GB2469057A - Separating apparatus for a cleaning appliance - Google Patents

Abstract

A cleaning appliance comprises separating apparatus 100 for separating dirt from a dirt-bearing air flow and a main body 202 housing a motor for drawing the air flow through the separating apparatus, the separating apparatus comprising a cyclonic separating unit 106 comprising at least one cyclone; a filter unit 136 located downstream of the cyclonic separating unit, and a duct assembly 138 having a body comprising at least one inlet duct 174 for conveying the air flow from the cyclonic separating unit towards the filter unit 136 and at least one outlet duct (176, fig 14b) for conveying the air flow from the filter unit 136 towards the main body, wherein the duct assembly 138 is mounted within the cyclonic separating unit 106.

Description

I

A Cleaning Appliance The present invention relates to a cleaning appliance.

Cleaning appliances such as vacuum cleaners are well known. The majority of vacuum cleaners are either of the "upright" type or of the "cylinder" type (called canister or barrel machines in some countries). Cylinder vacuum cleaners generally comprise a main body which contains a motor-driven fan unit for drawing a dirt-bearing fluid flow into the vacuum cleaner, and separating apparatus, such as a cyclonic separator or a bag, for separating dirt and dust from the fluid flow. The dirt-bearing fluid flow is introduced to the main body through a suction hose and wand assembly which is connected to the main body. The main body of the vacuum cleaner is dragged along by the hose as a user moves around a room. A cleaning tool is attached to the remote end of the hose and wand assembly. The main body of the cleaner typically comprises a pair of wheels rotatably mounted on the main body which rotate as the vacuum cleaner is dragged over the floor surface.

Irrespective of the type of separating apparatus used, there may be a risk of a small amount of dirt and dust passing through the separating apparatus and being carried to the motor-driven fan unit. It is undesirable for dirt and dust particles to pass through the fan of a motor and fan unit because the fan may become damaged or may operate less efficiently. In order to reduce this problem, some vacuum cleaners include a fine filter in an air flow path between the separating apparatus and the airflow generator. This filter is commonly known as a pre-motor filter and is used to extract any fine dirt and dust particles remaining in the air flow after it has passed through the separating apparatus.

It is also known to provide a filter in an air flow path downstream of the air flow generator in order to extract any remaining dirt and dust particles prior to the air flow exiting the appliance. This type of filter is known as a post-motor filter. The post-motor filter also captures particles produced by the brushes of the motor.

Filter assemblies for removing dust or debris from the air stream of a vacuum cleaner or other dust retaining appliances are therefore common. Such filter assemblies generally comprise at least one filter located in a filter housing.

During normal operation of a vacuum cleaner, dirt and dust may be deposited on a filter and, after a period of time, it could become blocked. Blockages reduce the efficiency at which a vacuum cleaner operates. Therefore, a typical filter will occasionally need to be replaced or cleaned in order to maintain the performance of the vacuum cleaner. In order to allow cleaning or replacement of the filter, it is common for such filters to be removable from a vacuum cleaner. Re-useable filters can reduce filter maintenance costs. US 4,902,306, for example, discloses an air filter assembly including electrostatic filter elements and a foam filter that can be cleaned by washing.

Another type of known filter assembly is that used on the Dyson range of vacuum cleaners, for example, on model numbers DCO4, DCO7, DC12, DC14 and DC15. The principle by which filter assemblies of this type operate is described in GB 2349105 and EP 1239760B.

The present invention provides a cleaning appliance comprising separating apparatus for separating dirt from a dirt-bearing air flow and a main body housing a motor for drawing the air flow through the separating apparatus, the separating apparatus comprising a cyclonic separating unit comprising at least one cyclone; a filter unit located downstream of the cyclonic separating unit, and a duct assembly having a body comprising at least one inlet duct for conveying the air flow from the cyclonic separating unit towards the filter unit and at least one outlet duct for conveying the air flow from the filter unit towards the main body, wherein the duct assembly is mounted within the cyclonic separating unit.

The arrangement of the duct assembly within the cyclonic separating unit can channel the air flow towards the filter unit efficiently and reduce the flow path and route over which the fluid travels. This can lead to a reduction in noise generation and losses in the system. Preferably, the air flow exiting the cyclonic separating unit enters a manifold part of the cyclone arrangement and a series of manifold fingers channel the air flow towards the filter unit. Preferably, the manifold part comprises a continuous outer surface and preferably the manifold fingers are arranged at an angle to the filter unit and direct the air flow downwardly and at an angle matched to an inlet of the filter unit. The manifold fingers may comprise a separate portion of the cyclonic separating unit or may be moulded within the separating unit.

The arrangement provides for a particularly compact separation system and cleaning appliance configuration, allowing smaller, more compact appliances to be manufactured.

Preferably, the said at least one inlet duct and said at least one outlet duct are arranged to convey the air flow in substantially opposite directions. The route taken by the air flow is a feature of the orientation and provision of the ducts in the body of the duct assembly. The arrangement allows air flow from the separation unit to be directed towards the filter, and cleaner air to be directed away from the filter unit.

In the preferred embodiment the duct assembly comprises an annular fluid inlet for receiving the air flow from the cyclonic separating unit, and then at least one inlet duct arranged to receive the air flow from the fluid inlet. This can provide an unrestricted fluid flow of air towards the filter unit, leading to efficient separation of any dirt or debris from the air flow before reaching the motor. Preferably, an inlet duct has a circular cross-section, preferably each inlet duct has a circular cross section, and the transition between the cross-section of the annular fluid inlet and the cross-section of one, or each, inlet duct is gradual and smooth. A circular duct cross section and a smoothly changing cross section from one region of ducting to another help to minimise losses in the air flow path and maintain separation efficiency.

Preferably the duct assembly comprises a fluid outlet for receiving the air flow from at least one outlet duct, wherein the fluid outlet of the duct assembly is located on an upper surface of the separating apparatus. Locating the outlet on the upper surface can reduce the route traveled by the air flow exiting the duct assembly and the filter unit, leading to a reduction in noise and flow path complexity. More preferably, the fluid inlet surrounds the fluid outlet, allowing for further simplification and miniaturisation of the separating apparatus and the overall cleaning appliance.

Preferably, the duct assembly comprises means for isolating the fluid inlet from the fluid outlet. More preferably, the means for isolating the fluid inlet from the fluid outlet comprises a cup-shaped portion of the duct assembly. Isolating the fluid inlet from the fluid outlet inhibits cleaned air exiting the filter unit recirculating back to the inlet and also prevents any air flow passing to the fluid outlet (an on to the motor-driven fan unit) before being cleaned by the filter unit, thus preserving the efficiency of the separation apparatus. Without the cup-shaped portion the efficiency of the cleaning appliance would be degraded due to losses and contamination of the air flow. The cup-shaped portion preferably seals against a ball joint of an outlet duct. The outlet duct provides a passage for conveying air from the separating apparatus to the main body. Preferably the cup-shaped portion comprises a graspable pillar and a plurality of support members, preferably lugs. The graspable pillar is preferably arranged to upstand from an inner surface of the cup-shaped portion.

In the preferred embodiment, at least one outlet duct has an inlet located on the side wall of the body. Preferably, the said at least one inlet duct comprises a plurality of inlet ducts, preferably in the range from 2 to 10 inlet ducts. Preferably, said at least one outlet duct comprises a plurality of outlet ducts, preferably in the range from 2 to 10 outlet ducts. The number and arrangement of the ducts in the duct assembly facilitates efficient air flow from the separating unit into the filter assembly and out of the filter assembly back towards the main body for then exhausting from the cleaning appliance.

Preferably, the plurality of inlet ducts is arranged in an annular formation and in which the inlet ducts are evenly spaced. Preferably, the plurality of inlet ducts is angularly offset relative to the inlet ducts, more preferably by an angle of around 45 degrees.

In the preferred embodiment the cyclonic separating unit comprises a further cyclonic separating unit located downstream of the at least one cyclone, the further cyclonic separating unit including a plurality of cyclones arranged in parallel. More preferably, the plurality of cyclones of the further cyclonic separating unit is arranged around the duct assembly. This arrangement can increase the separation efficiency of the separating apparatus whilst retaining a compact appliance.

