Vacuum cleaner

Abstract

A vacuum cleaner includes an airflow source including an impeller rotatable about an axis and a motor operable to rotate the impeller about the axis in a first direction to generate a suction airflow. The motor is 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.

Description

Attorney Docket No. 025818-0142-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, the entire contents all of which are hereby incorporated by reference herein.BACKGROUND

[0002] The present disclosure relates to vacuum cleaners and emptying debris from vacuum cleaners.SUMMARY

[0003] In one embodiment, a vacuum cleaner includes an inlet configured to receive debris from a surface being cleaned, a separator in fluid communication with the inlet, the separator configured to separate debris from a suction airflow and retain debris separated from the suction airflow. The vacuum cleaner further includes an airflow source operable to generate the suction airflow, the airflow source in fluid communication with the inlet and the separator. The airflow source includes an impeller rotatable about an axis and a motor operable to rotate the impeller about the axis in a first direction to generate the suction airflow. The motor is 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] Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Fig. l is a perspective view of a vacuum cleaner according to one embodiment.

[0006] Fig. 2 is a cross-sectional view of the vacuum cleaner of Fig. 1.

[0007] Fig. 3 is an alternative cross-sectional view of the vacuum cleaner of Fig. 1.Attorney Docket No. 025818-0142-W001

[0008] Fig. 4 is a perspective view of the vacuum cleaner of Fig. 1 and a portion of a docking station.

[0009] Fig. 5 is a schematic illustration of a portion of the vacuum cleaner of Fig. 1 and the vacuum cleaner of Figs. 6 - 7.

[0010] Fig. 6 illustrates a vacuum cleaner according to another embodiment.

[0011] Fig. 7 is a cross-sectional view of a portion of the vacuum cleaner of Fig. 6.

[0012] Fig. 8 is a cross-sectional view of an airflow source of the vacuum cleaner of Fig. 5 and the vacuum cleaner of Fig. 1.

[0013] 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

[0014] Figs. 1 and 2 illustrate a vacuum cleaner 10. The vacuum cleaner 10 includes an inlet 12, an exhaust 14, a separator 16, and an airflow source 18. The airflow source 18 is operable to generate a suction airflow along an airflow path from the inlet 12 to the exhaust 14 to draw debris from a surface being cleaned through the inlet 12 and into the separator 16. As will be discussed in more detail below, the airflow source 18 is also operable to generate a discharge airflow to expel debris from the separator 16 to facilitate emptying the separator 16.

[0015] Referring to Fig. 2, the separator 16 is in fluid communication with the inlet 12 via a passageway 20. The separator 16 is configured to separate debris from the suction airflow and retain the debris within the separator 16. The separator 16 includes a separator inlet 22 that receives the airflow and debris from the passageway 20. In the illustrated embodiment, the separator 16 includes a filter 24 that removes debris from the suction airflow before the suction airflow passes through the airflow source 18, shown surrounded by a structure supporting a mesh or screen 19. The filter 24 can include a pleated filter, a foam filter, or a multi-layer filterAttorney Docket No. 025818-0142-W001including a foam layer and a pleated fdter layer, and the like. In other embodiments, the separator 16 can be configured as a cyclonic separator and may include a filter to further remove debris from the airflow before the airflow passes through the airflow source 18.

[0016] The airflow source 18 includes an impeller 26 and a motor 28. The motor 28 is operable to rotate the impeller 26 about an axis 30 in a first direction to generate the suction airflow and the motor 28 is also operable to rotate the impeller 26 about the axis 30 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. The vacuum cleaner 10 includes an airflow path that extends from the inlet 12, through the separator 16, through the airflow source 18, and through the exhaust 14. When the motor 28 rotates the impeller 26 about the axis 30 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 the passageway 20, then through the separator 16, including the filter 24, then through the airflow source 18, and then through the exhaust 14, creating a negative pressure or suction within the passageway 20 and separator 16.

