WO2007008770A2

WO2007008770A2 - Vacuum cleaner upright assembly

Info

Publication number: WO2007008770A2
Application number: PCT/US2006/026695
Authority: WO
Inventors: Alan J. Krebs; Jonathan L. Miner
Original assignee: Bissell Homecare, Inc.
Priority date: 2005-07-12
Filing date: 2006-07-11
Publication date: 2007-01-18
Also published as: WO2007008771A2; GB2466896A; WO2007008770A3; WO2007008771B1; GB2466896B; GB0800665D0; GB2441724A; GB201014562D0; GB2470320B; US20120131764A1; GB2470320A; US20080216283A1; WO2007008771A3; GB2441724B; US8752242B2; US20090056069A1; GB201006670D0

Abstract

A vacuum cleaner comprises a primary support section that provides a modular platform for connecting different vacuum cleaner assemblies, such as different base assemblies, handle assemblies, and dirt separation assemblies. The primary support section comprises a motor and filter casing that houses a motor/fan assemble, a pre-motor filter assembly, and a post-motor filter assembly. The casing is formed in two parts that having integrally formed chambers for the motor/fan assembly, pre-motor filter assembly, and post-motor filter assembly and integrally formed ducts for fluid communication between the chambers. Several accessory tools, including a multi-purpose upholstery tool having a removable bristle block with different types of agitators are disclosed. The bristle block can selectively be used with the upholstery tool and can be orientated so that a desired agitator is in position to engage a surface to be cleaned.

Description

VACUUM CLEANER UPRIGHT ASSEMBLY

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/595,515, filed July 12, 2005, all of which is incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

Field of the Invention [0002] The invention relates to suction cleaners. In one of its aspects, the invention relates to suction cleaners having an integrally formed motor and filter housing, hi another of its aspects, the invention relates to a modular suction cleaner platform upon which various dirt separators, base assemblies, and handle assemblies can be interchanged. In yet another of its aspects, the invention relates to an accessory tool for a vacuum cleaner.

Description of the Related Art

[0003] Upright vacuum cleaners employing cyclone separators are well known. Some cyclone separators follow textbook examples using frusto-conical shape separators and others use high-speed rotational motion of the air/dirt to separate the dirt by centrifugal force. Typically, working air enters and exits at an upper portion of the cyclone separator as the bottom portion of the cyclone separator is used to collect debris. Furthermore, in an effort to reduce weight, the motor/fan assembly that creates the working air flow is typically placed at the bottom of the handle, below the cyclone separator. [0004] BISSELL Homecare, Inc. presently manufactures and sells in the United States an upright vacuum cleaner that has a cyclone separator and a dirt cup. A horizontal plate separates the cyclone separator from the dirt cup. The air flowing through the cyclone separator passes through an annular cylindrical cage with baffles and through a cylindrical filter before exiting the cyclone separator at the upper end thereof. The dirt cup and the cyclone separator are further disclosed in the U.S. Patent No. 6,810,557 which is incorporated herein by reference in its entirety. [0005] U.S. Patent No. 4,571,772 to Dyson discloses an upright vacuum cleaner employing a two stage cyclone separator. The first stage is a single separator wherein the outlet of the single separator is in series with an inlet to a second stage frusto- conical separator.

