Vacuum cleaner

Abstract

A vacuum cleaner includes an inlet, an airflow source, and a separator is in fluid communication with the inlet and the airflow source. The separator is configured to separate the debris from a suction airflow. The separator includes a separator inlet that receives the debris and the suction airflow, a separator outlet that discharges the suction airflow, a debris collector configured to store debris separated from the suction airflow, and a filter including a filter media and a frame. The filter media is configured to separate debris from the suction airflow. The frame includes an agitator that engages the filter media. A motor is operable to vibrate the agitator such that the agitator contacts the filter media to vibrate the filter media to dislodge debris from the filter media.

Description

Attorney Docket No. 025818-0159-W001VACUUM CLEANER CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No.63 / 740,359 filed December 31, 2024, and to U.S. Provisional Patent Application No. 63 / 843,410 filed July 14, 2025, and to U.S. Provisional Patent Application No. 63 / 843,427 filed July 14, 2025, the entire contents all of which are hereby incorporated by reference herein.BACKGROUND

[0002] The present disclosure relates to vacuum cleaners and a method of operating a vacuum cleaner.SUMMARY

[0003] In one embodiment the disclosure provides a vacuum cleaner includes an inlet, an airflow source in fluid communication with the inlet, the airflow source operable to generate a suction airflow configured to draw debris through the inlet. A separator is in fluid communication with the inlet and the airflow source, the separator is configured to separate the debris from the suction airflow. The separator includes a separator inlet that receives the debris and the suction airflow, a separator outlet that discharges the suction airflow, a debris collector configured to store debris separated from the suction airflow, and a filter including a filter media and a frame. The filter media is configured to separate debris from the suction airflow. The frame includes an agitator that engages the filter media. A motor is operable to vibrate the agitator such that the agitator contacts the filter media to vibrate the filter media to dislodge debris from the filter media. The airflow source further includes an impeller rotatable about an axis and an airflow source motor operable to rotate the impeller about the axis in a first direction to generate the suction airflow, the airflow source motor further operable to rotate the impeller about the axis in a second direction, opposite the first direction, to generate a discharge airflow, the discharge airflow configured to expel debris from the separator.

[0004] In another embodiment the disclosure provides a vacuum cleaner including an inlet, a airflow source in fluid communication with the inlet, the airflow source operable to generate a suction airflow configured to draw debris through the inlet. A separator is in fluidAttorney Docket No. 025818-0159-W001communication with the inlet and the airflow source, the separator configured to separate the debris from the suction airflow. The separator includes a separator inlet that receives the debris and the suction airflow, a separator outlet that discharges the suction airflow, a debris collector configured to store debris separated from the suction airflow, a filter including a filter media and a frame. The filter media is configured to separate debris from the suction airflow. The frame includes an agitator. A motor operable to vibrate the agitator such that the agitator vibrates the filter media to dislodge debris from the filter media. The agitator has a resonance frequency, and the motor vibrates at a motor vibration frequency to vibrate the agitator. The motor vibration frequency causes the agitator to resonate.

[0005] In another embodiment, the disclosure provides a method of operating a vacuum cleaner. The method includes generating a suction airflow to draw debris through an inlet using a airflow source in fluid communication with the inlet, separating debris from the suction airflow in a separator in fluid communication with the inlet and the airflow source, and separating debris from the suction airflow includes filtering debris from the suction airflow using a filter having a filter media and a frame. The filter media separates debris from the suction airflow between a separator inlet and a separator outlet and deposits the debris into a debris collector. The frame includes an agitator. The method further includes operating a motor at a motor vibration frequency and vibrating the agitator using the motor operating at the motor vibration frequency such that vibrating the agitator vibrates the filter media to dislodge debris from the filter media. Vibrating the agitator using the motor at the motor vibration frequency includes causing the agitator to resonate by vibrating the agitator at a resonance frequency of the agitator.

[0006] In another embodiment, the disclosure provides a method of operating a vacuum cleaner. The method includes generating a suction airflow to draw debris through an inlet using a airflow source in fluid communication with the inlet, and separating debris from the suction airflow in a separator in fluid communication with the inlet and the airflow source, separating debris from the suction airflow includes filtering debris from the suction airflow using a filter having a filter media and a frame, the filter media separates debris from the suction airflow between a separator inlet and a separator outlet and deposits the debris into a debris collector, the frame including an agitator. The method further includes operating a motor to rotate a weight to cause the motor to vibrate at a motor vibration frequency and vibrating the agitator using theAttorney Docket No. 025818-0159-W001motor operating at the motor vibration frequency such that vibrating the agitator vibrates the filter media to dislodge debris from the filter media. Operating the motor to vibrate at a motor vibration frequency includes changing the speed at which the motor rotates the weight to adjust the motor vibration frequency.

[0007] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig. 1 is a perspective view of a vacuum cleaner according to one embodiment.

[0009] Fig. 2 is a cross-sectional view of a portion of the vacuum cleaner of Fig. 1.

[0010] Fig. 3 is an alternative cross-sectional view of a portion of the vacuum cleaner of Fig.1.

[0011] Fig. 4 is an alternative cross-sectional view of a portion of the vacuum cleaner of Fig.1.

[0012] Fig. 5 is a perspective view of a filter frame and a motor housing of the vacuum cleaner of Fig. 1.

[0013] Fig. 6 is a schematic illustration of a portion of the vacuum cleaner of Fig. 1.

