly connected to the reservoir interior space, with the spigot having a valve that is adjustable between a fully open position and a fully closed position.

[0006] However, there are certain problems associated with the prior art vacuum cleaner systems. One of the main issues is the increased manufacturing cost due to the use of different components for each vacuum cleaner model. This leads to higher production expenses as multiple designs need to be created and maintained for each model. Additionally, having various components for each model complicates the assembly process, requiring more time and resources. Another problem with the prior art vacuum cleaner systems is the inefficient production line. The use of different components for each model requires separate production lines or frequent changeovers in the manufacturing process. This leads to inefficiencies in production, increased downtime, and higher production expenses.

[0007] Summary

[0008] According to a first aspect of the disclosure, a vacuum cleaner device is provided that comprises a collection tank portion and a suction head portion. The suction head portion includes a motor fan assembly configured to generate an airflow along an airflow path extending between a dirty air inlet and a clean air outlet. The device also includes a separator plate that is mountable between the collection tank portion and the suction head portion. The separator plate is configured to receive either a first module insert or a second module insert.

[0009] Optionally, the first module insert and the second module insert both comprise one or more operative components of the vacuum cleaner device. Optionally, the first module insert and the second module insert can comprise other components different from the operative components of the vacuum cleaner device. This configuration allows for easy assembly of different parts into the vacuum cleaning device which provides a platform for streamlined manufacture of different models of the vacuum cleaning device. Optionally, only the first module insert or the second module insert comprise one or more operative components of the vacuum cleaner device. Alternatively, one or both of the first module insert and the second module insert comprise no operative components or any other components of the vacuum cleaner device.

[0010] Optionally in some examples, the separator plate comprises a module recess configured to receive the first module insert or the second module insert. This feature allows for easy and secure mounting of the module inserts onto the separator plate.

[0011] Optionally in some examples, the first module insert or the second module insert is configured to be located on the airflow path and in fluid communication with the motor fan assembly when mounted on the separator plate. This configuration ensures that the operative components of the module inserts are effectively integrated into the airflow path of the vacuum cleaner device.

[0012] Optionally in some examples, the first module insert comprises first valve components corresponding to a first vacuum cleaner functionality. This feature allows for customization of the vacuum cleaner device to suit specific cleaning needs.

[0013] Optionally in some examples, the second module insert comprises second valve components corresponding to a second vacuum cleaner functionality. This feature provides additional customization options for the vacuum cleaner device.

[0014] Optionally in some examples, the first vacuum cleaner functionality is different from the second vacuum cleaner functionality. This feature allows for the vacuum cleaner device to be adapted for different cleaning tasks.

[0015] Optionally in some examples, the first module insert and the second module insert have standardised dimensions. This feature simplifies the manufacturing process of the vacuum cleaner device and reduces the number of unique components required.

[0016] Optionally in some examples, the vacuum cleaner device further comprises a filter mounted on the separator plate and configured to remove dirt and debris from the airflow in the vacuum cleaner device.

[0017] Optionally in some examples, vacuum cleaner device comprises a stackable housing. Optionally in some examples, the housing of the vacuum cleaner device is box-shaped. Optionally, in some examples, vacuum cleaner device comprises a stackable housing which is stackable on another box-shaped device or toolbox. Optionally, the stackable housing is a shape other than box-shaped. This feature provides a compact and efficient design for the vacuum cleaner device, making it easy to store and transport.

[0018] Optionally in some examples, the separator plate comprises guide legs configured to project into the collection tank portion and guide the separator plate into correct alignment with the collection tank portion. This feature ensures that the separator plate is correctly positioned within the housing.

[0019] Optionally in some examples, the vacuum cleaner device comprises a seal element between the collection tank portion and the suction head portion and configured to seal therebetween. This feature prevents leakage of air from the vacuum cleaner device.

[0020] Optionally in some examples, the first module insert and the second module insert are interchangeable. This feature allows for easy replacement or upgrading of the operative components of the vacuum cleaner device.

[0021] Optionally in some examples, the first module insert comprises a first module insert air inlet mounted on the airflow path and in fluid communication with the clean air outlet.

[0022] Optionally in some examples, the second module insert comprises a second module insert air inlet mounted on the airflow path and in fluid communication with the clean air outlet.

[0023] Optionally in some examples, the first module insert and the second module insert comprise module mounting holes configured to receive one or more fasteners and secure the respective module insert to the separator plate.