[0017] When the motor 28 rotates the impeller 26 about the axis 30 in the second direction, the discharge airflow travels in a second airflow direction along the airflow path. The second airflow direction in the illustrated embodiment is from the exhaust 14, through the airflow source 18, through the filter 24 and the separator 16, through the separator inlet 22, through the passageway 20, and through the inlet 12. In the illustrated embodiment, the discharge airflow travels through the vacuum cleaner 10 in generally the opposite direction as the suction airflow. However, in other embodiments, the discharge airflow may take an airflow path different than the suction airflow path. In some embodiments, the discharge airflow and debris may exit the vacuum cleaner through a discharge opening other than the inlet 12. That is, in the illustrated embodiment, the inlet 12 is the discharge opening through which the discharge airflow and debris exit the vacuum cleaner 10. As will be discussed below, in other embodiments, the discharge airflow travels through the filter 24, through the separator 16, and exits through a discharge opening other than the inlet 12. The discharge opening may be formed in a wall of the separator 16 configured with a cover openable to discharge debris during the discharge airflow, wherein the cover is closed during operation of the cleaner during the suction airflow.Attorney Docket No. 025818-0142-W001

[0018] In one embodiment, the motor 28 is a direct current (DC) motor and the vacuum cleaner 10 include battery 36 that powers the motor 28. Also, in one embodiment the motor 28 is a bi-polarity motor, or reversible motor, also referred to as a mixed-flow motor, that allows the motor 28 to rotate the impeller 26 about the axis 30 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 a mixed-flow impeller that defines an angled flow segment 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.

[0019] With continued reference to Fig. 2, the vacuum cleaner 10 in the illustrated embodiment further includes a valve 38. The valve 38 is adjacent the separator inlet 22 in the illustrated embodiment. The illustrated valve 38 is formed by an elastomeric member that is biased to a closed position (position shown in Figs. 2 and 3). The valve 38 moves to an open position in response to either the suction airflow or the discharge airflow. In response to the suction airflow, the valve 38 moves to a first open position, represented by dashed lines 40 in Fig. 2 to allow debris and the suction airflow to enter the inlet 12 and the separator 16. In response to the discharge airflow, the valve 38 moves to a second open position, represented by dashed lines 42 in Fig. 2, to allow the discharge airflow and debris to exit the separator 16. In the closed position, the valve 38 inhibits debris from traveling out of the separator 16 through the separator inlet 22. For example, if the user is carrying the vacuum cleaner 10, the valve 38, in the closed position, prevents debris from falling out of the separator 16 though the inlet 12 due to gravity. The valve 38 is biased toward and into the closed position such that the valve 38 is in the closed position when the airflow source 18 is off (i.e., not generating either the suction airflow or the discharge airflow). For example, when the airflow source 18 is turned off and not generating either the suction airflow or the discharge airflow, the valve 38 automatically moves to the closed position. In other embodiments, other types of valves may be utilized. For example, in some embodiments, the valve may include a valve member formed from a rigid material, such as plastic, that is spring biased toward a closed position. In other embodiments, the valve may include an actuator that opens and closes the valve based on operation of the airflow source 18. For example, the actuator may move the valve to the open position when the airflow source 18 is generating either the suction airflow or the discharge airflow. In such an embodiment, if the airflow source 18 is not generating either the suction airflow or the dischargeAttorney Docket No. 025818-0142-W001airflow, the actuator may move the valve to the closed position. The actuator may include an electronic valve actuator power by a battery. In yet other embodiments, the valve 38 may be omitted.

[0020] Referring to Figs. 1 and 2, the illustrated vacuum cleaner 10 includes a first end 44 and a second end 46 opposite the first end 44 in a direction along the axis 30. The inlet 12 is adjacent the first end 44. The vacuum cleaner 10 includes a motor housing 48 and a handle 50 adjacent the second end 46. The handle 50 extends from the motor housing 48 and the handle 48 is configured to be grabbed by a user to move the vacuum cleaner 10 along a surface to be cleaned. The airflow source 18, including both the motor 28 and the impeller 26, are located within the motor housing 48. In some embodiments, the separator 16 is removably coupled to the motor housing 48. For example, the user may remove the separator 16 from the motor housing 48 to empty the separator 16 and / or clean or replace the filter 24. In some embodiments, only a portion of the separator 16 is removable from the motor housing 48. For example, the separator 16 or a portion of the separator 16 may be connected to the motor housing 48 by a hinge such that the portion of the separator can pivot relative to the motor housing 48 to open the separator 16 to empty the separator 16 and / or clean or replace the filter 24.