[0014] Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.DETAILED DESCRIPTION

[0015] Fig. 1 illustrates a vacuum cleaner 10. Referring to Fig. 2, the vacuum cleaner 10 includes an inlet 12, an airflow source 14, and a separator 16. The airflow source 14 is in fluid communication with the inlet 12 and the airflow source 14 is operable to generate a suctionAttorney Docket No. 025818-0159-W001airflow to draw debris through the inlet 12. As will be discussed in more detail below, the airflow source 14 is also operable to generate a discharge airflow to expel debris from the separator 16 to facilitate emptying the separator 16.

[0016] The airflow source 14 includes an impeller 20 and a motor 18 (Fig. 4). The motor 18 is operable to rotate the impeller 20 about an airflow source axis 22 in a first direction to generate the suction airflow and the motor 18 is also operable to rotate the impeller 20 about the axis 22 in a second direction, opposite the first direction, to generate a discharge airflow. The discharge airflow can be utilized to expel or empty debris from the separator 16 when the separator is opened. The vacuum cleaner 10 includes an airflow path that extends from the inlet 12, through the separator 16, through the airflow source 14, and through an exhaust 23. When the motor 18 rotates the impeller 20 about the axis 22 in the first direction, the suction airflow travels in a first airflow direction along the airflow path. The first airflow direction in the illustrated embodiment is from the inlet 12, through a passageway or inlet duct 30, then through the separator 16, including a filter 52, then through the airflow source 14, and then through the exhaust 23, creating a negative pressure or suction airflow within the passageway 30 and separator 16.

[0017] When the motor 18 rotates the impeller 20 about the axis 22 in the second direction, the discharge airflow travels in a second airflow direction along a discharge airflow path. The second airflow direction in the illustrated embodiment is from the exhaust 23, through the airflow source 14, through the filter 52 and the separator 16 and through a discharge opening to empty the separator 16, which will be discussed in more detail below.

[0018] In one embodiment, the motor 18 is a direct current (DC) motor and the vacuum cleaner 10 include battery 31 that powers the motor 18. Also, in one embodiment the motor 18 is a bi-polarity motor, or reversible motor, also referred to as a mixed-flow motor, that allows the motor 18 to rotate the impeller 20 about the axis 22 in either the first or second directions as discussed above by switching the polarity of the input voltage to the motor. The bi-polarity motor includes the mixed-flow impeller 20 that defines an angled flow segment 49 having an axial flow vector component and a radial flow vector component, the radial flow vector component configured to generate the suction airflow in the first airflow direction. The airflowAttorney Docket No. 025818-0159-W001source 14 further includes a diffuser 100. The diffuser 100 does not rotate about the axis 22. The motor 18 includes a shaft 102 that rotates about the axis 22 to rotate the impeller 20.Bearings 104 facilitate rotation of the shaft 102 relative to a stator 106.

[0019] Referring to Fig. 2, the vacuum cleaner 10 in the illustrated embodiment further includes a valve 33. The illustrated valve 33 is a check valve that rotates about a pivot 35. In other embodiments, the valve flexes or bends by airflow between open and closed positions. In the absence of airflow, the valve 33 is in the closed position such that the valve 33 is in the closed position when the airflow source 14 is off (i.e., not generating either the suction airflow or the discharge airflow). The valve 33 moves to an open position in response to the suction airflow and the valve 33 is forced toward the closed position in response to the discharge airflow such that the discharge airflow is directed through the separator 16 rather than through the inlet 12. The valve 33 can include a spring to move the valve to the closed position or the valve may be formed from an elastomeric material that returns to the closed position by its resilience. When the airflow source 14 is turned off and not generating either the suction airflow or the discharge airflow, the valve 33 automatically moves to the closed position. The valve 33 is adjacent to the inlet 12 in the illustrated embodiment, but in other embodiments, the valve 33 is adjacent to the connection between the inlet duct 30 and the separator 16, or in yet another location as desired. In other embodiments, other types of valves may be utilized. For example, the valve may include an actuator that opens and closes the valve based on operation of the airflow source 14. For example, the actuator may move the valve to the open position when the airflow source 14 is generating the suction airflow and to the closed position when the airflow source 14 is generating the discharge airflow. In such an embodiment, if the airflow source 14 is not generating either the suction airflow or the discharge airflow, the actuator may move the valve to the closed position. The actuator may include an electronic valve actuator powered by a battery. In yet other embodiments, the valve 33 may be omitted.

[0020] Referring to Fig. 1, in the illustrated embodiment, the vacuum cleaner 10 includes a removable and optional wand 24. The wand 24 includes a duct 26 and a floor nozzle 28. The duct 26 provides fluid communication between the floor nozzle 28 and the inlet 12 to direct debris and the suction airflow from the floor nozzle 28 to the inlet 12.Attorney Docket No. 025818-0159-W001