SUMMARY OF THE INVENTION

[0006] A vacuum cleaner according to the invention comprises a base assembly having a suction nozzle and working airpath therethrough, an upright assembly pivotally mounted to the base assembly, a dirt separation assembly mounted to the upright assembly and in fluid communication with the suction nozzle, a suction source mounted in the upright assembly adapted to establish and maintain a dirt-containing airstream from the base assembly through the dirt separation assembly, an integrally formed first casing that at least partially houses a pre-motor filter assembly and at least partially houses the suction source, and a second casing that is mated with the first casing and that at least partially houses the suction source. [0007] In one embodiment of the invention, the second casing can at least partially house a post-motor filter assembly. Further, the second casing can be integrally formed and can at least partially house the pre-motor filter assembly. Still further, the second casing can comprise a first integrally formed duct fluidly communicating the cyclone module assembly with the pre-motor filter assembly and a second integrally- formed duct fluidly communicating an outlet of the suction source with the post-motor filter assembly. Still further, at least one of the first and second casings can at least partially form an exterior wall of the upright assembly. [0008] In a preferred embodiment of the invention, the vacuum cleaner can further comprise a third casing that mates with the first and second casings. The third casing can at least partially form a pocket for removably mounting the dirt separation assembly. The dirt separation assembly can be a cyclone separation assembly. The vacuum cleaner can further comprise at least two cyclone separation assemblies of different configurations that are each adapted to be selectively mounted to the upright assembly within the pocket. The first casing can at least partially form the pocket along with the third casing. The first and second casings can have integrally formed bearings for pivotally mounting the upright assembly to the base assembly. [0009] According to another embodiment of the invention, a vacuum cleaner comprises a primary support platform comprising a dirt separation assembly receiving portion including a first opening, adapted to receive dirt-laden air from a suction nozzle and connected to one end of a working air duct, and a second opening connected to an exhaust conduit. A plurality of different dirt separation assemblies, each of which is adapted to be removably mounted in the dirt separation assembly receiving portion, has an inlet opening adapted to be fluidly coupled with the first opening in the receiving portion and has an outlet opening adapted fluidly coupled to the second opening in the receiving portion. A suction source in mounted in the primary support platform is adapted to establish and maintain a dirt-containing airstream from the suction nozzle through one of the dirt separation assemblies. A base assembly is pivotally mounted to the primary support platform and adapted to be moved along a surface to be cleaned.

[0010] The different dirt separation assemblies include at least one cyclone separation assembly. Preferably, the cyclone separation assemblies include at least two of a single-stage cyclone separator, a concentric two-stage cyclone separator, a non-concentric two-stage cyclone separator, and a two-stage cyclone separator with a plurality of second stage cyclones.

[0011] Further, the base assembly can comprise a suction nozzle that is fluidly connected to the suction source through an inlet opening. [0012] The vacuum cleaner can further comprise a plurality of different base assemblies, each of which are adapted to be pivotally mounted to the primary support platform and further include a suction nozzle fluidly connected to the suction source through an inlet opening.

[0013] The vacuum cleaner can further comprise a plurality of different handle assemblies adapted to be connected to an upper portion of the primary support platform. The plurality of different handle assemblies can comprise different grips for a user to grasp to maneuver the vacuum cleaner over a surface to be cleaned. [0014] According to yet another embodiment of the invention, an accessory tool for a vacuum cleaner comprises a housing having a suction nozzle and an air conduit adapted to be connected to a source of suction for generating a working air flow from the suction nozzle through the housing, a first agitator formed on the housing adjacent to the suction nozzle, and a second agitator that is different from the first agitator and that is selectively mounted to the housing such that the second agitator is in fluid communication with the suction nozzle.

[0015] In accordance with one embodiment of the invention, the attachment further has a third agitator that is different from the first and second agitators and the attachment is selectively mounted to the housing so that the second agitator is in fluid communication with the suction nozzle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] hi the drawings: [0017] FIG. 1 is a perspective view of an upright vacuum cleaner according to the invention.

[0018] FIG. 2 is a rear quarter perspective view of the upright vacuum cleaner of

FIG. 1.

[0019] FIG. 3 is an exploded front quarter perspective view of the upright vacuum cleaner of FIG. 1, illustrated with alternate components of the vacuum cleaner.

[0020] FIG. 4 is an exploded front quarter perspective view of a primary support section of the vacuum cleaner according to the invention.

[0021] FIG. 5 is a front perspective view of a front motor housing according to the present invention. [0022] FIG. 6 is a rear perspective view of a front motor housing according to the present invention.

[0023] FIG. 7 is a schematic cross-section view illustrating a portion of the working air path through the vacuum cleaner.

[0024] FIG. 8 is a schematic cross-section view illustrating another portion of the working air path through the vacuum cleaner. [0025] FIG. 9 is an exploded front quarter perspective view of an alternate embodiment of the primary support section.

[0026] FIG. 10 is a perspective view of an upholstery tool according to the invention. [0027] FIG. 11 is a cross section view of the upholstery tool of FIG. 10 taken along line 11-11 of FIG. 10.

[0028] FIG. 12 is a perspective view of an alternate upholstery tool according to the invention. [0029] FIG. 13 is a cross section view of the upholstery tool of FIG. 12 taken along line 13-13 of FIG. 12.