It is preferred that the filter unit is removable from the separating apparatus. Preferably, the filter unit can be washable. The filter unit is preferably attached to the duct assembly, avoiding the filter unit and the duct assembly becoming detached and separated by a user during a washing operation, which could lead to one or other being lost or misplaced.

Preferably, the filter unit comprises a plurality of filter members held adjacent one another in a cylindrical shape. Preferably, the plurality of filter members are held in a cylindrical shape by a deformable rim formed around an upper end of the filter unit.

More preferably, the plurality of filter members are held in a cylindrical shape closed by a base member. This arrangement provides a robust filter unit that can be positioned within the separating apparatus by a user and handled and manipulated with ease for cleaning and washing.

Preferably, the filter unit comprises a means manually accessible by a user to remove the filter unit from the appliance. The means manually accessible by a user may be a pillar, a tab or tag. The means may comprise a grippable or graspable portion to facilitate removal of the filter unit by a user. These features of the filter unit mean that a filter requiring cleaning or replacement will be more readily dealt with, thus avoiding unnecessary strain or overloading on the filter which could, in turn, lead to dirt and dust passing through the filter and, in the case of a pre-motor filter, passing onto the motor and fan unit, leading to damage to motor and fan components.

In a further aspect the present invention also provides a filter assembly for a cleaning appliance, the filter assembly being in the form of a cartridge removably insertable within the appliance, and comprising a filter unit and a duct assembly connected to the filter unit, the duct assembly comprising a fluid inlet, a fluid outlet, and a body having at least one inlet duct for conveying an air flow from the fluid inlet towards the filter unit and at least one outlet duct for conveying the air flow from the filter unit to the fluid outlet.

The arrangement provides for a filter assembly arranged in a compact manner within a cleaning appliance, the filter assembly can be removed from a cleaning appliance as required, for cleaning or maintenance.

S

Preferably, the duct assembly comprises means for isolating the fluid inlet from the fluid outlet. Preferably, said means for isolating the fluid inlet from the fluid outlet comprises a flexible portion of the duct assembly. A flexible portion of the duct assembly can provide an air tight seal between the fluid inlet and the fluid outlet and can inhibit contamination of the inlet and outlet air flows.

Preferably, the flexible portion of the duct assembly is connected to the upper surface of the body, and wherein said at least one inlet duct has an inlet located on an upper surface of the body and an outlet located on a lower surface of the body. More preferably, said at least one outlet duct has an inlet located on the side wall of the body.

In the preferred embodiment the filter assembly is washable. Preferably, at least one inlet duct comprises a plurality of inlet ducts, preferably in the range from 2 to 10 inlet ducts. Preferably, at least one outlet duct comprises a plurality of outlet ducts, preferably in the range from 2 to 10 outlet ducts. It is preferred that the at least one filter assembly as claimed in any of claims 25 to 32 removably located in the airflow path.

In the cleaning appliance of the preferred embodiment, comprising a motor for causing air to flow along the airflow path, the filter assembly is positioned upstream of the motor.

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a vacuum cleaner; Figure 2 is a side view of the vacuum cleaner of Figure 1; Figure 3 is an underside view of the vacuum cleaner of Figure 1; Figure 4 is a top view of the vacuum cleaner of Figure 1; Figure 5 is a sectional view taken along line F-F in Figure 2; Figure 6 is a sectional view taken along line G-G in Figure 4; Figure 7 is a perspective view of the vacuum cleaner of Figure 1, with the chassis articulated in one direction; Figure 8 is an underside view of the vacuum cleaner of Figure 1, with the chassis articulated in one direction and the separating apparatus removed; Figure 9 is a top view of the vacuum cleaner of Figure 1, with the chassis articulated in one direction and the separating apparatus removed; Figure 10 is a front view of the vacuum cleaner of Figure 1, with the separating apparatus removed; Figure 11 is a perspective view of the vacuum cleaner of Figure 1, with the separating apparatus removed; Figure 12 is a top view of the separating apparatus of the vacuum cleaner of Figure 1; Figure 13 is a rear view of the separating apparatus of Figure 12; Figure 1 4a is top view of a portion of the separating apparatus of Figure 12; Figure 14b is a sectional view through line I-I in Figure 12; Figure 14c is a perspective view of the cross-over duct assembly of the separating apparatus of Figure 12; Figure 15 is a side view of a filter of the separating apparatus of Figure 12; Figure 16 is a side view of the separating apparatus of Figure 12, with the filter of Figure 15 partially removed therefrom; Figure 17 is a side view of the separating apparatus of Figure 12, with the filter of Figure 15 fully inserted thereinto and with a handle of the separating apparatus in a stowed position; Figure 18 is a side view of the separating apparatus of Figure 12, with the filter of Figure 15 fully inserted thereinto and with the handle of the separating apparatus in a deployed position; Figure 19 is a sectional view of the handle of the separating apparatus of Figure 12 in its stowed position; Figure 20 is a sectional view of the handle of the separating apparatus of Figure 12 in its deployed position; Figure 21a is a side view of the vacuum cleaner of Figure 1, with a duct extending from the separating apparatus to the main body in a raised position; Figure 21b is a side sectional view taken along line J-J of Figure 4; Figure 22 is an enlarged side view of the main body of the vacuum cleaner of Figure 1; and Figure 23 is a sectional view taken along line F-F in Figure 22.

Figures 1 to 4 illustrate external views of a cleaning appliance in the form of a vacuum cleaner 10. The vacuum cleaner 10 is of the cylinder type. In overview, the vacuum cleaner 10 comprises separating apparatus 100 for separating dirt and dust from an airflow. The separating apparatus 100 is preferably in the form of cyclonic separating apparatus, and comprises an outer bin 102 having an outer wall 104 which is substantially cylindrical in shape. The lower end of the outer bin 102 is closed by base 106 which is pivotably attached to the outer wall 104. A motor-driven fan unit for generating suction for drawing dirt laden air into the separating apparatus 100 is housed within a rolling assembly 200 located behind the separating apparatus 100. The rolling assembly 200 comprises a main body 202 and two wheels 204, 206 rotatably connected to the main body 202 for engaging a floor surface. An inlet duct 300 conveys dirt-bearing air into the separating apparatus 100, and an outlet duct 350 conveys air exhausted from the separating apparatus 100 into the rolling assembly 200. An articulated steering mechanism 400 steers the vacuum cleaner 10 as it is manoeuvred across a floor surface to be cleaned.

The steering mechanism 400 comprises a chassis 402 connected to the main body 202 of the rolling assembly 200. The chassis 402 is generally arrow-shaped, and comprises an elongate body 404 connected at the rear end thereof to the main body 202 of the rolling assembly 200, and a pair of arms 406 each extending rearwardly from the front end of the elongate body 404 and inclined to the elongate body 404. The steering mechanism 400 further comprises a pair of wheel assemblies 408 for engaging the floor surface, and a control mechanism for controlling the orientation of the wheel assemblies 408 relative to the chassis 402, thereby controlling the direction in which the vacuum cleaner 10 moves over the floor surface. The distance between the points of contact of the wheel assemblies 408 with the floor surface is greater than that between the points of contact of the wheels 204, 206 of the rolling assembly 200 with that floor surface.

The wheel assemblies 408 may be considered as articulated front wheels of the vacuum cleaner 10, whereas the wheels 204, 206 of the rolling assembly 200 may be considered as the rear wheels of the vacuum cleaner 10.

The control mechanism comprises a pair of steering hubs 410 each connecting a respective wheel assembly 408 to the chassis 402. Each steering hub 410 is substantially L-shaped. Each steering hub 410 is pivotably connected at a first end thereof to the end of a respective arm 406 of the chassis 402 for pivoting movement about a respective hub axis H. Each hub axis H is substantially orthogonal to the axes of rotation of the wheel assemblies 408. The second end of each steering hub 410 is connected to a respective wheel assembly 408 so that the wheel assembly 408 is free to rotate as the vacuum cleaner 10 is moved over the floor surface.

The control mechanism also comprises an elongate track control arm 412 for controlling the pivoting movement of the steering hubs 410 about their hub axes H, thereby controlling the direction in which the vacuum cleaner 10 moves over the floor surface.