[0021] Referring to Figs. 2 and 3, the inlet duct 30 extends from the inlet 12 to the separator 16 to direct debris and the suction airflow from the inlet 12 to the separator 16. The separator 16 is in fluid communication with the inlet 12 via the inlet duct 30. The separator 16 includes a separator inlet 32 in fluid communication with the inlet duct 30. The separator inlet 32 receives the debris and the suction airflow from the inlet duct 30. The illustrated separator 16 includes a sidewall 34 having an inner surface 36 that is generally cylindrical. The separator 16 further includes a first end 38 and a second end 40 opposite the first end 38. The inner surface 36 extends from the first end 38 to the second end 40. The first end 38 includes a separator outlet 42 that discharges the relatively clean suction airflow from the separator 16 to the airflow source 14. The second end 40 includes a debris outlet 44. A debris collector 46 is adjacent the second end 40 of the separator 16. The debris collector 46 receives and stores debris separated from the suction airflow. A door 48 covers the debris outlet 44 and the door 48 is openable to empty debris from debris collector 46 of the separator 16 using gravity and / or the discharge airflow. The inner surface 36 surrounds a separator axis 50 (Fig. 2) that extends centrally through the separator 16 and centrally through the first end 38 and the second end 40. In the illustrated embodiment, the separator inlet 32 extends through the sidewall 34 generally tangential to the inner surface 36 of the sidewall 34 such that the inlet 32 and the inner surface 36, which is cylindrical, direct the debris and the suction airflow around the separator axis 50 to facilitate separating the debris from the suction airflow. In the illustrated embodiment, the separator 16 is a cyclonic separator. In other embodiments, the separator may not include a cyclonic separator and in yet other embodiments, the separator may include multiple cyclonic separators. The illustrated and described embodiment is one possible configuration of the separator 16 and in other embodiments, features of the separator may be arranged in different configurations. In yet other embodiments, the separator may not include all the features of the separator 16 and / or may include different features.

[0022] The separator 16 further includes an air outlet 84 for the suction airflow to exit the cyclone. The air outlet 84 is adjacent to the first end 38 of the separator 16. The air outlet 84 includes a shroud 86 that further removes debris from the suction airflow. The illustrated shroud 86 includes a cylindrical screen extending around and along the separator axis 50.Attorney Docket No. 025818-0159-W001

[0023] The separator 16 further includes a tube 96 forming a filter dirt chamber. The tube is between the air outlet 84 and the second end 40 of the separator 16 configured to collect dirt or debris that falls from the filter 52. The end of the tube forms a discharge opening when the door 48 is open through which to exhaust discharge airflow and expel debris, including debris that was collected on the filter 52 or that was retained within the tube 96.

[0024] Referring to Figs. 2 and 4, the vacuum cleaner 10 further includes the filter 52 and a motor 54 that vibrates the filter 52 to dislodge debris from the filter 52 as will be discussed in more detail below. Referring to Figs. 4 and 5, the filter 52 includes a filter media 56 and a frame 58. The filter media 56 separates debris from the suction airflow while allowing the suction airflow to pass through the filter media 56 toward the separator outlet 42 and the airflow source 14. In the illustrated embodiment, the filter media 56 includes a pleated filter media. In other embodiments, the filter media 56 can include other types of filter media, including a foam filter media. In yet other embodiments, the filter media may include multiple layers of filter media including multiple layers of different types of filter media. For example, the filter media 56 may include a pleated filter media layer and a foam filter media layer. In yet other embodiments, the filter media may not be pleated and may include a second foam filter media layer. The illustrated frame 58 includes a sidewall 60. The sidewall 60 forms an aperture 62 and the filter media 56 is located within the aperture 62 such that the sidewall 60 extends around the filter media 56. The frame 58 further include an agitator 64 that extends across the aperture 62. The agitator 64 engages the filter media 56 and in the illustrated embodiment, the agitator 64 contacts the filter media 56. The illustrated agitator 64 includes teeth 66 that correspond to pleats of the pleated filter media 56. One of the teeth 66 is arranged between adjacent pleats of the pleated filter media 56. In one embodiment, the agitator 64 includes an engagement surface that contacts the filter media 56, such as contacting the peak edges of the pleats of a folded media filter, or contacting one or more portions of a foam or non-woven media filter. The material for the agitator is selected to transfer vibrations from the vibration motor 54 to the filter media 56, such as plastic or metal, or other material as desired. In the illustrated embodiment, the frame 58, including the agitator 64, is integrally formed as a single component. In one embodiment, the frame 58 is integrally formed as a single component from an elastomeric material such as rubber or a thermoplastic elastomer.Attorney Docket No. 025818-0159-W001

[0025] Referring to Fig. 4, the vibration motor 54 further includes a motor housing 70. In the illustrated embodiment, the vibration motor 54 is an eccentric mass vibration motor including a shaft 72 and a weight 74 that is coupled to the shaft 72 for rotation with the shaft 72. The weight 74 is an offset weight (i.e., offset relative to the shaft 72) such rotation of the shaft 72 to rotate the weight 74 produces vibration that results from rotating the offset weight 74. In other embodiments, the vibration motor 54 is a linear magnetic ram motor, or a linear or solenoid or piezoelectric actuator, or another vibration motor as desired for the application. In the illustrated embodiment, the motor housing 70 includes a projection 76 that is received in a recess 78 of the agitator such that the motor housing 70 engages the agitator 64 to transfer vibration from the vibration motor 54 and the motor housing 70 to the agitator 64. In one embodiment, the motor housing 70 is positioned with a small gap to the agitator 64, such as less than 1 mm, or between 1 and 2 mm, or another gap as desired for the amplitude of the motor housing movement, so that vibration of the motor housing 70 would cause the motor housing 70 to impinge on the agitator 64, acting as a hammer periodically hitting the frame. This embodiment may include an elastomer molded around the motor housing 70 so that it acts like a mallet inducing lower frequencies. In another embodiment, the motor housing 70 is positioned in contact with an outer surface the agitator 64, without a projection received in a recess, such that the motor housing 70 engages the surface of the agitator 64 to transfer vibration from the motor 54 and the motor housing 70 to the agitator 64.