[0021] Referring to Fig. 5, the vacuum cleaner 10 includes a controller 52 and a user interface 54 in communication with the controller 52. The controller 52 is configured to operate the airflow source 18 to generate the suction airflow or the discharge airflow in response to a signal from the user interface 54. In some embodiments, the controller 52 is operable to control the polarity of the voltage applied to the motor 28 to control the direction of rotation of the impeller 26 about the axis 30 (i.e., whether the suction airflow or discharge airflow is generated by the airflow source 18).

[0022] The user interface 54 may be located on a surface 58 (Fig. 1) of the vacuum cleaner 10 adjacent the handle 50. In some embodiments, the user interface 54 allows a user to select either operating the airflow source 18 to generate the suction airflow or operating the airflow source 18 to generate the discharge airflow discussed above using one or more switches, buttons, touch screen, or other input, and sends a signal to the controller 52 to generate the selected suction airflow or the discharge airflow. The user interface 54 can include other features forAttorney Docket No. 025818-0142-W001providing user feedback, including display(s) indicating the amount of debris in the separator 16, a power level of the battery 36, and / or an indication of dirtiness of the filter 24. The user interface 54 can include any suitable user interface, including a touchscreen, touchpad, LCD, light emitting diodes, electromechanical switches, combinations thereof, and the like. Referring to Fig. 1, in some embodiments, the user interface 54 may further include a switch 60 adjacent the handle 50, shown schematically as a trigger. In some embodiments, the switch 60 can be moved to at least two different positions by the user (e.g., by toggling the switch 60 to different positions). In a first position or suction airflow position of the switch 60, the airflow source 18 generates the suction airflow. In a second position of the switch 60, the airflow source 18 generates the discharge airflow.

[0023] Referring to Figs. 4 and 5, in some embodiments, the vacuum cleaner 10 includes a sensor 62. The sensor 62 is configured to output a signal to the controller 52 when the vacuum cleaner 10 is connected to a docking station 64. The sensor 62 may include any suitable sensor that determines when the vacuum cleaner 10 is connected to the docking station 64. For example, the sensor may include a proximity sensor, a Hall effect sensor, a current / voltage sensor, and the like. The vacuum cleaner 10 and the docking station 64 may include electrical connectors that mate when the vacuum cleaner 10 is connected to the docking station and the controller 52 determines when the when the electrical connectors of the vacuum cleaner 10 and the docking station 64 are electrically or communicatively connected. In yet other embodiments, an electromechanical switch may be used to determine whether the vacuum cleaner 10 is connected to the docking station 64. The docking station 64 can be utilized to receive debris emptied from the separator 16. In the illustrated embodiment, the vacuum cleaner 10 is connected to the docking station 64 by inserting the inlet 12 into a receptacle 66 of the docking station 64. Based on the signal from the sensor 62, when the controller 52 determines that the vacuum cleaner 10 is connected to the docking station 64, the controller 52 may operate the airflow source 18 to generate the discharge airflow to empty debris from the separator 16 and into the docking station 64. In some embodiments, the controller 52 operates the airflow source 18 to generate the discharge airflow for a predetermined amount of time after determining that the vacuum cleaner 10 is connected to the docking station 64. For example, the controller 52 may operate the airflow source 18 for 15 seconds (or any suitable time) to generate the discharge airflow after the vacuum cleaner 10 is connected to the docking station 64. Also, the controllerAttorney Docket No. 025818-0142-W00152 may operate the airflow source 18 at a predetermined level of discharge airflow (e.g., less than the maximum discharge airflow) when the vacuum cleaner 10 is connected to the docket station 64. For example, the airflow source 18 may be able to generate a maximum discharge airflow 18 that is used in some applications, e.g., when the separator 16 is full of debris.However, in some instances when the vacuum cleaner 10 is emptied into the docking station 64, the maximum discharge airflow may not be needed. Therefore, the controller 52 may operate the airflow source 18 at the predetermined level of discharge airflow. The predetermined level of discharge airflow may be any suitable percentage (e.g., 50 percent) of the maximum discharge airflow. In other embodiments, the controller 52 may be configured to operate the airflow source 18 at two or more predetermined flow rates of discharge airflow. In one embodiment, the controller 52 operates the airflow source 18 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 52 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 18 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 52 operates the airflow source 18 to vary and / or pulse the discharge airflow to dislodge debris from the filter and the separator 16.