[0024] According to a second aspect of the disclosure, a vacuum cleaner device system is provided that comprises a collection tank portion and a suction head portion. The suction head portion includes a motor fan assembly configured to generate an airflow along an airflow path extending between a dirty air inlet and a clean air outlet. The system also includes a separator plate that is mountable in the housing between the collection tank portion and the suction head portion, a first module insert, and a second module insert. The separator plate is configured to receive either the first module insert or the second module insert. This system provides a flexible and customizable solution for various cleaning needs, thereby enhancing the utility and versatility of the vacuum cleaner device. Optionally in some examples, the first module insert or the second module insert are configured to be located on the airflow path and in fluid communication with the motor fan assembly when mounted on the separator plate.

[0025] According to a third aspect of the disclosure, a module insert for a vacuum cleaner device is provided. The vacuum cleaner device has a collection tank portion and a suction head portion. The suction head portion includes a motor fan assembly configured to generate an airflow along an airflow path extending between a dirty air inlet and a clean air outlet. Th module insert is interchangeable with another module insert.

[0026] In some examples, optionally, the module insert comprises one or more operative components of the vacuum cleaner device in a first arrangement and is arranged to be aligned on the airflow path and in fluid communication with the motor fan assembly when mounted on a separator plate. The module insert is interchangeable with another module insert having a different arrangement of one or more operative components of the vacuum cleaner device.

[0027] According to a fourth aspect of the disclosure, a method of manufacturing a vacuum cleaner device is provided. The method includes mounting a separator plate comprising a module recess in the vacuum cleaner device, and mounting either a first module insert or a second module insert in the module recess of the separator plate. This method simplifies the assembly process of the vacuum cleaner device and allows for customization of the device to suit specific cleaning needs.

[0028] Optionally in some examples, the first module insert comprises one or more operative components of the vacuum cleaner device in a first arrangement and the second module insert comprises one or more operative components of the vacuum cleaner device in a second arrangement.

[0029] Optionally in some examples, the method further includes mounting a filter on the separator plate. Optionally in some examples, the method further includes attaching a tool box to the vacuum cleaner device using mounting elements. This step provides additional storage space for cleaning tools and accessories, thereby enhancing the utility of the vacuum cleaner device.

[0030] Optionally in some examples, the method further includes selecting the first module insert or the second module insert based on a specific vacuum cleaner functionality.

[0031] Brief Description of the Drawings

[0032] Examples are described in more detail below with reference to the appended drawings. Figure 1 is a perspective view of the vacuum cleaner device according to an example; Figure 2 is an exploded perspective view of some components of a vacuum cleaner device according to an example;

[0033] Figure 2a is an exploded perspective view of some components of a vacuum cleaner device with an exemplary airflow path according to an example;

[0034] Figure 3 is a plan view of a module insert for a vacuum cleaner device according to an example;

[0035] Figure 4 is a perspective view with a partial cutaway of some components of a vacuum cleaner device according to some examples;

[0036] Figure 5 is a perspective view of a vacuum cleaner device with a first module insert and second module insert according to an example.

[0037] Detailed Description

[0038] The detailed description set forth below provides information and examples of the disclosed technology with sufficient detail to enable those skilled in the art to practise the disclosure.

[0039] Figure 1 illustrates an exemplary embodiment of the vacuum cleaner device 100. The vacuum cleaner device 100 is shown in a perspective view. The vacuum cleaner device 100 is designed to facilitate efficient cleaning operations by generating an airflow that carries dirt and debris from a dirty air inlet 108 to a collection tank 114. In one configuration, the vacuum cleaner device 100 comprises a housing 102, a suction head portion 104, and a collection tank portion 106. The housing 102 is designed to encase and protect the internal components of the vacuum cleaner device 100. The housing 102 is also designed to facilitate the flow of air through the vacuum cleaner device 100, from the dirty air inlet 108 to the collection tank portion 106. The housing 102 may be constructed from a durable material such as plastic or metal. Figure 1 and the other Figures generally indicate the housing 102 of the vacuum cleaner device 100. However, each of the suction head portion 104 and the collection tank portion 106 respectively have separate housings e.g. a suction head housing 102a and a collection tank housing 102b. In this way, the term housing 102 collectively refers to both the suction head housing 102a and the collection tank housing 102b. Hereinafter, the term housing 102 will be used to refer to the suction head housing 102a and the collection tank housing 102b individually or collectively.

[0040] In some implementations e.g. as shown in Figure 1 , the housing 102 is box-shaped, providing a compact and robust structure for the vacuum cleaner device 100. The housing 102 may be compatible with other toolboxes and stackable and I or securable with the other toolboxes. Whilst the examples shown in the Figures illustrate a vacuum cleaner device 100 with a box-shaped form, the housing 102 can be any suitable shape, e.g. a cylindrical shape. Indeed, in some examples the housing 102 of the vacuum cleaner device 100 is stackable on another toolbox or box-shaped device but the shape of the housing 102 itself is not box-shaped.