[0026] Referring to Fig. 6, the vacuum cleaner 10 includes a controller 80 and a user interface 81 in communication with the controller 80. The controller 80 controls operation of the airflow source 14 and the vibration motor 54. The controller 80 is also configured to operate the airflow source 14 to generate the suction airflow or the discharge airflow in response to a signal from the user interface 81. In some embodiments, the controller 80 is operable to control the polarity of the voltage applied to the motor 18 to control the direction of rotation of the impeller 20 about the axis 22 (i.e., whether the suction airflow or discharge airflow is generated by the airflow source 14).

[0027] The user interface 81 may be located on a surface (Fig. 1) of the vacuum cleaner 10 adjacent the handle 51. In some embodiments, the user interface 81 allows a user to select either operating the airflow source 14 to generate the suction airflow or operating the airflow source 14Attorney Docket No. 025818-0159-W001to generate the discharge airflow discussed above using one or more switches, buttons, touch screen, or other input, and sends a signal to the controller 80 to generate the selected suction airflow or the discharge airflow. The user interface 81 can include other features for providing user feedback, including display(s) indicating the amount of debris in the separator 16, a power level of the battery 31, and / or an indication of dirtiness of the filter 52. The user interface 81 can include any suitable user interface, including a touchscreen, touchpad, LCD, light emitting diodes, electromechanical switches, combinations thereof, and the like. In some embodiments, the user interface 81 may further include a switch adjacent the handle 51. The switch can be moved to at least two different positions by the user (e.g., by toggling the switch to different positions). In a first position or suction airflow position of the switch, the airflow source 14 generates the suction airflow. In a second position of the switch, the airflow source 14 generates the discharge airflow.

[0028] The illustrated vacuum cleaner 10 further includes a first debris sensor 69 and a second debris sensor 82 that are both in communication with the controller 80 (Fig. 6). The first debris sensor 69 is configured to sense the amount of debris within the separator 16 and the first debris sensor 69 communicates with the controller 80 to determine the amount of debris within the debris collector 46 and the controller communicates with the display 81 and the display 81 alerts the user when the separator 16 is full and / or requires emptying. In some embodiments, the display 81 may provide the user with an indication of the amount of debris within the debris collector 46 (e.g., 50% full, 75% full, 100% full, etc.). The first debris sensor 69 can include any suitable type of sensor for sensing the amount of debris within the separator 16, including an optical sensor, an infrared sensor, a proximity sensor, and the like.

[0029] The second sensor 82 is configured to sense a dirtiness level of the filter media 56. For example, in one embodiment, the sensor 82 is a pressure sensor that is operable to sense the difference in pressure of the suction airflow on each side of the filter media 56. The sensor 82 and the controller 80 determine the dirtiness level of the filter media 56 based on the pressure drop across the filter media 56. In other embodiments, other types of sensors (e.g., optical sensor) can be used to determine the dirtiness level of the filter media 56.Attorney Docket No. 025818-0159-W001

[0030] In some embodiments, the controller 80 may operate the airflow source 14 at a predetermined level of discharge airflow (e.g., less than the maximum discharge airflow) based on the level of dirtiness of the filter 52 and / or the amount of debris in the separator 16. For example, the controller 80 may decrease the amount of discharge airflow generated by the airflow source 14 if the relative level of dirtiness of the filter 52 is low and / or if there is a relatively small amount of debris in the separator 16. Likewise, the controller 80 may increase the amount of discharge airflow generated by the airflow source 14 if the filter 52 is dirtier or based on the amount of debris in the separator 16. Also, the controller 80 may operate the airflow source to pulse the amount of discharge airflow based on the level of dirtiness of the filter 52 and / or the amount of debris in the separator 16. In other embodiments, the controller 80 may be configured to operate the airflow source 14 at two or more predetermined flow rates of discharge airflow. In one embodiment, the controller 80 operates the airflow source 14 at a high discharge airflow rate, which may be correlated to a maximum flow rate, and a low discharge airflow rate (e.g. 50 percent of the high airflow rate, or a flow rate selected within a range between 25 and 75 percent of the high airflow rate). In one embodiment, the controller 80 is configured to operate the discharge airflow in response to a user input indicating that the cleaner is positioned over a bin or other trash receptacle, whereupon the controller operates the airflow source 14 at a predetermined dustbin discharge airflow rate selected to provide a flow through the filter to dislodge particles but selected to consider discharge in an open environment (e.g. a flow rate selected within a range between 5 and 40 percent of the maximum airflow rate). In some embodiments, the controller 80 operates the airflow source 14 to vary and / or pulse the discharge airflow to dislodge debris from the filter and the separator 16.