With reference also to Figures 5 and 6, the chassis 402 comprises a lower chassis section 414 which is connected to the main body 202 of the rolling assembly 200, and an upper chassis section 416 connected to the lower chassis section 414. Each chassis section 414, 416 may be formed from one or more component parts. The upper chassis section 416 comprises a lower portion 418 which forms, with the lower chassis section 414, the body 404 and the arms 406 of the chassis 402. The upper chassis section 416 also comprises a curved end wall 420 upstanding from the lower portion 418, and a profiled upper portion 422 connected to the end wall 420 and extending over part of the lower portion 418. The middle of the track control arm 412 is retained between the lower portion 418 and the upper portion 422 of the upper chassis section 416. The track control arm 412 is oriented relative to the chassis 400 so as to be substantially orthogonal to the body 404 of the chassis 402 when the vacuum cleaner 10 is moving forwards over the floor surface. Each end of the track control arm 412 is connected to the second end of a respective steering hub 410 so that movement of the track control arm 412 relative to the chassis 402 causes each steering hub 410 to pivot about its hub axis H. This is turn causes each wheel assembly 408 to orbit about the end of its respective arm 406 of the chassis 402 to change the direction of the movement of the vacuum cleaner 10 over the floor surface.

With reference to Figure 6, the lower chassis section 414 comprises a spindle 424 extending substantially orthogonally upward therefrom, and which passes through an aperture formed in the lower portion 418 of the upper casing section 416. The upper portion 422 of the upper casing section 416 of the spindle 424 comprises a cylindrical recess for receiving the upper end of the spindle 424. The longitudinal axis of the spindle 424 defines a main pivot axis P of the steering mechanism 400. Pivot axis P is substantially parallel to the hub axes H. The inlet duct 300 for conveying dirt-bearing air into the separating apparatus 100 is pivotably connected to the chassis 402 of the steering mechanism 400. The inlet duct 300 comprises a rearwardly extending arm 302 which is also retained between the lower portion 418 and the upper portion 422 of the upper chassis section 416. The arm 302 comprises an aperture for receiving the spindle 424 of the lower chassis section 414 so that the arm 302 is pivotable about axis P. The arm 302 also comprises a slot 304 for receiving a pin 426 connected to the track control arm 412, and within which the pin 426 is moveable as the arm 302 pivots about the axis P. The engagement between the slot 304 and the pin 426 causes the track control arm 412 to move relative to the chassis 402 as the arm 302 pivots about axis P. Returning to Figures 1 to 5, the vacuum cleaner 10 comprises a flexible hose 306 extending between the inlet duct 300 and a swivel coupling 308 for connection to a wand and hose assembly (not shown) for conveying the duct-bearing airflow to the inlet duct 300. The wand and hose assembly is connected to a cleaner head (not shown) comprising a suction opening through which a dirt-bearing airflow is drawn into the vacuum cleaner 10. The hose 306 is omitted from Figures 6 to 10 for clarity purposes only. The steering mechanism 400 comprises a yoke 428 for supporting the swivel coupling 308, and for connecting the swivel coupling 308 to the chassis 402. The yoke 428 comprises a front section extending forwardly from the front of the chassis 402, and a rear section which is located between the lower chassis section 414 and the upper chassis section 416. The rear section of the yoke 428 is connected to the chassis 402 for pivoting movement about a yoke pivot axis Y. Axis Y is spaced from, and substantially parallel to, axis P. The upper chassis section 416 is shaped to define an opening 430 through which the yoke 428 protrudes from the chassis 402, and which restricts the pivoting movement of the yoke 428 relative to the chassis 402 to within a range of �65°.

The yoke 428 comprises a floor engaging rolling element 432 for supporting the yoke 428 on the floor surface, and which has a rotational axis which is substantially orthogonal to axis Y. To manoeuvre the vacuum cleaner 10 over the floor surface, the user pulls the hose of the hose and wand assembly connected to the swivel coupling 308 to drag the vacuum cleaner 10 over the floor surface, which in turn causes the wheels 204, 206 of the rolling assembly 200, the wheel assemblies 408 and the rolling element 432 to rotate and move the vacuum cleaner 10 over the floor surface. With reference also to Figures 7 to 9, to steer the vacuum cleaner 10 to the left, for example, as it is moving across the floor surface, the user pulls the hose of the hose and wand assembly to the left so that the swivel coupling 308 and the yoke 428 connected thereto pivot to the left about axis Y. This pivoting movement of the yoke 428 about axis Y causes the hose 306 to flex and exert a force on the inlet duct 300. This force causes the inlet duct 300 and the arm 302 to pivot to the left about axis P. With particular reference to Figure 9, due to the flexibility of the hose 306, the amount by which the yoke 428 pivots about axis Y is greater than the amount by which the inlet duct 300 pivots about axis P. For example, when the yoke 428 is pivoted about axis Y by an angle of 65° the inlet duct 300 is pivoted about axis P by an angle of around 25°. As the arm 302 pivots about axis P, the pin 426 connected to the track control arm 412 moves with and within the slot 304 of the arm 302, causing the track control arm 412 to move relative to the chassis 402.

With particular reference to Figures 8 and 9, the movement of the track control arm 412 causes each steering hub 410 to pivot about its respective hub axis H so that the wheel assemblies 408 turn to the left, thereby changing the direction in which the vacuum cleaner 10 moves over the floor surface. The control mechanism is preferably arranged so that movement of the track control arm 412 relative to the chassis 402 causes each wheel assembly 408 to turn by a respective different amount relative to the chassis 402.

The vacuum cleaner 10 comprises a support 310 upon which the separating apparatus 100 is removably mounted. The support 310 is connected to the inlet duct 300 for movement therewith as the arm 302 pivots about axis P. With particular reference to Figures 9 and 10, in this example the support 310 comprises two parts located on opposite sides of the inlet duct 300, and each shaped to receive a respective catch 108 projecting outwardly from the outer wall 104 of the outer bin 102. In this example, the outer bin 102 comprises a single catch 108 which is received in one part of the support 310, but the outer bin 102 may comprises two such catches 108 spaced about the outer wall 104 of the outer bin 102.

The support 310 is preferably biased in an upward direction so that the separating apparatus 100 is urged toward the outlet duct 350 of the vacuum cleaner 10, which assists in maintaining an air-tight seal between the separating apparatus 100 and the outlet duct 350. For example, the support 310 may be connected to the arm 302 of the inlet duct 300 by resilient members that urge the separating apparatus 100 toward the outlet duct 350.

When the separating apparatus 100 is mounted on the support 310, the longitudinal axis of the outer bin 102 is inclined to the axis P, in this example by an angle in the range from 30 to 40°. Consequently, pivoting movement of the inlet duct 300 about axis P during a cleaning operation causes the separating apparatus 100 to pivot, or swing, about axis P, relative to the chassis 402, the rolling assembly 200 and the outlet duct 350.

The inlet duct 300 comprises a horizontal section 312 for receiving the dirt-bearing airflow from the hose 306, and an inclined section 314 which extends alongside the outer wall 104 of the outer bin 102 of the separating apparatus 100, and is substantially parallel to the longitudinal axis of the outer bin 102 when the separating apparatus 100 is mounted on the support 310. The inlet duct 300 further comprises an outlet 316 through which the dust-bearing airflow enters the separating apparatus 100. With reference to Figure 10, the outlet 316 of the inlet duct 300 is located on a curved bin support 318 which is preferably integral with the inlet duct 300, and which has a curvature which is substantially the same as that of the outer wall 104 of the outer bin 102. This allows the outer wall 104 of the outer bin 102 to bear against the bin support 318 when the separating apparatus 100 is mounted on the support 310.

The cyclonic separating apparatus 100 will now be described with reference to Figures 6, 12 to 14 and Figures 16 to 18. The specific overall shape of the cyclonic separating apparatus 100 can be varied according to the size and type of vacuum cleaner in which the separating apparatus 100 is to be used. For example, the overall length of the separating apparatus 100 can be increased or decreased with respect to the diameter of the apparatus, or the shape of the base can be altered so as to be, for example, flat and not generally frustro-conical, as illustrated.