[0041] The housing 102 may include various features to facilitate the operation of the vacuum cleaner device 100. For example, the housing 102 may include mounting elements 112 for securely attaching a toolbox or other accessories. The housing 102 may optionally also include latches 160 for securing the collection tank portion 106 and the suction head portion 104 together. This means that the suction head portion 104 can be removed from the collection tank portion 106 by the user in order to empty a collection tank 114 within the collection tank portion 106.

[0042] In one example, the suction head portion 104 is a volume of the vacuum cleaner device 100 located within the housing 102 as shown in Figure 1. The suction head portion 104 contains one or more operative components of the vacuum cleaner device 100, such as the motor fan assembly 118 (best shown in Figure 2). The suction head portion 104 is designed to generate an airflow along an airflow path 130 within the vacuum cleaner device 100, drawing air in through the dirty air inlet 108 and exhausting clean air out through the clean air outlet 110. The term operative component is any component or mechanism within the vacuum cleaner device 100 which affects the operation of the vacuum cleaner device 100.

[0043] In some configurations, the collection tank portion 106 is a volume of the vacuum cleaner device 100 located within the housing 102 and remote from the operative components of the vacuum cleaner device 100 in the suction head portion 104. The collection tank portion 106 is designed to receive and store dirt, debris, or water contained in the airflow received at the dirty air inlet 108. The collection tank portion 106 is in fluid communication with the motor fan assembly 118 and the dirty air inlet 108, and is positioned on the airflow path 130. As mentioned above, the collection tank portion 106 may be removable for easy disposal of collected debris by the user e.g. by releasing the latches 160.

[0044] As shown in Figure 1 , the dirty air inlet 108 is mounted in the housing 102 in the suction head portion 104. The dirty air inlet 108 is designed to receive air carrying dirt and debris from a cleaning tool accessory, such as a hose (not shown) or other cleaning accessory (not shown). The dirty air inlet 108 is in fluid communication with the collection tank 114, allowing the airflow to pass from the dirty air inlet 108 to the collection tank 114.

[0045] In some examples, the housing 102 includes mounting elements 112. These mounting elements 112 are configured to securely attach a toolbox or other accessory to the housing 102. The mounting elements 112 may be designed to accommodate a variety of different accessories, providing flexibility in the use of the vacuum cleaner device 100.

[0046] Figure 2 shows an exploded perspective view of some components of a vacuum cleaner device 100 which will now be discussed in more detail.

[0047] In one example, the filter 116 is responsible for removing dirt and debris from the airflow in the vacuum cleaner device 100 before the airflow has enters from the motor fan assembly 118. In some examples the filter 116 is upstream of the motor fan housing 124 and removes small particulates from the airflow before entering the motor fan housing 124. In other examples, the vacuum cleaner device 100 comprises additional filters (not shown) which are located downstream of the motor fan assembly 118. For example, the additional filter can be mounted after the motor fan housing 124 on the airflow path 130.

[0048] The filter 116 may be made from a variety of materials suitable for trapping dirt and debris while allowing air to pass through. In some examples the filter 116 may be a pleated filter. In other examples, other types of filters can be used. The filter 116 may be designed to be easily removable and replaceable, facilitating regular maintenance of the vacuum cleaner device 100.

[0049] In some implementations, the motor fan assembly 118 is responsible for generating airflow within the device. The motor fan assembly 118 includes a motor 120 and a fan 122, which work together to draw air in through the dirty air inlet 108 and push it out through the clean air outlet 110. The motor fan assembly 118 may be designed to provide a high level of suction power, enabling the vacuum cleaner device 100 to effectively pick up dirt and debris.

[0050] In one configuration, the motor fan assembly 118 is housed within a motor fan assembly housing 124. The motor fan assembly housing 124 is designed to protect the motor 120 and the fan 122 from damage and to facilitate the efficient flow of air through the motor fan assembly 118. The motor fan assembly housing 124 may be constructed from a durable material such as plastic or metal.

[0051] In some examples, the motor fan assembly 118 includes a motor fan inlet 126 which is formed from part of the motor fan assembly housing 124. The motor fan inlet 126 is configured to receive airflow from the collection tank 114. The motor fan inlet 126 is designed to direct the airflow into the motor fan assembly 118.