[0024] Referring to Figs. 2, 4, and 5, the illustrated vacuum cleaner 10 further includes a first debris sensor 68 and a second debris sensor 70 that are both in communication with the controller 52. The first debris sensor 68 is configured to sense the amount of debris within the separator 16 and the first debris sensor 68 communicates with the controller 52 to determine the amount of debris within the separator 16. The first debris sensor 68 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. The second debris sensor 70 is configured to sense a level of dirtiness of the filter 24 and the second debris sensor 70 communicates with the controller 52 to determine the level of dirtiness of the filter 24. The second debris sensor 70 can include a pressure sensor for determining the pressure drop across the filter 24, which is anAttorney Docket No. 025818-0142-W001indicator of the level of dirtiness of the fdter 24. In other embodiments, the second debris sensor 70 may include an optical sensor or an infrared sensor to sense the level of dirtiness of the fdter 24, positioned to sense the dirty side of the fdter. When the vacuum cleaner 10 is connected to the docking station 64, the controller 52 may operate the airflow source 18 to generate the discharge airflow in response to signals from the first debris sensor 68 and / or the second debris sensor 70. For example, the controller 52 may operate the airflow source 18 to generate the discharge airflow when the vacuum cleaner 10 is connected to the docking station 64 and the controller 52 determines that the amount of debris in the separator 16 exceeds a predetermined level indicating that the separator 16 is at or near capacity based on feedback from the first debris sensor 68. Also, the controller 52 may operate the airflow source 18 to generate the discharge airflow when the vacuum cleaner 10 is connected to the docking station 64 and the controller 52 determines that the level of dirtiness of the filter 24 exceeds a predetermined level indicating the filter 24 requires cleaning based on feedback from the second debris sensor 70. The controller 52 may operate the airflow source 18 at a predetermined level of discharge airflow (e.g., less than the maximum discharge airflow) based on the level of dirtiness of the filter 24 and / or the amount of debris in the separator 16. For example, the controller 52 may decrease the amount of discharge airflow generated by the airflow source 18 if the relative level of dirtiness of the filter 24 is low and / or if there is a relatively small amount of debris in the separator 16. Likewise, the controller 52 may increase the amount of discharge airflow generated by the airflow source 18 if the filter 24 is dirtier or based on the amount of debris in the separator 16. Also, the controller 52 may operate the airflow source to pulse the amount of discharge airflow based on the level of dirtiness of the filter 24 and / or the amount of debris in the separator 16.

[0025] In operation, the user actuates the user interface 54 to signal the controller 52 to generate the suction airflow to draw debris through the inlet 12. The suction airflow is generated by the motor 28 rotating the impeller 26 about the axis 30 in the first direction. The suction airflow moves the valve 38 to the open position 40 to allow debris and the suction airflow to enter the separator 16 through the separator inlet 22. Debris is retained in the separator 16 and the suction airflow travels through the filter 24 and through the airflow source 18. After traveling through the airflow source 18, the suction airflow is exhausted from the vacuum cleaner 10 through the exhaust 14. When the user is finished using the vacuum cleaner 10 and the airflow source 18 is turned off, the valve 38 returns to the closed position to retain debris inAttorney Docket No. 025818-0142-W001the separator 16 and inhibit debris from falling out of the separator 16 through the separator inlet 22 and inlet 12. When the user desires to empty the separator 16, the user may use the user interface 54 to signal the controller 52 to generate the discharge airflow to expel debris from the separator 16. The discharge airflow is generated by the motor 28 rotating the impeller 36 about the axis 30 in the second direction. In the illustrated embodiment, the discharge airflow travels from the exhaust 14, through the airflow source 18, and through the filter 24 in generally the opposite direction as the suction airflow. The discharge airflow may dislodge debris from the filter 24. The discharge airflow travels through the separator 16 in generally the opposite direction as the suction airflow and moves the valve 38 to the open position 42 to allow the discharge airflow and debris to exit the separator 16 through the passageway 20 and inlet 12. When the airflow source 18 is turned off, the valve 38 returns to the closed position.