As mentioned above, the separating apparatus 100 comprises an outer bin 102 which has an outer wall 104 which is substantially cylindrical in shape. The lower end of the outer bin 102 is closed by a base 106 which is pivotably attached to the outer wall 104 by means of a pivot 110 and held in a closed position by a catch 111 which engages a lip located on the outer wall 104. In the closed position, the base 106 is sealed against the lower end of the outer wall 104. The catch 111 is resiliently deformable so that, in the event that downward pressure is applied to the uppermost portion of the catch 111, the catch 111 will move away from the lip and become disengaged therefrom. In this event, the base 106 will drop away from the outer wall 104.

The separating apparatus further comprises a second cylindrical wall 112. The second cylindrical wall 112 is located radially inwardly of the outer wall 104 and spaced therefrom so as to form an annular chamber 114 therebetween. The second cylindrical wall 112 meets the base 106 (when the base 106 is in the closed position) and is sealed thereagainst. The annular chamber 114 is delimited generally by the outer wall 104, the second cylindrical wall 112, the base 106 and an upper wall 116 positioned at the upper end of the outer bin 102.

A dirty air inlet 117 is provided at the upper end of the outer bin 102 below the upper wall 116 for receiving an airflow from the outlet 316 of the inlet duct 300. The dirty air inlet 117 is arranged tangentially to the outer bin 102 (see Figure 6 and Figure 1 4b) so as to ensure that incoming dirty air is forced to follow a helical path around the annular chamber 114. A fluid outlet is provided in the outer bin 102 in the form of a shroud.

The shroud has an upper portion 118 formed in a frustro-conical shape, a lower cylindrical wall 120 and a skirt portion 122 depending therefrom. The skirt portion 122 tapers outwardly from the lower cylindrical wall 120 in a direction towards the outer wall 104. A large number of perforations 124 are formed in the upper portion 118 of the shroud and in the cylindrical wall 120 of the shroud. The only fluid outlet from the outer bin 102 is formed by the perforations 124 in the shroud. A passage 126 is formed between the shroud and the second cylindrical wall 112. The passage 126 communicates with a plenum chamber 128. The plenum chamber 128 is arranged radially outwardly of the shroud and located above the upper portion of the shroud.

A third cylindrical wall 130 extends from adjacent the base 106 to a portion of the outer wall of the plenum chamber 128 and forms a cylindrical chamber 132. The lower end of the cylindrical chamber 132 is closed by an end wall 134. The end waIl 134 and the lower end of the cylindrical chamber 132 are shaped to correspond to the shape and curvature of the base 106, which in turn is shaped such that it can be located above steering mechanism 400, swivel coupling 308 and a coupling portion of a wand and hose assembly (not shown). The cylindrical chamber 132 is shaped to accommodate a removable filter assembly 136 comprising a cross-over duct assembly 138, which are described in more detail below. The filter assembly 136 is removably received within the cylindrical chamber 132 so that there is no relative rotation of the filter assembly 136 relative to the remainder of the separating apparatus 100 during use of the vacuum cleaner 10. For example, the separating apparatus 100 may be provided with one or more slots which receive formations formed on the filter assembly 136 as the filter assembly 136 is inserted into the separating apparatus 100.

Arranged circumferentially around the plenum chamber 128 is a plurality of cyclones 140 arranged in parallel with one another. Referring to Figures 1 4a and 1 4b, each cyclone 140 has a tangential inlet 142 which communicates with the plenum chamber 128, Each cyclone 140 is identical to the other cyclones 140 and comprises a cylindrical upper portion 144 and a tapering portion 146 depending therefrom. The tapering portion 146 of each cyclone 140 is frustro-conical in shape and terminates in a cone opening. The cyclone 140 extends into and communicates with an annular region 148 which is formed between the second and third cylindrical walls 112, 130. A vortex finder 150 is provided at the upper end of each cyclone 140 to allow air to exit the cyclone 140. Each vortex finder 150 communicates with a manifold finger 152 located above the cyclone 140. In the preferred embodiment there are twelve cyclones 140 and twelve manifold fingers 152. The twelve cyclones 140 are arranged in a ring which is centred on a longitudinal axis X of the outer bin 102. Each cyclone 140 has an axis C which is inclined downwardly and towards the axis X. The axes C are all inclined to the axis X at the same angle. The twelve cyclones 140 can be considered to form a second cyclonic separating unit, with the annular chamber 114 forming the first cyclonic separating unit.

In the second cyclonic separating unit, each cyclone 140 has a smaller diameter than the annular chamber 114 and so the second cyclonic separating unit is capable of separating finer dirt and dust particles than the first cyclonic separating unit. It also has the added advantage of being challenged with an airflow which has already been cleaned by the first cyclonic separating unit and so the quantity and average size of entrained particles is smaller than would otherwise have been the case. The separation efficiency of the second cyclonic separating unit is higher than that of the first cyclonic separating unit.

Each manifold finger 152 is a generally inverted U shape and is bounded by an upper wall 154 and lower wall 156 of a manifold 158 of the second cyclonic separating unit.

The manifold finger 152 extends from the upper end of each cyclone 140 to the cross-over duct assembly 138.

With particular reference to Figure 1 4c the cross-over duct assembly 138 comprises an annular seal 162 and a cross-over duct 164. In the preferred embodiment the seal 162 is rubber, and is secured around the outer surface of the cross-over duct 164 with a friction fit. The cross-over duct 164 comprises an upper portion and a lower portion. The seal 162 is located on an upper portion of the cross-over duct 164. The upper portion of the cross-over duct 164 comprises a generally cup shaped portion 166 which provides a fluid outlet from the separating apparatus 100, and which has a convex, preferably hemispherical outer surface. The lower portion of the cross-over duct 164 comprises a lip 168 and a cylindrical outer housing 170 shaped to correspond to the size and shape of the cylindrical chamber 132. The lip 168 is shaped to have a diameter slightly larger than that of the cylindrical outer housing 170 and is located towards the upper end of the cylindrical outer housing 170. An inlet chamber 172 is formed between the upper portion and the lower portion of the cross-over duct 164. The inlet chamber 172 is bounded by the lower surface of the cup shaped portion 166, the upper surface of the cylindrical outer housing 170 and the lip 168.

The cross-over duct 164 comprises a first set of ducts in which air passes in a first direction through the cross-over duct 164, and a second set of ducts in which air passes in a second direction, different from the first direction, through the cross-over duct 164.

In this embodiment, eight ducts are located within the cylindrical outer housing 170 of the cross-over duct 164. These ducts comprise a first set of four filter inlet ducts 174, and a second set of four filter outlet ducts 176. The filter inlet ducts 174 are arranged in an annular formation which is centred on the axis X and in which the filter inlet ducts 174 are evenly spaced. The filter outlet ducts 176 are similarly evenly arranged and spaced about the axis X, but are angularly offset from the filter inlet ducts 174 by an angle of around 45 degrees.

The cup shaped portion 166 of the cross-over duct 164 comprises a graspable pillar 178 and a plurality of side lugs 180. The graspable pillar 178 is arranged to upstand from the base of the cup shaped portion 166 along the axis X such that it extends proud of the second cyclonic separating unit. The side lugs 180 are arranged to depend from the lower surface of the cup portion 166 and act to support the upper portion of the cross-over duct 164 on the lower portion.

With reference to Figure 1 4b, the manifold fingers 152 communicate with the cross-over duct assembly 138. The outlet of each manifold finger 152 terminates at the inlet chamber 172 of the cross-over duct assembly 138. The removable filter assembly 136 is located below the cross-over duct 164, within the cylindrical chamber 132.

Each filter inlet duct 174 has an inlet opening located towards the upper surface of the cylindrical outer housing 170 and adjacent the inlet chamber 172, and an outlet opening located towards the base of the cylindrical outer housing 170. Each filter inlet duct 174 comprises a passage 184 extending between the inlet opening and the outlet opening.

The passage 184 has a smoothly changing cross-section for reducing noise and turbulence in the airflow passing through the cross-over duct 164.