[0031] In operation, the airflow source 14 is utilized to generate the suction airflow, which draws debris from a surface being cleaned, through the inlet 12. The suction airflow is generated by the motor 18 rotating the impeller 20 about the axis 22 in the first direction. The suction airflow moves the valve 33 to the open position to allow debris and the suction airflow to enter the inlet duct 30. The suction airflow and the debris travel through the inlet duct 30 and into the separator 16 through the separator inlet 32. In the illustrated embodiment, the separator inlet 32 and the inner surface 36 of the sidewall 34 direct at least some of the debris and at least some of the suction airflow around the separator axis 50, which causes some of the debris to separate from the suction airflow and travel into the debris collector 46. The illustrated separator 16Attorney Docket No. 025818-0159-W001includes a skirt 84 that facilitates retaining the debris in the debris collector 46. The suction airflow travels through the shroud 86 of the separator 16. The shroud 86 may include a screen, vanes, or the like that further separate debris from the suction airflow. After traveling through the shroud 86 in the illustrated embodiment, the suction airflow travels through the filter media 56 and toward the separator outlet 42 and the airflow source 14. The filter media 56 further separates debris from the suction airflow. Generally, some of the debris separated by the filter media 56 may be retained on the filter media 56 on a dirt collection side 88 of the filter media 56 facing the filter dirt chamber tube 96.

[0032] It may be desirable to remove debris that is retained on or by the filter media 56 on the dirt collection side 88 of the filter media 56. Such removal of debris may improve performance and / or increase the service life of the filter media 56. To remove debris from the filter media 56, the controller 80 activates or turns on the vibration motor 54 to vibrate the agitator 64. In the illustrated embodiment, the vibration motor 54 rotates the weight 74 causing the motor housing 70 to vibrate. The vibrations of the motor 54 are transferred to the agitator 64 through the connection or contact between the motor housing 70 and the frame 58. Vibration of the agitator 64 causes the agitator 64 to contact and / or vibrate the filter media 56, which dislodges debris from the filter media 56 to clean the filter media 56. In the illustrated embodiment, the debris dislodged from the filter media 56 falls into the filter dirt chamber tube 96 and / or the debris collector 46. The teeth 66 of the agitator 64 move and / or vibrate to facilitate removing debris from the filter media 56 and cleaning the filter media 56.

[0033] In one embodiment, the agitator 64 is designed to have a desired agitator resonance frequency (i.e., vibration frequency at which the agitator 64 resonates) when installed with the filter media. The agitator resonance frequency is affected by factors that may include the material, mass, and shape of the agitator 64 and stiffness of the filter media and amount of engagement with the filter media. The vibration motor 54 vibrates at a motor vibration frequency, which is transferred to the agitator 64 by way of the motor housing 70. In one method of operation, the controller 80 operates the vibration motor 54 to vibrate at a motor vibration frequency that causes the agitator 64 installed with the filter media to resonate. Resonance of the agitator 64 increases the amplitude or deformation of the agitator 64 when compared to vibrating the agitator 64 at frequencies that do not create a resonance of the agitator 64. Vibrating theAttorney Docket No. 025818-0159-W001agitator 64 at or near its resonance frequency during the filter cleaning operation causing the agitator 64 to resonate can increase the effectiveness of the filter cleaning operation compared to filter cleaning operations where the agitator 64 does not resonate. For example, in one embodiment, the motor vibration frequency of the motor 54 rotating the weight 74 at a predetermined speed is about 250 Hz. In such an embodiment, the agitator resonance frequency is designed to be about 250 Hz, which may be the first harmonic resonant frequency. With the agitator resonance frequency near the motor vibration frequency, the motor vibration frequency of the motor 54 rotating the weight 74 causes the agitator 64 to resonate. Resonance of the agitator 64 increases the amplitude or deformation of the agitator 64 relative to the filter media 56, which increases the amount the agitator 64 agitates and / or vibrates the filter media 56 to dislodge debris from the filter media 56. Although the example above has been described as the motor 54 operating at a motor vibration frequency that equal the agitator resonance frequency (e g., in one example, 250 Hz), in other embodiments, the motor vibration frequency may be within a sufficient range of the agitator resonance frequency to cause the agitator 64 to resonate. For example, in some embodiments, the motor vibration frequency is within a range of the resonance frequency of the agitator 64 plus or minus 10 percent of the agitator resonance frequency, which still causes the agitator 64 to resonate. In other embodiments, the motor vibration frequency is within a range of the resonance frequency of the agitator plus or minus 15 percent of the agitator resonance frequency, which still causes the agitator 64 to resonate. For example, a wider range may be useful for an agitator having a greater damping effect than for an agitator having a lower damping effect. Also, the examples above have been described with the motor vibration frequency within a suitable range of the agitator resonance frequency at the first harmonic, in other embodiments, the vibration motor 54 is configured to vibrate at a motor vibration frequency at the second, the third, or more harmonic resonance frequency of the agitator 64. In some embodiments, the harmonic is selected based on the vibration mode providing a desired agitation of the filter.