[0052] In some examples the motor fan assembly 118 is connected to a power source which is selectively controlled by a user interface. The power source can be a battery and / or a mains power supply. The use of a battery or main power supply with a motor fan assembly 118 is known. Similarly, control of such a motor fan assembly 118 with a user interface is also known and will not be discussed in further detail. As mentioned above, the vacuum cleaner device 100 includes an airflow path 130 that extends between the dirty air inlet 108 and the clean air outlet 110. The airflow path 130 is designed to guide the flow of air through the vacuum cleaner device 100, ensuring that the air passes through the collection tank 114, filter 116 and the motor fan assembly 118. The airflow path 130 can also pass through one or more operative components of the vacuum cleaner device 100 as discussed below. The airflow path 130 may be designed to minimise resistance to the flow of air, maximising the efficiency of the vacuum cleaner device 100.

[0053] In some configurations, the vacuum cleaner device 100 includes a separator plate 132. The separator plate 132 is mountable in the housing 102 and is configured to separate the suction head portion 104 of the vacuum cleaner device 100 from the collection tank portion 106 of the vacuum cleaner device 100. In some examples, the separator plate 132 can be fixed to the suction head portion 104. In this case, both the suction head portion 104 and the separator plate 132 can be removed together when the suction head portion 104 is removed from the collection tank portion 106. In some examples, the separator plate 132 is part of the suction head portion 104 and forms an outer wall of the suction head portion 104. The separator plate 132 acts as a barrier separating the collection tank portion 106 from the suction head portion 104.

[0054] In one example, the separator plate 132 includes a filter mounting structure 134. The filter mounting structure 134 is designed to securely attach the filter 116 to the separator plate 132. The filter mounting structure 134 may include various features to facilitate the secure attachment of the filter 116, such as clips, screws, or other fastening mechanisms. The filter mounting structure 134 may be designed to allow for easy removal and replacement of the filter 116, facilitating regular maintenance of the vacuum cleaner device 100.

[0055] In some implementations, the separator plate 132 includes guide legs 136. The guide legs 136 are designed to project into the collection tank portion 106 and guide the separator plate 132 into correct alignment with the collection tank portion 106. The guide legs 136 may be designed to provide a secure fit while also allowing for easy removal and replacement of the separator plate 132. The guide legs 136 may be constructed from a durable material such as plastic or metal. In one configuration, the vacuum cleaner device 100 includes a seal element 138. The seal element 138 is designed to seal against the wall of the housing 102, preventing the escape of air from the vacuum cleaner device 100 between the suction head portion 104 and the collection tank portion 106. The seal element 138 may be made from a flexible material such as rubber or silicone to provide a tight seal while also allowing for easy removal and replacement of the separator plate 132.

[0056] In some examples, the separator plate 132 optionally includes a module recess 140. The module recess 140 is designed to receive a module insert, such as the first module insert 144 or the second module insert 152, which are described in more detail below. The module recess 140 may be designed to provide a secure fit for the module insert while also allowing for easy removal and replacement of the module insert.

[0057] The module recess 140 provides a convenient way of aligning the first module insert 144 or the second module insert 152 in a predetermined position. However, in other examples, the module recess 140 is not used and the first module insert 144 or the second module insert 152 can be aligned and mounted using other features e.g. ribs, peg etc.

[0058] In one implementation, the separator plate 132 includes module mounting holes 142. The module mounting holes 142 are designed to receive one or more fasteners, such as screws or bolts, and secure the module insert to the separator plate 132. The module mounting holes 142 may be located around the module recess 140, providing multiple points of attachment for the module insert.

[0059] In some configurations, the vacuum cleaner device 100 includes a first module insert 144 as shown in Figure 2. The first module insert 144 comprises one or more operative components of the vacuum cleaner device 100, such as valve components or other mechanisms. The first module insert 144 is designed to be located on the airflow path 130 when mounted on the separator plate 132, allowing it to interact with the airflow in the vacuum cleaner device 100. The first module insert 144 may be designed to provide a specific functionality for the vacuum cleaner device 100, such as a specific cleaning mode or operation. In one example, the first module insert 144 includes first module insert mounts 146. The first module insert mounts 146 are designed to align with the module mounting holes 142 on the separator plate 132. When the first module insert 144 is mounted on the separator plate 132, the first module insert mounts 146 receive one or more fasteners, such as screws or bolts, securing the first module insert 144 to the separator plate 132. The first module insert mounts 146 may be designed to provide a secure fit while also allowing for easy removal and replacement of the first module insert 144.

[0060] In some implementations, the first module insert 144 includes a first module insert air inlet 148 (best shown in Figure 3) and a first module insert air outlet 164. The airflow path 130 extends through the first module insert 144 from the first module insert air inlet 148 to the first module insert air outlet 164. The first module insert air inlet 148 and the first module insert air outlet 164are designed to be mounted on the airflow path 130 and in fluid communication via the motor and fan of the motor fan assembly 118 with the clean air outlet 110 when the first module insert 144 is mounted on the separator plate 132. The first module insert air inlet 148 allows the airflow to pass through the first module insert 144, interacting with the operative components of the first module insert 144.