Each filter outlet duct 176 comprises an inlet opening 188 in the outer surface of the cylindrical outer housing 170 adjacent the cylindrical chamber 132, and an exit port 190 for ducting cleaned air away from the filter assembly 136 and towards the outlet duct 350. A passage 186 extending between the inlet opening 188 and the exit port 190 passes through the cylindrical outer housing 170 from the outer surface of the cylindrical outer housing 170 towards the axis X. Consequently, the exit port 190 is located closer to the axis X than the outer opening 188. The exit port 190 is preferably circular in shape.

Returning to Figure 14b, and with reference also to Figures 15 and 16, the filter assembly 136 comprises a rim 600, a base cap 602, and four cylindrical filter members located between the rim 600 and the base cap 602. The filter assembly 136 is generally cylindrical in shape, and comprises a central open chamber 612 bounded by the rim 600, the base cap 602 and an innermost, first filter member 604.

The filter assembly 136 is constructed such that it is pliable, flexible and resilient. The rim 600 is annular in shape having a width, W in a direction Z perpendicular to the axis X. The rim 600 is manufactured from a material with a hardness and deformability that enable a user to deform the rim 600 (and thus the filter assembly 136) by pressing or grasping the rim 600 and twisting and squeezing the filter assembly 136 by hand, in particular during a washing operation. In this embodiment, the rim 600 and base cap 602 are formed from polyurethane.

Each filter member of the filter assembly 136 is manufactured with a rectangular shape.

The four filter members are then joined and secured together along their longest edge by stitching, gluing or other suitable technique so as to form a pipe length of filter material having a substantially open cylindrical shape, with a height, H, in the direction of the axis X. An upper end of each cylindrical filter member is then bonded to the rim 600, whilst a lower end of each filter member is bonded to the base cap 602, preferably by over-moulding the polyurethane material of the rim 600 and base cap 602 during manufacture of the filter assembly 136. Alternative manufacturing techniques for attaching the filter members include gluing, and spin-casting polyurethane around the upper and lower ends of the filter members. In this way the filter members are encapsulated by polyurethane during the manufacturing process to produce a strengthened arrangement capable of withstanding manipulation and handling by a user, particularly during washing of the filter assembly 136.

The first filter member 604 comprises a layer of scrim or web material having an open weave or mesh structure. A second filter member 606 surrounds the first filter member 406, and is formed from a non-woven filter medium such as fleece. The shape and volume of the second filter member 606 is selected so as to substantially fill the volume delimited by the width, W, of rim 600 and the height H of the filter assembly 136.

Therefore, the width of the second filter member 606 is substantially the same as the width, W, of the rim 600.

The third filter member 608 surrounds the second filter member 606, and comprises an electrostatic filter medium covered on both sides by a protective fabric. The layers are held together in a known manner by stitching or other sealing means.

The fourth filter member 610 surrounds the third filter member 608, and comprises a layer of scrim or web material having an open weave or mesh structure.

During manufacture an upper part of the first filter member 604 is bonded to the rim 600 and the base cap 602 immediately adjacent the second filter member 606. An upper part of the third filter member 608 is bonded to the rim 600 and the base cap 602 immediately adjacent the second filter member 606, and an upper part of the fourth filter member 610 is bonded to the rim 600 and the base cap 602 immediately adjacent the third filter member 608. In this manner the filter members 604, 606, 608, 610 are held in position in the filter assembly 136 with respect to the rim 600 and the base cap 602 such that an airflow will impinge first on the first filter member, before impinging, in turn, on the second, third and fourth filter members. For the third filter member 608, comprising an electrostatic filter medium covered on both sides by a protective fabric, it is preferred that all of the layers of the third filter member 608 are bonded to the rim 600 and the base cap 602 so that the risk of delamination of the second filter member 608 during use is reduced.

The outlet duct 350 will now be described with reference to Figures 21 a and 21 b. The outlet duct 350 comprises a generally curved arm spanning the separating apparatus 100 and the rolling assembly 200. The outlet duct 350 comprises a fluid inlet in the form of a ball joint 353 having a convex outer surface, and an elongate tube 354 for receiving air from the ball joint 353. The elongate tube 354 provides a passage 356 for conveying air from the separating apparatus 100 to the rolling assembly 200. With reference to Figure 6, the pivot axis P passes through the outlet duct 350, preferably through the ball joint 353 of the outlet duct 350.

The ball joint 353 is generally hemispherical in shape and is removably housed in the cup portion 166 of the cross-over duct 164. A ball and socket joint is thus formed between the separating apparatus 100 and the outlet duct 350. The cup portion 166 of the cross-over duct 164 is exposed through the open upper end of the manifold 158.

The ball joint 353 comprises an annular seal 355 extending thereabout, and which includes a lip 357 for engaging with an inner surface of the cup portion 166 of the cross-over duct 164. This facilitates efficient and robust sealing between the ball joint 353 and the cross-over duct 164. Alternatively the outer surface of the ball joint 353 may include features, such as an outwardly directed ledge, flange or ribs, which engage with the cup portion 166 of the cross-over duct 164. In addition, in the preferred embodiment the seal 162 of the cross-over duct assembly 138 is flexible and shaped such that the diameter of the upper portion of the seal 162 is slightly smaller that the diameter of the ball joint 353 to provide a snug, elastic fit around the outer surface of the ball joint 353. The seal 162 can also seal any gaps between the ball joint 353 and the second cyclonic separating unit.

As described previously, rotation of the inlet duct 300 about axis P during a cleaning operation causes the separating apparatus 100 to swing about axis P relative to the outlet duct 350. The seal 357 and the fit of the upper rim of the seal 162 with the ball joint 353 facilitate a continuous fluid connection between the (fixed) outlet duct passage 356 and the (moveable) exit ports 190 of the cross-over duct 164. Consequently, an air tight connection is maintained between the separating apparatus 100 and the outlet duct 350 as the separating apparatus 100 moves relative to the outlet duct 350 during movement of the vacuum cleaner 10 across a floor surface.

The rolling assembly 200 will now be described with reference to Figures 22 and 23.

The rolling assembly 200 comprises a main body 202 and two wheels 204, 206 rotatably connected to the main body 202 for engaging a floor surface. In this embodiment the main body 202 and the wheels 204, 206 define a substantially spherical rolling assembly 200. The rotational axes of the wheels 204, 206 are inclined upwardly towards the main body 202 with respect to a floor surface upon which the vacuum cleaner 10 is located so that the rims of the wheels 204, 206 engage the floor surface.

The angle of the inclination of the rotational axes of the wheels 204, 206 is preferably in the range from 5 to 15°, more preferably in the range from 6 to 10°, and in this embodiment is around 8°. Each of the wheels 204, 206 of the rolling assembly 200 is substantially hemispherical in shape. In the preferred embodiment, the diameter of the external surface of each wheel 204, 206 is smaller than the diameter of the rolling assembly 200, and is preferably in the range from 80 to 90% of the diameter of the rolling assembly 200.

The main body 202 of the rolling assembly 200 comprises a motor-driven fan unit 208, a cable rewind assembly 210 for retracting and storing within the main body 202 a portion of an electrical cable 212 providing electrical power to, inter alia, the motor of the fan unit 208, and a filter assembly 214. The fan unit 208 comprises a motor, and an impeller driven by the motor to drawn the dirt-bearing airflow into and through the vacuum cleaner 10. The fan unit 208 is housed in a motor bucket 216. The motor bucket 216 is connected to the main body 202 so that the fan unit 208 does not rotate as the vacuum cleaner 10 is manoeuvred over a floor surface. The motor bucket 216 is substantially hemispherical in shape. The filter assembly 214 is located downstream of the fan unit 208. The filter assembly 214 is cuff shaped and located around a part of the motor bucket 216. A plurality of perforations 218 are formed in a portion of the motor bucket 216 surrounded by the filter assembly 214. A seal 220 separates the cable rewind assembly 210 from the motor bucket 216. The seal 220 facilitates the division of the main body 202 into a first region including the fan unit 208, which will generate heat during use, and a second region accommodating the cable rewind assembly 210, for which heat is detrimental and which may require cooling during use.