[0026] Figs. 6 - 8 illustrate a vacuum cleaner 100 according to another embodiment. The vacuum cleaner 100 of Figs. 6 - 8 includes some features similar to the vacuum cleaner 10 of Figs. 1 - 5 and only some differences between the vacuum cleaners 10 and 100 will be discussed below and like components have been given the same reference number plus 100. Also, features from the vacuum cleaner 10 discussed above can be used in the vacuum cleaner 100 and likewise features from the vacuum cleaner 100 discussed below, can be used in the vacuum cleaner 10.

[0027] Referring to Figs. 6 and 7, the vacuum cleaner 100 includes an inlet 112, and an inlet duct 120 extending from the inlet 112 to a separator 116, and an airflow source 118. In the illustrated embodiment, the vacuum cleaner 100 includes a removable and optional wand 125. The wand 125 includes a duct 127 and a floor nozzle 129. The duct 127 provides fluid communication between the floor nozzle 129 and the inlet 112 to direct debris and the suction airflow from the floor nozzle 129 to the inlet 112.

[0028] The separator 116 includes a cyclone 172. In the illustrated embodiment, the separator 116 includes only a single cyclone or single stage cyclone and does not include any second stage cyclone(s). The cyclone 172 includes a first end 174 and a second end 176. The first end 174 is disposed between the airflow source 118 and the second end 176 of the cyclone 172. The second end 176 of the cyclone 172 includes a debris collector 134 and the second end 176 is openable to empty the separator 116. The discharge airflow, discussed above, generatedAttorney Docket No. 025818-0142-W001by the airflow source 118 expels debris from the separator 116 through the second end 176 of the cyclone 172 when the second end 176 is opened. That is, the second end 176 of the cyclone 172 forms the discharge opening through which the discharge airflow and debris are expelled from the vacuum cleaner 100. In the illustrated embodiment, the second end 176 includes a door 178 that is openable to open and close the cyclone 172 to facilitate emptying the cyclone 172 and the separator 116 through the second end 176. The door 178 pivots between the opened and closed positions. The vacuum cleaner 100 does not expel debris from the separator 116 through the inlet 112 like the vacuum cleaner 10. Rather, debris is expelled through the second end 176 of the separator 116 when the door 178 is opened. Stated another way, in the embodiment of Fig. 7, the second end 176 forms a discharge opening when the door 178 is opened. In other embodiments, the discharge opening may be formed in a wall of the separator 116 configured with a cover openable to discharge debris during the discharge airflow, wherein the cover is closed during operation of the cleaner during the suction airflow.

[0029] The vacuum cleaner 100 includes a flap or valve 138. The valve 138 moves to an open position in response to the suction airflow to permit the suction airflow to travel through the inlet. However, the discharge airflow pushes the valve 138 to a closed position inhibiting airflow back through the inlet 112 and directing the discharge airflow through the second end 176 of the separator 116 when the door 178 is opened. The valve 138 is adjacent the inlet 112 in the illustrated embodiment, but in other embodiments, the valve 138 is adjacent to the connection between the inlet duct 120 and the separator 116, or in yet another location as desired.

[0030] The separator 116 includes a separator housing having a sidewall 180 forming the cyclone 172 and extending between the first end 174 and the second end 176. The sidewall 180 extends around and defines a cyclone axis of rotation 182. When the airflow source 118 generates the suction airflow, the suction airflow travels around the cyclone axis of rotation 182 to separate debris from the suction airflow.

[0031] The cyclone 172 further includes an air outlet 184 for the suction airflow to exit the cyclone 172. The air outlet 184 is adjacent the first end 174 of the cyclone 172. The air outlet 184 includes a shroud 186 that further removes debris from the suction airflow. The illustrated shroud 186 includes a cylindrical screen extending around and along the cyclone axis of rotationAttorney Docket No. 025818-0142-W001182. The shroud 186 may include a screen, vanes, or the like that further separate debris from the suction airflow.