[0061] The airflow path 130 through the vacuum cleaner device will now be discussed in reference to Figure 2a. Figure 2a is an exploded perspective view of some components of a vacuum cleaner device 100 with an exemplary airflow path 130 according to an example.

[0062] The airflow through the vacuum cleaner device 100 is shown by airflow arrows 2, 4, 6, 8, 10, 12, 14, 16, 18. Dirty air enters the vacuum cleaner device 100 at the dirty air inlet 108 as shown by arrow 2. The airflow is then directed downward as shown by arrow 4 through the curved pipe 162. The air enters the collection tank 114 from the curved pipe 162 as shown by arrow 6. The air may then swirl in the collection tank 114 and deposit dirt and debris entrained in the airflow in the collection tank 114. Then the air in the collection tank 114 exits the collection tank 114 by passing through the filter 116 as shown by arrow 8.

[0063] The air exhausts from the filter 116 as shown by arrow 10 and then the air enters the first module insert 144 as shown by arrow 12 at the first module insert air inlet 148. The air exits the first module insert 144 via the first module inset air outlet 164 as shown by arrow 14. As discussed above, the airflow may flow through one or more operative components of the first module insert 144 as discussed in more detail with respect to Figure 3. However, in other examples, there may be no operative components in the first module insert 144.

[0064] The first module insert air outlet 164 comprises a rim 166 for engaging the motor fan assembly 118. The air exits the first module insert air outlet 164 and enters the motor fan inlet 126 as shown by arrow 16. The air then flows through the motor fan assembly 118 along the curve volute 168 surrounding the fan 122 until the air exits the motor fan assembly 118 at the motor fan outlet 128 as indicated by arrow 18. As discussed above, the motor fan outlet 128 is in fluid communication with the outlet 110.

[0065] Figure 3 provides a plan view of the first module insert 144. The first valve components 150 are operative components of the vacuum cleaner device 100 that provide a specific functionality, such as a specific cleaning mode or operation.

[0066] In one configuration, the first valve components 150 are mounted on the first module insert 144. The first valve components 150 may include various mechanisms, such as valves, switches, or other components, that interact with the airflow in the vacuum cleaner device 100 to provide a specific functionality. The first valve components 150 may be designed to be easily removable and replaceable, facilitating regular maintenance of the vacuum cleaner device 100.

[0067] The term operative component is any component or mechanism within the vacuum cleaner device 100 which affects the operation of the vacuum cleaner device 100. Whilst Figure 3 shows the first module insert 144 with one or more operative components, in some examples, the first module insert 144 can comprise other components of the vacuum clear device 100 which do not affect the operation of the vacuum cleaner device 100, for example storage for a tool. Alternatively, in other examples, the first module insert 144 does not contain any operative components or other components. In this way, the first module insert 144 is an “inert” element and has no function.

[0068] Figure 4 provides a detailed view of the motor fan outlet 128 of the motor fan assembly 118. In some examples, the motor fan assembly 118 includes a motor fan outlet 128. The motor fan outlet 128 is designed to output the airflow from the motor fan assembly 118 to the clean air outlet 110. The motor fan outlet 128 may be designed to direct the airflow in a specific direction, maximising the efficiency of the vacuum cleaner device 100. The motor fan outlet 128 may be constructed from a durable material such as plastic or metal.

[0069] In one implementation, the motor fan assembly 118 includes a fan 122. The fan 122 is designed to accelerate the airflow within the motor fan assembly 118, drawing air in through the motor fan inlet 126 and exhausting it out through the motor fan outlet 128. The fan 122 may be designed to provide a high level of suction power, enabling the vacuum cleaner device 100 to effectively pick up dirt and debris. The fan 122 may be constructed from a durable material such as plastic or metal.

[0070] In some configurations, the motor fan assembly 118 includes a motor 120. The motor 120 is designed to drive the fan 122, generating the airflow within the vacuum cleaner device 100.

[0071] Figure 5 provides a detailed view of the vacuum cleaner device 100, the first module insert 144, and the second module insert 152.

[0072] Figure 5 also shows the clean air outlet 110 of the vacuum cleaning device 100. In one example, the clean air outlet 110 is mounted in the housing 102 in the suction head portion 104. The clean air outlet 110 is designed to expel the cleaned air from the vacuum cleaner device 100, after it has passed through the filter 116 and the motor fan assembly 118.