The main body 202 of the rolling assembly 200 further comprises a fluid inlet port 222, an annular shaped motor chamber 224 for receiving air from the inlet port 222, and a passage 226 bounded by the motor chamber 224. The chamber 224 is shaped such that there is a smooth change in cross sectional area of the airflow passing from the inlet port 222 to the fan unit 208. The chamber 224 facilitates a change in direction of the passage 226 of around 90 degrees. A smooth path and a smooth change in cross sectional area of a passage for airflow can reduce inefficiencies in the system, for example losses through the motor bucket 216. A grille 228 is located between the inlet port 222 and the motor chamber 224. The grille 228 is fixed to the main body 202 by, for example, a snap-fit connection. The grille 228 protects the fan unit 208 and motor bucket 216 from damage by objects that could otherwise enter, block andlor obstruct the motor chamber 224, for example during removal of the separating apparatus 100 from the main body 202, as described below.

The fan unit 208 comprises a series of exhaust ducts 230 located around the outer circumference of the fan unit 208. In the preferred embodiment four exhaust ducts 230 are arranged around the fan unit 208 and provide communication between the fan unit 208 and the motor bucket 216. The filter assembly 214 is located around the motor bucket 216, and the perforations 218 facilitate communication between the motor bucket 216 and the main body 202. The main body 202 further comprises an air exhaust port for exhausting cleaned air from the vacuum cleaner 10. The exhaust port is formed towards the rear of the main body 202. In the preferred embodiment the exhaust port comprises a number of outlet holes 232 located in a lower portion of the main body 202.

In use, the fan unit 208 is activated by the user, for example by pressing a button located on the upper surface of the main body 202 of the rolling assembly 200, and a dirt-bearing airflow is drawn into the vacuum cleaner 10 through the suction opening in the cleaner head. The dirt-bearing air passes through the hose and wand assembly, and enters the inlet duct 300. The dirt-bearing air passes through the inlet duct 300 and enters the dirty air inlet 117 of the separating apparatus 100. Due to the tangential arrangement of the dirty air inlet 117, the airflow follows a helical path relative to the outer wall 104. Larger dirt and dust particles are deposited by cyclonic action in the annular chamber 114 and collected therein.

The partially-cleaned airflow exits the annular chamber 114 via the perforations 124 in the shroud and enters the passage 126. The airflow then passes into the plenum chamber 128 and from there into one of the twelve cyclones 140 at inlet 142 wherein further cyclonic separation removes some of the dirt and dust still entrained within the airflow. This dirt and dust is deposited in the annular region 148 whilst the cleaned air exits the cyclones 140 via the vortex finders 150 and enters the manifold fingers 152.

The airflow then passes into the cross-over duct 164 via the inlet chamber 172 and enters the four filter inlet ducts 174 of the cross-over duct 164. From the filter inlet ducts 174 the airflow enters the central open chamber 612 of the filter assembly 132.

The airflow passes through the central open chamber 612, and is forced tangentially outwardly towards the filter members of the filter assembly 132. The airflow enters the first filter member 604 first, and then passes sequentially through the second filter member 606, the third filter member 608 and the fourth filter member 610, with dirt and dust being removed from the air flow as it passes through each filter member.

The airflow emitted from the filter assembly 136 passes into the cylindrical chamber 132 and is drawn into the filter outlet ducts 176 of the cross-over duct 164. The airflow passes through the filter outlet ducts 176 and exits the cross-over duct 164 through the four exit ports 190 in the cup portion 166 of the cross-over duct 164. The airflow enters the ball joint 353 of the outlet duct 350, passes along the passage 356 and enters the main body 202 of the rolling assembly 200 through the fluid inlet port 222.

Within the rolling assembly 200, the airflow passes sequentially through the grille 228 and passage 226, and enters the chamber 224. The chamber 224 guides the airflow into the fan unit 208. The airflow is prevented from passing through the cable rewind assembly 210 by the cable rewind seal 220. The airflow is exhausted from the motor exhaust ducts 230 into the motor bucket 216. The airflow then passes out of the motor bucket 216 in a tangential direction via the perforations 218 and passes through the filter assembly 214. Finally the airflow follows the curvature of the main body 202 to the outlet holes 232 in the main body 202, from which the cleaned airflow is ejected from the vacuum cleaner 10.

The outlet duct 350 is detachable from the separating apparatus 100 to allow the separating apparatus 100 to be removed from the vacuum cleaner 10. The end of the tube 354 remote from the ball joint 353 of the outlet duct 350 is pivotably connected to the rolling assembly 200 to enable the outlet duct 350 to be moved between a lowered position shown in Figure 2, in which the outlet duct 350 is in fluid communication with the separating apparatus 100, and a raised position shown in Figure 21 a, which allows the separating apparatus 100 to be removed from the vacuum cleaner 10.

With reference again to Figures 21a and 21b, and also to Figure 4, the outlet duct 350 is biased towards the raised position by a spring 358 mounted on the main body 202. The main body 202 also comprises a catch 360 for retaining the outlet duct 350 in the lowered position against the force of the spring 358, and a catch release button 362.

The outlet duct 350 comprises a handle 352 to allow the vacuum cleaner 10 to be carried by the user when the outlet duct 350 is retained in its lowered position. In the preferred embodiment the spring 358 is a torsion spring provided in engagement with a portion of the handle 352. The catch 360 is located on the main body 202 proximate the outlet duct 350 and along the line G-G in Figure 4.

The catch 360 is arranged to co-operate with a flange 516 of the outlet duct 350. The flange 516 depends from the underside of the outlet duct 350 and extends in a direction extending towards the main body 202. The flange 516 comprises a groove 364 shaped to accommodate an engaging member of the catch 360.

The catch 360 comprises a hook 366 and a rod 368. The rod 368 extends horizontally between the catch release button 362 and the catch 360 and has a width, V, as shown in Figure 4. The hook 366 is arranged at an angle of 90 degrees to the rod 368, and is connected to an end of the rod 368 which is proximate the outlet duct 350. The hook 366 is sized so as to be accommodated within the groove 364 of the flange 516. The hook and rod assembly of the catch 360 is pivotably mounted on the main body 202 and arranged to rotate about pivot axis Q, which is substantially orthogonal to the pivot axis P of the separating apparatus 100.

The catch release button 362 comprises an upper housing 370. An upper surface of the upper housing 370 is smooth and may be coloured or feature other indications of its function to highlight the catch release button 362 for a user. The catch release button 362 further comprises a pin 372 and a guide channel 374. The pin 372 depends from a lower surface of the upper housing 370 and is slidably mounted within the guide channel 374. The pin 372 is moveable along the guide channel 374 from an upper deactivation position to a lower activation position. In the activation position the pin 372 extends beyond the guide channel 374 and is arranged to impinge on the rod portion 368 of the catch 360.

In use, the filter assembly 136 is arranged in the airflow path of the vacuum cleaner 10, as described above. Through use, the filter assembly 136 can become clogged, causing a reduction in the filtration efficiency. In order to alleviate this, the filter assembly 136 will require periodic cleaning or replacement. In the preferred embodiment the filter assembly 136 and all of the filter members are capable of being cleaned by washing.

The filter assembly 136 can be accessed by the user for cleaning when the outlet duct 350 is in its raised position. The pillar 178 of the filter assembly 136 extends beyond the manifold 158, and acts to prompt the user as to where the filter assembly 136 is located, thus aiding removal of the filter assembly 136. The user removes the filter assembly 136 from the separating apparatus 100 by the gripping the pillar 178, and pulling the pillar 178 outwardly and upwardly from the cylindrical chamber 132 of the separating apparatus 100. In this way, the user is not required to handle directly the clogged filter members of the filter assembly 136. This makes replacing or cleaning the filter assembly 136 a hygienic task. The filter assembly 136 is washed by rinsing under a household tap in a known manner and allowed to dry. The filter assembly 136 is then re-inserted into the cylindrical chamber 132 of the separating apparatus 100, the outlet duct 350 is moved to its lowered position and use of the vacuum cleaner 10 can continue.