[0032] The separator 116 further includes a filter chamber 188 housing a filter 124. The filter 124 is disposed in the airflow passage between the screen 186 and the airflow source 118. The filter 124 is upstream of the airflow source 118 during suction airflow such that the filter 124 removes debris from the suction airflow before the suction airflow travels through the airflow source 118. The discharge airflow expels debris collected on the filter 124 when the door 178 is open. The filter 124 includes an outer perimeter 190 that engages the wall of the airflow passage inhibiting airflow from bypassing the filter media. In the illustrated embodiment, the diameter 192 of the outer perimeter 190 is greater than a diameter 194 of the screen 186. In the illustrated embodiment, the separator 116 includes the filter chamber 188 positioned in the separator housing. In some embodiments, the separator 116 includes the filter chamber 188 positioned external to the separator housing.

[0033] The separator 116 further includes a tube 196 forming a filter dirt chamber. The tube 196 is between the air outlet 184 and the second end 176 of the cyclone 172 configured to collect dirt or debris that falls from the filter 124. The end of the tube 196 at the second end 176 of the cyclone 172 forms a discharge opening 198 when the door 178 is open through which to exhaust the discharge airflow and expel debris, including debris that was collected on the filter 124 or that was retained within the tube 196. When the door 178 is open the discharge airflow passes along the shroud 186 and through the filter dirt chamber tube 196. Some of the discharge airflow downstream of the filter 52 passes through the shroud 186 from inside of the shroud outwardly, and then through the debris collector 134 before exiting the second end 176.

[0034] Fig. 8 illustrates a cross-sectional view of the airflow source 118. The airflow source 118 is the same as the airflow source 18 illustrated and described above. The airflow source 118 includes an impeller 126 and a motor 128 that rotates the impeller 126 about an axis 130 to generate the suction and discharge airflows. The airflow source 118 is a mixed-flow impeller that defines an angled flow segment 149 having an axial flow vector component (relative to axis 130) and a radial flow vector component (relative to axis 130), the radial flow vector component is configured to generate the suction airflow. The airflow source 118 further includes a diffuserAttorney Docket No. 025818-0142-W001100. The diffuser 100 does not rotate about the axis 130. The motor 128 includes a shaft 102 that rotates about the axis 130 to rotate the impeller 126. Bearings 104 facilitate rotation of the shaft 102 relative to a stator 106. The motor 128 is a direct current (DC) motor and the vacuum cleaner 100 includes the battery 136 that powers the motor 128. Also, in one embodiment the motor 128 is a bi-polarity motor, or reversible motor, also referred to as a mixed-flow motor, that allows the motor 128 to rotate the impeller 126 about the axis 130 in either the first or second directions as discussed above by switching the polarity of the input voltage to the motor.

[0035] Referring to Fig. 5, the vacuum cleaner 100, similar to the vacuum 10, includes a controller 152 and a user interface 154 in communication with the controller 152. The controller 152 controls operation of the airflow source 118 and the motor 128. The controller 152 is also configured to operate the airflow source 118 to generate the suction airflow or the discharge airflow in response to a signal from the user interface 154. In some embodiments, the controller 152 is operable to control the polarity of the voltage applied to the motor 128 to control the direction of rotation of the impeller 126 about the axis 130 (i.e., whether the suction airflow or discharge airflow is generated by the airflow source 118).

[0036] The user interface 154 may be located on a surface (Fig. 5) of the vacuum cleaner 100 adjacent the handle 150. In some embodiments, the user interface 154 allows a user to select either operating the airflow source 118 to generate the suction airflow or operating the airflow source 118 to generate the discharge airflow discussed above using one or more switches, buttons, touch screen, or other input, and sends a signal to the controller 152 to generate the selected suction airflow or the discharge airflow. The user interface 154 can include other features for providing user feedback, including display(s) indicating the amount of debris in the separator 116, a power level of the battery 136, and / or an indication of dirtiness of the filter 124. The user interface 154 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 154 may further include a switch adjacent the handle 150. 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 118 generates the suction airflow. In a second position of the switch, the airflow source 118 generates the discharge airflow.Attorney Docket No. 025818-0142-W001

[0037] The illustrated vacuum cleaner 100 further includes a first debris sensor 168 and a second debris sensor 170 that are both in communication with the controller 152. The first debris sensor 168 is configured to sense the amount of debris within the separator 116 and the first debris sensor 168 communicates with the controller 152 to determine the amount of debris within the debris collector 134 and the controller communicates with the display 154 and the display 154 alerts the user when the separator 116 is full and / or requires emptying. In some embodiments, the display 154 may provide the user with an indication of the amount of debris within the debris collector 134 (e.g., 50% full, 75% full, 100% full, etc.). The first debris sensor 168 can include any suitable type of sensor for sensing the amount of debris within the separator 116, including an optical sensor, an infrared sensor, a proximity sensor, and the like.