[0073] In some implementations, the vacuum cleaner device 100 includes a second module insert 152. The second module insert 152 comprises one or more operative components of the vacuum cleaner device 100, such as second valve components 158 or other mechanisms. The second module insert 152 is designed to be located on the airflow path 130 when mounted on the separator plate 132, allowing it to interact with the airflow in the vacuum cleaner device 100. The second module insert 152 may be designed to provide a specific functionality for the vacuum cleaner device 100, such as a specific cleaning mode or operation.

[0074] In one configuration, the second module insert 152 includes a second module insert air inlet 154. The second module insert air inlet 154 is designed to be mounted on the airflow path 130 and in fluid communication with the clean air outlet 110 when the second module insert 152 is mounted on the separator plate 132. The second module insert air inlet 154 allows the airflow to pass through the second module insert 152, interacting with the operative components of the second module insert 152. This is similar to the previously discussed first module insert 144.

[0075] In some examples, the second module insert 152 includes second module insert mounts 156. The second module insert mounts 156 are designed to align with the module mounting holes 142 on the separator plate 132. When the second module insert 152 is mounted on the separator plate 132, the second module insert mounts 156 receive one or more fasteners, such as screws or bolts, securing the second module insert 152 to the separator plate 132. The second module insert mounts 156 may be designed to provide a secure fit while also allowing for easy removal and replacement of the second module insert 152.

[0076] The arrangement of the second module insert mounts 156 on the second module insert 152 is identical to the arrangement of the first module insert mounts 146 on the first module insert 144. Furthermore, the cross-sectional area, shape, and size of the first module insert 144 is the same as the second module insert 152. This means that the first module insert 144 and the second module insert 152 are interchangeable on the same separator plate 132. However, in some examples as mentioned above, the first module insert 144 and the second module insert 152 are interchangeable whilst having differing cross-sectional areas, shapes and I or sizes.

[0077] In one implementation, the second module insert 152 includes second valve components 158. The second valve components 158 are operative components of the vacuum cleaner device 100 that provide a specific functionality, such as a specific cleaning mode or operation. The second valve components 158 may include various mechanisms, such as valves, switches, or other components, that interact with the airflow in the vacuum cleaner device 100 to provide the specific functionality. The second valve components 158 may be designed to be easily removable and replaceable, facilitating regular maintenance of the vacuum cleaner device 100.

[0078] Whilst Figure 5 shows the second module insert 152 with one or more operative components, in some examples, the second module insert 152 can comprise other components of the vacuum clear device 100 which do not affect the operation of the vacuum cleaner device 100, for example storage for a tool. Alternatively, in other examples, the second module insert 152 does not contain any operative components or other components. In this way, the second module insert 152 is an “inert” element and has no function.

[0079] In some examples, the first module insert 144 comprises first valve components 150 which provide a dry workshop vacuum functionality. In some other examples, the second module insert 152 comprises second valve components 158 that provides a wet-dry vacuum functionality e.g. including extra safety valves to prevent ingress of water into the suction head portion 104. Alternatively, the first module insert 144 can provide a different functionality from the second module insert 152. For example, the first module insert 144 may comprise additional filter elements e.g. a HEPA filter. Alternatively, the first module insert 144 may comprise an airflow path 130 that allows a different air flow speed or airflow volume when compared to the second module insert 152. In some examples, the first module insert 144 and the second module insert 152 comprise one or more operative components of the vacuum cleaning device 100 which are upstream and I downstream of the motor fan assembly 118.

[0080] The method of manufacturing a vacuum cleaner device 100 involves a series of steps designed to assemble the various components of the vacuum cleaner device 100 in a specific order. The method may be designed to maximise the efficiency of the manufacturing process, reducing the time and cost required to produce each vacuum cleaner device 100.

[0081] In one example, the method begins with the preparation of the various components of the vacuum cleaner device 100. This may involve the fabrication of the housing 102, the separator plate 132, and the first and second module inserts 144, 152. The components may be fabricated using a variety of manufacturing processes, such as moulding, machining, or 3D printing, depending on the specific requirements of each component.

[0082] In some implementations, the preparation of the housing 102 involves the fabrication of the housing 102 from a durable material such as ABS plastic or metal. The housing 102 may be fabricated using a moulding process, in which the material is heated and injected into a mould in the shape of the housing 102. Once the material has cooled and solidified, the housing 102 is removed from the mould and any excess material is trimmed away. In some other examples, the vacuum cleaner device 100 can be made using any other suitable methods.

[0083] In one configuration, the preparation of the separator plate 132 involves the fabrication of the separator plate 132 from a durable material such as plastic or metal. The separator plate 132 may be fabricated using a machining process, in which the material is cut and shaped using a variety of tools to achieve the desired shape and dimensions of the separator plate 132.