[0034] In one embodiment, the controller 80 controls the motor vibration frequency so that the motor vibration frequency is within a range of the agitator resonance frequency to cause the agitator 64 to resonate. In the illustrated embodiment using an eccentric mass vibration motor, the controller 80 controls the motor vibration frequency by controlling the speed or frequency at which the motor 54 rotates the weight 74 or speed or frequency at which the shaft 72 rotates. InAttorney Docket No. 025818-0159-W001one embodiment, the speed at which the motor 54 rotates the weight 74 is changed by adjusting the voltage applied to the motor 54. For example, the agitator resonance frequency may vary between a manufacturer’s products within the same product line due to manufacturing tolerances, amount of fdter loading, and other factors. Therefore, it may be desirable to change or vary the motor vibration frequency across a range of motor vibration frequencies over a period of time, the range of motor vibration frequencies selected so that a portion of the motor vibration frequencies within the range are close to or matching the agitator resonance frequency causing the agitator 64 to resonate. In one embodiment, the controller 80 adjusts the voltage applied to the motor 54 by incrementally increasing from 11.5 volts to 12.5 volts, for one example, at 0.1 volt increments, over a predetermined period of time (e.g., 15 seconds). In another embodiment, the controller 80 adjusts the voltage applied to the motor 54 by incrementally decreasing from 12.5 volts to 11.5 volts over a predetermined period of time. In yet another embodiment, the controller 80 adjusts the voltage applied to the motor 54 by incrementally increasing the voltage from a first voltage to a second voltage, and then incrementally decreases the voltage from the second voltage to the first voltage, or other motor control patterns as desired. In this method, the speed at which the motor 54 rotates the weight 74 changes over the predetermined period, causing the motor vibration frequency to change over the period. During the period, when the motor vibration frequency is close to or matching the agitator resonance frequency, the vibration causes the agitator 64 to resonate.

[0035] In some methods of operation, the controller 80 operates the motor 54 to generate the motor vibration frequency to vibrate the agitator 64 for a predetermined period of time after the airflow source 14 is turned off. For example, when the airflow source 14 is turned off (i.e., suction airflow stops), the controller 80 operates the motor 54 to generate the motor vibration frequency at a constant speed or a variable speed, as discussed above, for a period of 15 seconds. In other embodiments, other periods of time can be utilized.

[0036] In some embodiments, the controller 80 operates the motor 54 based on the dirtiness level of the filter media 56. As discussed above, the sensor 82 and the controller 80 determine the dirtiness level of the filter media 56. Then, the controller 80 operates the motor 54 for a longer period of time if the controller 80 determines that the filter media 56 is relatively dirty. If the filter media 56 is relatively clean, the controller 80 operates the motor 54 for a shorter periodAttorney Docket No. 025818-0159-W001of time. In yet other embodiments, the controller 80 operates the motor 54 to generate the motor vibration frequency only when the airflow source 14 is turned off and when the controller 80 determines that the dirtiness level of the filter media 56 exceeds a threshold.

[0037] When the user desires to empty the separator 16, the user opens the door 48 of the separator 16. Opening the door 48 opens an airflow path for the discharge airflow and enables debris within the debris collector 46 to fall out of the separator 16 through the debris outlet 44 depending on the orientation of the vacuum cleaner 10. The user can also use the discharge airflow to facilitate emptying the separator 16. The user may use the user interface 81 to signal the controller 80 to generate the discharge airflow to expel debris and the discharge airflow from the separator 16 through the debris outlet 44. The discharge airflow may also dislodge debris from the filter 52. The discharge airflow is generated by the motor 18 rotating the impeller 20 about the axis 22 in the second direction. In the illustrated embodiment, the discharge airflow travels from the exhaust 23, through the airflow source 14, through the filter 52 in generally the opposite direction as the suction airflow, through the separator 16 and through the debris outlet 44. When the door 48 is open the discharge airflow passes along the shroud 86 and through the filter dirt chamber tube 96. Some of the discharge airflow downstream of the filter 52 passes through the shroud 86 from inside of the shroud outwardly, and then through the debris collector 46 before exiting the debris outlet 44.

[0038] Various features and advantages of the disclosure are set forth in the following claims.

Claims

Attorney Docket No. 025818-0159-W001CLAIMSWhat is claimed is:

1. A vacuum cleaner comprising:an inlet;an airflow source in fluid communication with the inlet, the airflow source operable to generate a suction airflow configured to draw debris through the inlet;a separator in fluid communication with the inlet and the airflow source, the separator configured to separate the debris from the suction airflow, the separator including,a separator inlet that receives the debris and the suction airflow,a separator outlet that discharges the suction airflow,a debris collector configured to store debris separated from the suction airflow, a filter including a filter media and a frame, the filter media configured to separate debris from the suction airflow, the frame including an agitator that engages the filter media; anda motor operable to vibrate the agitator such that the agitator contacts the filter media to vibrate the filter media to dislodge debris from the filter media,wherein the airflow source further includesan impeller rotatable about an axis,an airflow source motor operable to rotate the impeller about the axis in a first direction to generate the suction airflow, the airflow source motor further operable to rotate the impeller about the axis in a second direction, opposite the first direction, to generate a discharge airflow, the discharge airflow configured to expel debris from the separator.

2. The vacuum cleaner of claim 1, wherein the filter media includes a pleated filter media, and wherein the agitator includes teeth received between adjacent pleats of the pleated filter media.

3. The vacuum cleaner according to any of the preceding claims, further comprising a weight, wherein the motor rotates the weight to vibrate the agitator.Attorney Docket No. 025818-0159-W0014. The vacuum cleaner according to any of the preceding claims, wherein the frame includes a sidewall that forms an aperture, the filter media located within the aperture and the sidewall extends around the filter media, wherein the agitator extends across the aperture.

5. The vacuum cleaner according to any of the preceding claims, further comprising a motor housing, wherein the motor is located within the motor housing, wherein the motor housing engages the agitator to transfer vibration from the motor to the agitator.

6. The vacuum cleaner according to any of the preceding claims, wherein the filter frame is integrally formed as a single component.

7. The vacuum cleaner according to any of the preceding claims, wherein the agitator has a resonance frequency, wherein the motor vibrates at a motor vibration frequency to vibrate the agitator, and wherein the motor vibration frequency causes the agitator to resonate.