[0038] The second sensor 170 is configured to sense a dirtiness level of the filter 124. For example, in one embodiment, the sensor 170 is a pressure sensor that is operable to sense the difference in pressure of the suction airflow on each side of the filter 124. The sensor 170 and the controller 152 determine the dirtiness level of the filter 124 based on the pressure drop across the filter 124. In other embodiments, other types of sensors (e.g., optical sensor) can be used to determine the dirtiness level of the filter 124.

[0039] In some embodiments, the controller 152 may operate the airflow source 118 at a predetermined level of discharge airflow (e.g., less than the maximum discharge airflow) based on the level of dirtiness of the filter 124 and / or the amount of debris in the separator 116. For example, the controller 152 may decrease the amount of discharge airflow generated by the airflow source 118 if the relative level of dirtiness of the filter 124 is low and / or if there is a relatively small amount of debris in the separator 116. Likewise, the controller 152 may increase the amount of discharge airflow generated by the airflow source 118 if the filter 124 is dirtier or based on the amount of debris in the separator 116. Also, the controller 152 may operate the airflow source to pulse the amount of discharge airflow based on the level of dirtiness of the filter 124 and / or the amount of debris in the separator 116. In other embodiments, the controller 152 may be configured to operate the airflow source 118 at two or more predetermined flow rates of discharge airflow. In one embodiment, the controller 152 operates the airflow source 118 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 aAttorney Docket No. 025818-0142-W001range between 25 and 75 percent of the high airflow rate). In one embodiment, the controller 152 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 118 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 152 operates the airflow source 118 to vary and / or pulse the discharge airflow to dislodge debris from the filter and the separator 116.

[0040] Various features and advantages of the disclosure are set forth in the following claims.

Claims

Attorney Docket No. 025818-0142-W001CLAIMSWhat is claimed is:

1. A vacuum cleaner comprising:an inlet configured to receive debris from a surface being cleaned with a suction airflow; a separator in fluid communication with the inlet, the separator configured to separate debris from the suction airflow and retain debris separated from the suction airflow; andan airflow source operable to generate the suction airflow, the airflow source in fluid communication with the inlet and the separator, the airflow source including,an impeller rotatable about an axis,a motor operable to rotate the impeller about the axis in a first direction to generate the suction airflow, the 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, further comprising a valve movable between an open position and a closed position, in the closed position the valve inhibits debris from traveling out of the separator.

3. The vacuum cleaner of claim 2,wherein when the airflow source generates the suction airflow, the valve moves toward an open position to allow the debris and the suction airflow to enter the separator, and wherein when the airflow source generates the discharge airflow, the valve moves toward the open position to allow the debris to exit the separator.

4. The vacuum cleaner according to any of claims 2 to 3, wherein the valve is in the closed position when the airflow source is not generating either the suction airflow or the discharge airflow.

5. The vacuum cleaner according to any of claims 2 to 4, wherein the discharge airflow travels through the separator in generally the opposite direction as the suction airflow when the valve is in the open position.Attorney Docket No. 025818-0142-W0016. The vacuum cleaner according to any of the preceding claims, wherein the separator includes a filter that removes debris from the suction airflow before the suction airflow passes through the airflow source, and wherein the discharge airflow passes through the filter in generally the opposite direction as the suction airflow.

7. The vacuum cleaner according to any of the preceding claims, wherein the separator includes a separator inlet that receives the debris with the suction airflow, and wherein the discharge airflow travels through the separator inlet to expel the debris from at least one of the separator and the filter through the separator inlet.

8. The vacuum cleaner according to any of the preceding claims, wherein the discharge airflow is directed into the separator and travels through the inlet to expel the debris from the separator through the inlet.

9. The vacuum cleaner according to any of the preceding claims, further comprising a filter that removes debris from the suction airflow before the suction airflow passes through the airflow source, wherein the discharge airflow is directed through the filter and travels through the inlet to expel debris from the separator through the inlet.