[0084] In some examples, the preparation of the first and second module inserts 144, 152 involves the fabrication of the first and second module inserts 144, 152 from a durable material such as plastic or metal. The first and second module inserts 144, 152 may be fabricated using a moulding process, similar to the process used to fabricate the housing 102. Once the first and second module inserts 144, 152 have been fabricated, the operative components of the vacuum cleaner device 100, such as the valve components, may be mounted on the first and second module inserts 144, 152.

[0085] In one implementation, the assembly process involves the assembly of the various components of the vacuum cleaner device 100 in a specific order. The assembly process may begin with the mounting of the separator plate 132 in the housing 102. The separator plate 132 may be secured in the housing 102 using a variety of fastening mechanisms, such as screws or clips. Once the separator plate 132 is securely mounted in the housing 102, the first or second module inserts 144, 152 may be mounted on the separator plate 132. The first or second module insert 144, 152 may be secured to the separator plate 132 using a variety of fastening mechanisms, such as screws or clips. Once the first or second module insert 144, 152 is securely mounted on the separator plate 132, the filter 116 may be mounted on the separator plate 132. The filter 116 may be secured to the separator plate 132 using a variety of fastening mechanisms, such as clips or screws. The motor fan assembly 118 may be secured in the housing 102 using a variety of fastening mechanisms, such as screws or clips.

[0086] In some configurations, the assembly process includes the selection of a module insert based on the specific functionality desired for the vacuum cleaner device 100. The first module insert 144 and the second module insert 152 each provide a different functionality for the vacuum cleaner device 100, and the appropriate module insert is selected based on the specific cleaning needs of the user. For example, the first module insert 144 may provide a functionality suitable for a workshop vacuum, while the second module insert 152 may provide a functionality suitable for a wet-dry workshop vacuum.

[0087] In one example, the first module insert 144 and the second module insert 152 are designed to be interchangeable, allowing the functionality of the vacuum cleaner device 100 to be easily changed by replacing the module insert. The first module insert 144 and the second module insert 152 have standardised dimensions, allowing either module insert to fit securely within the module recess 140 of the separator plate 132. This interchangeability of the module inserts simplifies the manufacturing process and reduces the number of unique components required for the vacuum cleaner device 100.

[0088] In one implementation, the use of interchangeable first and second module inserts 144, 152 simplifies the manufacturing process. By using standardised dimensions for the first and second module inserts 144, 152, the same separator plate 132 and housing 102 can be used for different models of the vacuum cleaner device 100. This reduces the number of unique components that need to be manufactured and assembled, simplifying the manufacturing process.

[0089] In some configurations, the use of interchangeable first and second module inserts 144, 152 reduces the number of unique components required for the vacuum cleaner device 100. This can result in cost savings in the manufacturing process, as fewer unique moulds and other manufacturing tools are required. It can also simplify the inventory management process, as fewer unique components need to be stocked.

[0090] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and / or "including" when used herein specify the presence of stated features, integers, actions, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, actions, steps, operations, elements, components, and / or groups thereof.

[0091] It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element without departing from the scope of the present disclosure.

[0092] Relative terms such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical" may be used herein to describe a relationship of one element to another element as illustrated in the Figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present.

[0093] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealised or overly formal sense unless expressly so defined herein. It is to be understood that the present disclosure is not limited to the aspects described above and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the present disclosure and appended claims. In the drawings and specification, there have been disclosed aspects for purposes of illustration only and not for purposes of limitation, the scope of the disclosure being set forth in the following claims.

Claims

CLAIMS1. A vacuum cleaner device (100) comprising: a collection tank portion (106) and a suction head portion (104) having a motor fan assembly (118) configured to generate an airflow along an airflow path (130) extending between a dirty air inlet (108) and a clean air outlet (110); a separator plate (132) mountable between the collection tank portion (106) and the suction head portion (104); wherein the separator plate (132) is configured to receive a first module insert (144) or a second module insert (152).

2. The vacuum cleaner device (100) according to claim 1 wherein, the first module insert (144) and I or second module insert (152) comprise one or more operative components of the vacuum cleaner device (100).

3. The vacuum cleaner device (100) according to claims 1 or 2, wherein the separator plate (132) comprises a module recess (140) configured to receive the first module insert (144) or the second module insert (152).

4. The vacuum cleaner device (100) according to any of claims 1 to 3, wherein the first module insert (144) or the second module insert (152) is configured to be located on the airflow path (130) and in fluid communication with the motor fan assembly (118) when mounted on the separator plate (132).

5. The vacuum cleaner device (100) according to any of claims 1 to 4, wherein the first module insert (144) comprises first valve components (150) corresponding to a first vacuum cleaner functionality.