8. The vacuum cleaner according to claim 7, wherein the motor vibration frequency is within a range of the resonance frequency plus or minus 15 percent of the resonance frequency.

9. The vacuum cleaner according to claim 7, wherein the motor vibration frequency is within a range of the resonance frequency plus or minus 10 percent of the resonance frequency.

10. The vacuum cleaner according to any of claims 7 to 9, wherein the motor vibration frequency equals the resonance frequency.

11. The vacuum cleaner according to any of the preceding claims, further comprising a controller configured to control operation of the motor and a voltage applied to the motor, wherein the controller adjusts the voltage applied to the motor across a range of voltages while the motor vibrates the agitator.

12. The vacuum cleaner according to claim 11, wherein the range of voltages is from 11.5 volts to 12.5 volts.

13. The vacuum cleaner according to any of the preceding claims, further comprising a controller configured to control operation of the motor, wherein the controller turns on the motor to vibrate the agitator for a period of time after the airflow source is turned off.Attorney Docket No. 025818-0159-W00114. The vacuum cleaner according to claim 13, wherein the period of time is based on a dirtiness level of the filter.

15. The vacuum cleaner according to claim 14, wherein the dirtiness level of the filter is based on a pressure drop across the filter when the airflow source is turned on.

16. The vacuum cleaner according to any of the preceding claims, wherein the discharge airflow passes through the filter in generally the opposite direction as the suction airflow.

17. The vacuum cleaner according to any of the preceding claims, further comprising a user interface and a controller, the user interface in communication with the controller, the user interface configured to allow a user to select operating the airflow source to generate the suction airflow or the discharge airflow, the controller configured to operate the airflow source to generate the suction airflow or the discharge airflow in response to a signal from the user interface.

18. The vacuum cleaner according to claim 17, further comprising a debris sensor, the debris sensor configured to output a debris signal to the controller, wherein the controller operates the airflow source to generate the discharge airflow in response to the debris signal.

19. The vacuum cleaner according to claim 18, wherein the debris signal relates to an amount of debris in the separator.

20. The vacuum cleaner according to any one of the preceding claims, the separator having a cyclone having a first end and a second end and a sidewall extending between the first end and the second end, the first end disposed between the second end and the airflow source, and a cyclone axis of rotation defined by the sidewall.

21. The vacuum cleaner according to claim 21, wherein the second end is openable, the discharge airflow configured to expel debris from the separator through the second end.

22. The vacuum cleaner according to claim 22, wherein the second end of the cyclone includes an openable door, wherein the openable door closes the cyclone chamber and the discharge opening.Attorney Docket No. 025818-0159-W00123. A vacuum cleaner comprising:an inlet;a airflow source in fluid communication with the inlet, the airflow source operable to generate a suction airflow configured to draw debris through the inlet;a separator in fluid communication with the inlet and the airflow source, the separator configured to separate the debris from the suction airflow, the separator including,a separator inlet that receives the debris and the suction airflow,a separator outlet that discharges the suction airflow,a debris collector configured to store debris separated from the suction airflow, a filter including a filter media and a frame, the filter media configured to separate debris from the suction airflow, the frame including an agitator; anda motor operable to vibrate the agitator such that the agitator vibrates the filter media to dislodge debris from the filter media,wherein the agitator has a resonance frequency, wherein the motor vibrates at a motor vibration frequency to vibrate the agitator, and wherein the motor vibration frequency causes the agitator to resonate.

24. The vacuum cleaner according to claim 23, wherein the motor vibration frequency is within a range of the resonance frequency plus or minus 15 percent of the resonance frequency.

25. The vacuum cleaner according to claim 23, wherein the motor vibration frequency is within a range of the resonance frequency plus or minus 10 percent of the resonance frequency.

26. The vacuum cleaner according to any of claims 23 to 25, wherein the motor vibration frequency equals the resonance frequency.

27. The vacuum cleaner according to any of claims 23 to 26, further comprising a controller configured to control operation of the motor and a voltage applied to the motor, wherein the controller adjusts the voltage applied to the motor across a range of voltages while the motor vibrates the agitator.

28. The vacuum cleaner according to claim 27, wherein the range of voltages is from 11.5 volts to 12.5 volts.Attorney Docket No. 025818-0159-W00129. The vacuum cleaner according to any of claims 23 to 28, further comprising a controller configured to control operation of the motor, wherein the controller turns on the motor to vibrate the agitator for a period of time after the airflow source is turned off.

30. The vacuum cleaner according to claim 29, wherein the period of time is based on a dirtiness level of the filter.

31. The vacuum cleaner according to claim 30, wherein the dirtiness level of the filter is based on a pressure drop across the filter when the airflow source is turned on.

32. The vacuum cleaner of any of claims 23 to 31, wherein the filter media includes a pleated filter media, and wherein the agitator includes teeth received between adjacent pleats of the pleated filter media.

33. The vacuum cleaner according to any of claims 23 to 32, wherein the motor includes a weight, wherein the motor rotates the weight to vibrate the agitator.

34. The vacuum cleaner according to any of claims 23 to 33, wherein the motor is a first motor, wherein the airflow source includes a second motor and an impeller rotatable by the second motor to generate the suction airflow.

35. The vacuum cleaner according to any of claims 23 to 34, wherein the airflow source includes the motor and a impeller rotatable by the motor to generate the suction airflow.