10. The vacuum cleaner according to any of claims 2 to 9, wherein the separator includes a separator inlet that receives the debris with the suction airflow, wherein the valve is adjacent the separator inlet.

11. The vacuum cleaner according to any of the preceding claims, further comprising an exhaust, wherein an airflow path extends from the inlet, through the separator, through the airflow source, and through the exhaust, wherein the suction airflow travels in a first airflow direction along the airflow path from the inlet, then through the separator, then through the airflow source, and then through the exhaust.

12. The vacuum cleaner according to claim 11, wherein the discharge airflow travels in a second airflow direction along the airflow path from the exhaust, then through the airflow source, then through the separator, and then through the inlet.Attorney Docket No. 025818-0142-W00113. The vacuum cleaner according to any of the preceding claims, further comprising a motor housing, the motor located within the motor housing and the separator is coupled to the motor housing; and a handle that extends from the motor housing, the handle configured to be grasped by a user to move the vacuum cleaner along the surface to be cleaned.

14. The vacuum cleaner according to claim 13, wherein the vacuum cleaner includes a first end and a second end opposite the first end in a direction along the axis, wherein the handle is adjacent the second end and the inlet is adjacent the first end.

15. The vacuum cleaner according to any one of claims 13 to 14, wherein the separator is removably coupled to the motor housing.

16. The vacuum cleaner according to claim 15, wherein the separator includes a filter configured to separate debris from the airflow, wherein the separator is removable from the motor housing to access the filter.

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 any of the preceding claims, further comprising a sensor and a controller, the sensor configured to output a signal to the controller when the vacuum cleaner is connected to a docking station, wherein the airflow source generates the discharge airflow in response to the controller determining that the vacuum cleaner is connected to the docking station.

19. The vacuum cleaner according to claim 18, 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.Attorney Docket No. 025818-0142-W00120. The vacuum cleaner according to claim 19, wherein the debris signal relates to an amount of debris in the separator.

21. The vacuum cleaner according to claim 19, wherein the separator includes a filter configured to separate debris from the airflow, wherein the debris signal relates to a level of dirtiness of the filter.

22. The vacuum cleaner according to claim 18, wherein the controller operates the airflow source to generate the discharge airflow for a predetermined amount of time after determining that the vacuum cleaner is connected to the docking station.

23. The vacuum cleaner according to any of claims 19 to 22, wherein the airflow source has a maximum discharge airflow, wherein the controller operates the airflow source at a predetermined level of discharge airflow less than the maximum discharge airflow in response to the debris signal.

24. The vacuum cleaner according to any of the preceding claims, wherein the valve includes an elastomeric member movable in a first direction to the open position to allow the debris and the suction airflow to enter the separator, and the elastomeric member movable in a second direction to the open position to allow the debris to exit the separator.

25. The vacuum cleaner according to any one of the preceding claims, the separator having a single 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;the cyclone having an air outlet adjacent the first end, the air outlet including a screen; a filter disposed in an airflow passage between the screen and the airflow source, the filter being upstream of the airflow source during suction airflow.

26. The vacuum cleaner according to claim 25, wherein the second end is openable, the discharge airflow configured to expel debris from the separator through the second end.

27. The vacuum cleaner according to claim 25 or claim 26, the discharge airflow configuredAttorney Docket No. 025818-0142-W001to expel debris from the filter.

28. The vacuum cleaner according to any one of claims 25 to 27, the screen being a cylindrical screen along the cyclone axis of rotation.

29. The vacuum cleaner according to claim 28, wherein the filter includes an outer perimeter retaining the filter in the airflow passage, wherein a diameter of the outer perimeter is greater than a diameter of the screen.

30. The vacuum cleaner according to claim 25, wherein the second end of the cyclone includes an openable door, wherein the openable door closes the cyclone chamber and the discharge opening.

31. The vacuum cleaner according to claim 30, the separator further comprising a tube between the air outlet and the second end, wherein the tube forms a discharge opening at the second end.

32. The vacuum cleaner according to any one of claims 6 to 31, wherein the separator includes a separator housing and the filter is positioned inside of the separator housing

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