6. The vacuum cleaner device (100) according to any of claims 1 to 5, wherein the second module insert (152) comprises second valve components (158) corresponding to a second vacuum cleaner functionality.

7. The vacuum cleaner device (100) according to claim 6 wherein the first vacuum cleaner functionality is different from the second vacuum cleaner functionality.

8. The vacuum cleaner device (100) according to any one of claims 1 to 7, wherein the first module insert (144) and the second module insert (152) have standardised dimensions.

9. The vacuum cleaner device (100) according to any one of claims 1 to 8, further comprising a filter (116) mounted on the separator plate (132) and configured to remove dirt and debris from the airflow in the vacuum cleaner device (100).

10. The vacuum cleaner device (100) according to any one of claims 1 to 9, wherein the vacuum cleaner device (100) comprises a stackable housing (102).

11. The vacuum cleaner device (100) according to any one of claims 1 to 10, wherein the separator plate (132) comprises guide legs (136) configured to project into the collection tank portion (106) and guide the separator plate (132) into correct alignment with the collection tank portion (106).

12. The vacuum cleaner device (100) according to any one of claims 1 to 11 , wherein the vacuum cleaner device (100) comprises a seal element (138) between the collection tank portion (106) and the suction head portion (104) configured to seal therebetween.

13. The vacuum cleaner device (100) according to any one of claims 6 to 12, wherein the first module insert (144) and the second module insert (152) are interchangeable.

14. The vacuum cleaner device (100) according to any one of claims 1 to 13, wherein the first module insert (144) comprises a first module insert air inlet (148) mounted on the airflow path (130) and in fluid communication with the clean air outlet (110).

15. The vacuum cleaner device (100) according to any one of claims 1 to 14, wherein the second module insert (152) comprises a second module insert air inlet (154) mounted on the airflow path (130) and in fluid communication with the clean air outlet (110).

16. The vacuum cleaner device (100) according to any one of claims 1 to 15, wherein the first module insert (144) and the second module insert (152) comprise module mounting holes (142) configured to receive one or more fasteners and secure the respective module insert to the separator plate (132).

17. A vacuum cleaner device (100) system comprising: a collection tank portion (106) and a suction head portion (104) having a motor fan assembly (118) configured to generate an airflow along an airflow path (130) extending between a dirty air inlet (108) and a clean air outlet (110); a separator plate (132) mountable in the housing (102) between the collection tank portion (106) and the suction head portion (104); a first module insert (144); a second module insert (152); wherein the separator plate (132) is configured to receive either the first module insert (144) or the second module insert (152).

18. A vacuum cleaner device (100) system according to claim 17 wherein the first module insert (144) or the second module insert (152) are configured to be located on the airflow path (130) and in fluid communication with the motor fan assembly (118) when mounted on the separator plate (132).

19. A module insert (144, 152) for a vacuum cleaner device (100) having a collection tank portion (106) and a suction head portion (104) having a motor fan assembly (118) configured to generate an airflow along an airflow path (130) extending between a dirty air inlet (108) and a clean air outlet (110) and a separator plate (132) mountable in the housing (102) between the collection tank portion (106) and the suction head portion (104), wherein the module insert (144, 152) is interchangeable with another module insert (144, 152).

20. The module insert (144, 152) according to claim 19 wherein the module insert (144, 152) comprises: one or more operative components of the vacuum cleaner device (100) in first arrangement and arranged to be aligned on the airflow path (130) and in fluidcommunication with the motor fan assembly (118) when mounted on the separator plate (132); wherein the module insert (144, 152) is interchangeable with another module insert (144, 152) having a different arrangement of one or more operative components of the vacuum cleaner device (100).

21. A method of manufacturing a vacuum cleaner device (100) according to any one of claims 1 to 16, the method comprising: mounting a separator plate (132) comprising a module recess (140) in the vacuum cleaner device (100); and mounting either a first module insert (144) or a second module insert (152) in the module recess (140) of the separator plate (132).

22. A method according to claim 21 wherein the first module insert (144) comprises one or more operative components of the vacuum cleaner device (100) in a first arrangement and the second module insert (152) comprises one or more operative components of the vacuum cleaner device (100) in a second arrangement.

23. The method according to claims 21 or 22 further comprising mounting a filter (116) on the separator plate (132).

24. The method according to any one of claims 21 to 23, further comprising attaching a toolbox to the vacuum cleaner device (100) using mounting elements (112).

25. The method according to any one of claims 21 to 24, further comprising selecting the first module insert (144) or the second module insert (152) based on a specific vacuum cleaner functionality.

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