36. The vacuum cleaner according to any of claims 23 to 35, wherein the frame includes a sidewall that forms an aperture, the filter media located within the aperture and the sidewall extends around the filter media, wherein the agitator extends across the aperture.

37. The vacuum cleaner according to any of claims 23 to 36, further comprising a motor housing, wherein the motor is located within the motor housing, wherein the motor housing engages the agitator to transfer vibration from the motor to the agitator.

38. The vacuum cleaner according to any of claims 23 to 37, wherein the filter frame is integrally formed as a single component.Attorney Docket No. 025818-0159-W00139. A method of operating a vacuum cleaner, the method comprising:generating a suction airflow to draw debris through an inlet using a airflow source in fluid communication with the inlet;separating debris from the suction airflow in a separator in fluid communication with the inlet and the airflow source, separating debris from the suction airflow includes filtering debris from the suction airflow using a filter having a filter media and a frame, the filter media separates debris from the suction airflow between a separator inlet and a separator outlet and deposits the debris into a debris collector, the frame including an agitator;operating a motor at a motor vibration frequency; andvibrating the agitator using the motor operating at the motor vibration frequency such that vibrating the agitator vibrates the filter media to dislodge debris from the filter media, wherein vibrating the agitator using the motor at the motor vibration frequency includes causing the agitator to resonate by vibrating the agitator at a resonance frequency of the agitator.

40. The method according to claim 39, further comprising operating the motor across a range of voltages to adjust the motor vibration frequency.

41. The method according to claim 40, wherein the range of voltages is from 11.5 volts to 12.5 volts.

42. The method according to any of claims 39 to 41, further comprising stopping generation of the suction airflow, and wherein operating the motor at the motor vibration frequency occurs after stopping generation of the suction airflow.

43. The method according to claim 42, wherein operating the motor at the motor vibration frequency includes operating the motor at the motor vibration frequency for a predetermined period of time after stopping generation of the suction airflow.

44. The method according to any of claims 39 to 43, wherein operating the motor at the motor vibration frequency includes operating the motor at the motor vibration frequency for a period of time based on a dirtiness level of the filter.

45. The method according to claim 44, wherein the dirtiness level of the filter includes determining a pressure drop across the filter while generating the suction airflow.Attorney Docket No. 025818-0159-W00146. The method according to any of claims 39 to 45, wherein vibrating the filter media includes contacting the filter media with the agitator.

47. The method according to any of claims 39 to 46, wherein contacting the filter media with the agitator includes positioning teeth of the agitator between adjacent pleats of the filter media.

48. The method according to any of claims 39 to 47, wherein operating the motor at the motor vibration frequency includes rotating a weight with the motor.

49. The method according to any of claims 39 to 48, wherein generating the suction airflow includes generating the suction airflow with the motor.

50. The method according to any of claims 39 to 49, wherein generating the suction airflow includes generating the suction airflow with a second motor.

51. The method according to any of claims 39 to 50, wherein vibrating the agitator using the motor includes engaging a motor housing of the motor with the agitator.

52. A method of operating a vacuum cleaner, the method comprising:generating a suction airflow to draw debris through an inlet using a airflow source in fluid communication with the inlet;separating debris from the suction airflow in a separator in fluid communication with the inlet and the airflow source, separating debris from the suction airflow includes filtering debris from the suction airflow using a filter having a filter media and a frame, the filter media separates debris from the suction airflow between a separator inlet and a separator outlet and deposits the debris into a debris collector, the frame including an agitator;operating a motor to rotate a weight to cause the motor to vibrate at a motor vibration frequency; andvibrating the agitator using the motor operating at the motor vibration frequency such that vibrating the agitator vibrates the filter media to dislodge debris from the filter media, and wherein operating the motor to vibrate at a motor vibration frequency includes changing the speed at which the motor rotates the weight to adjust the motor vibration frequency.Attorney Docket No. 025818-0159-W00153. The method according to claim 52, wherein changing the speed at which the motor rotates the weight includes operating the motor across a range of voltages to adjust the motor vibration frequency.

54. The method according to claim 53, wherein the range of voltages is from 11.5 volts to 12.5 volts.

55. The method according to any of claims 52 to 54, further comprising stopping generation of the suction airflow, and wherein operating the motor at the motor vibration frequency occurs after stopping generation of the suction airflow.

56. The method according to claim 56, wherein operating the motor at the motor vibration frequency includes operating the motor at the motor vibration frequency for a predetermined period of time after stopping generation of the suction airflow.

57. The method according to any of claims 52 to 56, wherein operating the motor at the motor vibration frequency includes operating the motor at the motor vibration frequency for a period of time based on a dirtiness level of the fdter.

58. The method according to claim 57, wherein the dirtiness level of the filter includes determining a pressure drop across the filter while generating the suction airflow.

59. The method according to any of claims 52 to 58, wherein vibrating the filter media includes contacting the filter media with the agitator.

60. The method according to any of claims 59, wherein contacting the filter media with the agitator includes positioning teeth of the agitator between adjacent pleats of the filter media.

61. The method according to any of claims 52 to 60, wherein generating the suction airflow includes generating the suction airflow with the motor.

62. The method according to any of claims 52 to 62, wherein generating the suction airflow includes generating the suction airflow with a second motor.Attorney Docket No. 025818-0159-W00163. The method according to any of claims 52 to 62, wherein vibrating the agitator using the motor includes engaging a motor housing of the motor with the agitator.

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