To enable the outlet duct 350 to be moved from its lowered position to its raised position, the user depresses the catch release button 362. The movement of the catch release button 362 and the lowering of the pin 372 within the guide channel 374 causes a lower part of the pin 372 to impinge on the rod 368 of the catch 360. The rod 368 is forced away from the deactivated position and caused to rotate in an anticlockwise direction about pivot axis Q. The hook 366, being connected to the rod 368, is also caused to rotate in an anticlockwise direction about pivot axis Q and moves out of engagement with groove 364 of flange 516. The movement of the hook 366 of the catch 360 away from the flange 516 allows the biasing force of the spring 358 to urge the handle 352, and thus the outlet duct 350, away from the main body 202 and thereby swing the outlet duct 350 away from its lowered position toward its raised position When the outlet duct 350 is in its raised position, the separating apparatus 100 may be removed from the vacuum cleaner 10 for emptying and cleaning. The separating apparatus 100 comprises a handle 500 for facilitating the removal of the separating apparatus 100 from the vacuum cleaner 10. The handle 500 is positioned on the separating apparatus 100 so as to be located beneath the outlet duct 350 when the outlet duct 350 is in its lowered position. As discussed in more detail below, the handle 500 is moveable relative to the outer bin 102 of the separating apparatus 100 between a stowed position, as illustrated in Figures 17 and 19, and a deployed position, as illustrated in Figures 18 and 20, in which the handle 500 is readily accessible by the user. The extent of the movement of the handle 500 between its stowed and deployed positions is preferably in the range from 10 to 30 mm, and in this preferred embodiment is around 15mm.

The handle 500 comprises a head 502 defining an aperture 504 into which the user inserts one or more fingers to pull the separating apparatus 100 away from the support 310. The head 502 is attached to an elongate body 506 which is slidably located within a recess 508 formed in the second cyclonic separating unit of the separating apparatus 100. The body 506 is located between two adjacent cyclones 140 of the second cyclonic separating unit, and is inclined at a similar angle to the axis X as the axes C of the cyclones 140. The body 506 comprises a front portion 506a connected to the head 502, and a rear portion 506b. The head 500 is biased toward its deployed position by a resilient member located within the recess 508. In this embodiment, this resilient member comprises a first helical spring 510. The lower end of the first helical spring 510 engages the lower surface 512 of the recess 508, and the upper end of the first helical spring 510 engages the lower end 514 of the front portion 506a of the body 506 so that the elastic energy stored in the first helical spring 510 urges the body 506 away from the lower surface 512 of the recess 508.

The handle 500 is urged towards its stowed position by the outlet duct 350. With reference to Figure 21, the outlet duct 350 comprises a flange 516 depending downwardly therefrom for engaging the head 502 of the handle 500. Returning to Figures 17 to 20, the head 502 comprises a groove 518 for receiving the flange 516 of the outlet duct 350. When the outlet duct 350 is moved from its raised position, shown in Figure 21, to its lowered position, shown in Figure 2, the flange 516 locates within the groove 518 and pushes the handle 500 towards its stowed position against the biasing force of the first helical spring 510. Once the handle 500 has reached its stowed position, any further movement of the outlet duct 350 towards its lowered position urges the separating apparatus 100 against the support 310 to firmly retain the separating apparatus 100 on the chassis 402.

To enable the separating apparatus to be subsequently removed from the vacuum cleaner 10 for emptying, the user depresses the catch release button 362 to move the outlet duct 350 to its raised position. The movement of the flange 516 of the outlet duct 350 away from the separating apparatus 100 allows the biasing force of the first helical spring 510 to urge the lower end 514 of the body 506 of the handle 500 away from the lower surface 512 of the recess 508 and thereby push the handle 500 towards its deployed position. As shown in Figure 21, when the outlet duct 350 is in its raised position, the aperture 504 is accessible to enable a user to grasp the head 502 of the handle 500 and pull the handle 500 in a generally upward direction so as to remove the catch 108 of the separating apparatus 100 from the support 310. This action causes a catch 520 located on the lower end 514 of the body 506 of the handle 500 to engage a shoulder 522 located on the cyclone pack, which prevents the handle 500 from being fully withdrawn from the recess 508.

The handle 500 comprises a manually operable button 530 for actuating a mechanism for applying a downward pressure to the uppermost portion of the catch 111 to cause the catch 111 deform and disengage from the lip located on the outer wall 104 of the outer bin 102. This enables the base 106 to move away from the outer wall 104 to allow dirt and dust that has been collected in the separating apparatus 100 to be emptied into a dustbin or other receptacle. The button 530 is positioned on the handle 500 so that the button 530 is both located beneath the outlet duct 350 when the outlet duct 350 is in its lowered position and facing the main body 202 of the rolling assembly 200.

The actuating mechanism comprises a lower push member 532, preferably in the form of a rod, slidably mounted on the outer wall 104 of the outer bin 102. The outer wall 104 of the outer bin 102 comprises a plurality of retaining members 534 for retaining the lower push member 532 on the outer bin 102, and which constrain the lower push member 532 to slide towards or away from the catch 111. The lower push member 532 comprises an upper end 536 located adjacent the second cyclonic separating unit of the separating apparatus 100, and a lower end 538 for engaging the catch 111. The lower push member 532 is not biased in any direction.

The actuating mechanism further comprises an upper push member 540, preferably also in the form of a rod, slidably located within a recess 542 located between the front portion 506a and the rear portion 506b of the body 506 of the handle 500. The upper push member 540 comprises a lower body 543 having a lower end 544 for engaging the upper end 536 of the lower push member 532. The lower end 544 protrudes radially outward through an aperture formed in the outer wall of the second cyclonic separating unit. The upper push member 540 further comprises an upper body 546 connected to, and preferably integral with, the lower body 543, and which comprises an outer frame 548 extending about an arm 550. The arm 550 is pivotable relative to the lower body 543, and internally biased towards the front portion 506a of the body 506 of the handle 500. The upper push member 540 is biased in a generally upward direction by a second resilient member located in the recess 508. In this embodiment, this second resilient member comprises a second helical spring 552. The lower end of the second helical spring 552 engages the lower surface 512 of the recess 508, whereas the upper end of the second helical spring 552 engages the lower end 544 of the upper push member 540 so that the elastic energy stored in the second helical spring 552 urges the lower end 544 of the upper push member 540 away from the lower push member 532 and against the outer wall of the second cyclonic separating unit.

The manually operable button 530 is biased in a generally upward direction by a third resilient member. This resilient member is in the form of a third helical spring 560.

The lower end of the third helical spring 560 engages the upper end 562 of the front portion 506a of the body 506, whereas the upper end of the third helical spring 560 engages the button 530 to urge a front shoulder 564 of the button 560 against a rearwardly extending ridge 566 located on the head 502 of the handle 500. The button 530 also comprises a downwardly extending portion 568 which extends into the recess 542 formed in the body 506 of the handle 500.

With particular reference to Figure 19, when the handle 500 is in its retracted position the downwardly extending portion 568 of the button 530 is located between the front portion 506a of the body 506 and the upper body 546 of the upper push member 540.

The downwardly extending portion 568 of the button 530 engages and urges the arm 550 of the upper push member 540 away from the front portion 506a of the body 506.

As the handle 500 moves towards its extended position, under the action of the third helical spring 560 the button 530 is forced to move with the handle 500, causing the downwardly extending portion 568 of the button 530 to slide upwardly relative to the upper push member 540 and move beyond the upper end of the arm 550 of the upper push member 540. This allows the arm 550 to move towards the front portion 506a of the body 506 of the handle 500. As illustrated in Figure 20, when the handle 500 is in its extended position the downwardly extending portion 568 of the button 530 is located above the arm 550.

To enable the collected dirt and dust to be emptied from the separating apparatus 500, the user removes the separating apparatus 100 from the vacuum cleaner 10. While holding the separating apparatus 100 by the handle 500, the user depresses the button 530, which moves downwardly against the biasing force of the third helical spring 560 and abuts the upper end of the arm 550 of the upper push member 540. Continued downward movement of button 530 against the biasing force of the second helical spring 552 pushes the lower end 544 of the upper push member 540 against the upper end 536 of the lower push member 532. This in turn pushes the lower end 538 of the lower push member 532 against the catch 111. The downward pressure thus applied to the catch 111 causes the catch 111 to move away from the lip on the outer wall 104 of the outer bin 102, allowing the base 106 to drop away from the outer wall 104 so that dirt and dust collected within the separating apparatus 100 can be removed therefrom.

When the user releases pressure from the button 530, the second helical spring 552 and the third helical spring 560 return the upper push member 540 and the button 530 respectively to the positions illustrated in Figure 20. As the lower push member 532 is not biased in any direction, the lower push member 532 is not returneu to we posiuon illustrated in Figures 13 and 20 until the base 106 is swung back to re-engage the catch 111 with the lip on the outer wall 104 of the outer bin 102, whereupon the catch 111 pushes the lower push member 532 back to the position illustrated in Figures 13 and 20.

The invention is not limited to the detailed description given above. Variations will be apparent to the person skilled in the art. For example the shape and size of the filter assembly, the shape and size of the rim or the base of the filter assembly and of the filter members within the assembly may be altered without departing from the scope of the invention. The rim may be formed around part of the filter portions or surround the entire boundary of the filter portions. The rim may be manufactured by manufacturing methods such as moulding or potting using materials such as plastics, rubber or polyurethane. Alternatively, the rim may be bonded to the filter members by other techniques and manufacturing methods, For example the rim and assembly may be manufactured by heat welding, ultra sonic welding, casting, and adhesive.

It will be appreciated that other filter media having different density and thickness, such as foam materials, paper, HEPA filter media, fabric or open cell polyurethane foam could be used in any combination within the filter members and within the assembly.

The number of filter members or layers may be varied. The order of the filter members may be varied. The filter assembly may form the pre-motor filter of a vacuum cleaner or may form the post-motor filter of a vacuum cleaner.

The filter members may or may not be washable. The filter assembly may be housed in a housing or cage, the housing or cage may be capable of being cleaned by washing. It will also be appreciated that the shape of the filter and any filter housing need not be cylindrical and other shapes will be equally suitable. The means manually accessible by a user can be any suitable material or shape to facilitate removal of the filter from the appliance or a filter housing, for example, the pillar or tab may be hook shaped or the type of tab commonly used for textile materials.

Claims (34)

1. CLAIMS1. A cleaning appliance comprising separating apparatus for separating dirt from a dirt-bearing air flow and a main body housing a motor for drawing the air flow through the separating apparatus, the separating apparatus comprising a cyclonic separating unit comprising at least one cyclone; a filter unit located downstream of the cyclonic separating unit, and a duct assembly having a body comprising at least one inlet duct for conveying the air flow from the cyclonic separating unit towards the filter unit and at least one outlet duct for conveying the air flow from the filter unit towards the main body, wherein the duct assembly is mounted within the cyclonic separating unit.
2. 2. A cleaning appliance as claimed in claim 1, wherein said at least one inlet duct and said at least one outlet duct are arranged to convey the air flow in substantially opposite directions.
3. 3. A cleaning appliance as claimed in claim I or claim 2, wherein the duct assembly comprises an annular fluid inlet for receiving the air flow from the cyclonic separating unit, and wherein said at least one inlet duct is arranged to receive the air flow from the fluid inlet.
4. 4. A cleaning appliance as claimed in claim 3, wherein said at least one inlet duct has a circular cross-section, and the transition between the cross-section of the annular fluid inlet and the cross-section of said at least one inlet duct is gradual and smooth.
5. 5. A cleaning appliance as claimed in claim 3 or claim 4, wherein the duct assembly comprises a fluid outlet for receiving the air flow from said at least one outlet duct, wherein the fluid outlet of the duct assembly is located on an upper surface of the separating apparatus.
6. 6. A cleaning appliance as claimed in claim 5, wherein the fluid inlet surrounds the fluid outlet.
7. 7. A cleaning appliance as claimed in claim 5 or claim 6, wherein the duct assembly comprises means for isolating the fluid inlet from the fluid outlet.
8. 8. A cleaning appliance as claimed in claim 7, wherein said means for isolating the fluid inlet from the fluid outlet comprises a flexible portion of the duct assembly.
9. 9. A cleaning appliance as claimed in claim 8, wherein the flexible portion of the duct assembly is connected to the upper surface of the body, and wherein said at least one inlet duct has an inlet located on an upper surface of the body and an outlet located on a lower surface of the body.
10. 10. A cleaning appliance as claimed in claim 9, wherein said at least one outlet duct has an inlet located on a side wall of the body.
11. 11. A cleaning appliance as claimed in any of the preceding claims, wherein said at least one inlet duct comprises a plurality of inlet ducts, preferably in the range from 2 to 10 inlet ducts.
12. 12. A cleaning appliance as claimed in any of claims 1 to 10, wherein said at least one outlet duct comprises a plurality of outlet ducts, preferably in the range from 2 to 10 outlet ducts.
13. 13. A cleaning appliance as claimed in claim 11, wherein said at least one outlet duct comprises a plurality of outlet ducts, preferably in the range from 2 to 10 outlet ducts.
14. 14. A cleaning appliance as claimed in claim 13, wherein the plurality of inlet ducts is angularly offset relative to the plurality of inlet ducts.
15. 15. A cleaning appliance as claimed in any preceding claim, wherein the cyclonic separating unit comprises a further cyclonic separating unit located downstream of the at least one cyclone, the further cyclonic separating unit including a plurality of cyclones arranged in parallel.
16. 16. A cleaning appliance as claimed in claim 15, wherein the plurality of cyclones of the further cyclonic separating unit is arranged around the duct assembly.
17. 17. A cleaning appliance as claimed in any preceding claim, wherein the filter unit is removable from the separating apparatus.
18. 18. A cleaning appliance as claimed in any preceding claim, wherein the filter unit is washable.
19. 19. A cleaning appliance as claimed in any preceding claim, wherein the filter unit is attached to the duct assembly.
20. 20. A cleaning appliance as claimed in any preceding claim, wherein the filter unit comprises a plurality of filter members held adjacent one another in a cylindrical shape.
21. 21. A cleaning appliance as claimed in claim 20, wherein the plurality of filter members are held in a cylindrical shape by a deformable rim formed around an upper end of the filter unit.
22. 22. A cleaning appliance as claimed in claim 20 or claim 21, wherein the plurality of filter members are held in a cylindrical shape closed by a base member.
23. 23. A cleaning appliance as claimed in any preceding claim, wherein the filter unit comprises a means manually accessible by a user to remove the filter unit from the appliance.
24. 24. A cleaning appliance substantially as herein described with reference to the accompanying drawings.
25. 25. A filter assembly for a cleaning appliance, the filter assembly being in the form of a cartridge removably insertable within the appliance, and comprising a filter unit and a duct assembly connected to the filter unit, the duct assembly comprising a fluid inlet, a fluid outlet, and a body having at least one inlet duct for conveying an air flow from the fluid inlet towards the filter unit and at least one outlet duct for conveying the air flow from the filter unit to the fluid outlet.
26. 26. A filter assembly as claimed in claim 25, wherein the duct assembly comprises means for isolating the fluid inlet from the fluid outlet.
27. 27. A filter assembly as claimed in claim 26, wherein said means for isolating the fluid inlet from the fluid outlet comprises a flexible portion of the duct assembly.
28. 28. A filter assembly as claimed in claim 27, wherein the flexible portion of the duct assembly is connected to the upper surface of the body, and wherein said at least one inlet duct has an inlet located on an upper surface of the body and an outlet located on a lower surface of the body.
29. 29. A filter assembly as claimed in claim 28, wherein said at least one outlet duct has an inlet located on the side wall of the body.
30. 30. A filter assembly as claimed in any of claims 25 to 29, wherein the filter assembly is washable.
31. 31. A cleaning appliance as claimed in any of claims 25 to 30, wherein said at least one inlet duct comprises a plurality of inlet ducts, preferably in the range from 2 to 10 inlet ducts.
32. 32. A cleaning appliance as claimed in any of claims 25 to 31, wherein said at least one outlet duct comprises a plurality of outlet ducts, preferably in the range from 2 to 10 outlet ducts.
33. 33. A cleaning appliance having an airflow path and at least one filter assembly as claimed in any of claims 25 to 32 removably located in the airflow path.
34. 34. A cleaning appliance as claimed in claim 33, comprising a motor for causing air to flow along the airflow path, wherein the filter assembly is positioned upstream of the motor.