[0030] FIG. 14 is an exploded bottom perspective view of the upholstery tool from FIG. 12.

DESCRIPTION OF THE PREFERRED EMBODIMENT [0031] An upright vacuum cleaner 10 according to the invention is shown in FIGS. 1-3 and comprises an upright assembly 12 pivotally mounted to a base assembly 14. The upright assembly 12 carries a dirt and dust separating and collecting means, such as a cyclone module 16. The upright assembly 12 comprises a primary support section 18 and an upper handle assembly 20. The upper handle assembly 20 is generally shaped like an inverted Y, and comprises a yoke 22 that is coupled with an upper portion of the primary support section 18. The two sides of the yoke 22 merge together to form an elongated handle 24 with a grip 26 on one end to facilitate movement by the user. A commonly known motor/fan assembly 30 (FIG. 4) is housed within the primary support section at an opposite end of the upright assembly 12 and is oriented transversely therein. The upright assembly 12 pivots relative to the base assembly 14 through an axis formed relative to a shaft within the fan/motor assembly 30.

[0032] The base assembly 14 generally comprises a lower housing 32 that mates with an upper housing 34 to form a brush chamber 36 in a forward portion thereon. A suction nozzle 38 is formed at a lower surface of the brush chamber 36 and is in fluid communication with the surface to be cleaned. A foot conduit 40 provides an air path from the suction nozzle 38 through the base assembly 14 and terminates in a hose receiver 42. A rotating brash roll assembly (not shown) is positioned within the brash chamber 36. A pair of rear wheels 44 is secured to a rearward portion of the base assembly 14, rearward being defined relative to the brash chamber 36. The base assembly 14 further comprises a suction nozzle height adjustment mechanism that raises and lowers the suction nozzle 38 relative to the surface to be cleaned using a pair of front wheels 46 mounted on a carriage (not shown). A height adjustment actuator 48 that is coupled with the wheeled carriage is provided on the base assembly in a location that is easily accessible for the user. A suitable height adjustment mechanism is described in U.S. Patent No. 6,081,963, issued July 4, 2000, which is incorporated herein by reference in its entirety and will not be detailed herein. The base assembly 14 further comprises other typical components of a vacuum cleaner base assembly that are well-known in the art and will not be discussed in detail herein. A variety of different base assembly 14 configurations can be assembled to the handle assembly 12 that comprise various features. [0033] A live hose 50 terminates in a fixed hose grip 52 on one end and a cyclone inlet receiver 54 on the other end. The live hose 50 is preferably a commonly known flexible vacuum hose. The cyclone inlet receiver 54 is rigidly fixed to an upper portion of the primary support section 18 of the upright assembly 12. As illustrated the hose grip 52 is removably stored on the vacuum cleaner 10 with a curved accessory wand 240 that in turn is received in the hose receiver 42 via a friction fit so as to create an air tight seal when the curved wand it inserted therein. The curved accessory wand 240 can be removed from the hose receiver 42 when above-the-floor cleaning is desired. The hose grip 52 can be disconnected from the curved wand 240 for above-the-floor cleaning using only the live hose 50 or one of the other accessory tools provided, which can comprise a turbine-powered brash 230, a straight accessory wand 250, a crevice tool 260 (shown stored within the straight accessory wand 250), and/or an upholstery tool 270. Alternately, the hose grip 52 can be directly received in the hose receiver 42 via a bayonet latch or a friction fit. The live hose 50 is managed via a pair of commonly known hose hooks 56, 58 at a lower portion of the primary support section 18 and near the grip 26, respectively, as is commonly known in the vacuum industry. [0034] A cyclone outlet receiver 60 is integrally formed on an upper portion of the primary support section 18 in close proximity to the cyclone inlet receiver 54 and is in fluid communication with a pre-motor filter assembly 64 positioned upstream of an inlet to the fan/motor assembly 30 via a working air conduit 66 on the rear of the vacuum cleaner 10. Fluid communication can be accomplished by an air path (not shown) integrally formed in the primary support section 18 or can be a rigid blow molded tube or a commonly known flexible vacuum hose.

[0035] Referring to FIG. 4, the primary support section 18 comprises a housing front 68, a motor/filter housing 70, and a housing back 72. The motor/filter housing 70 mates with the housing back 72 to form a chamber for the motor/fan assembly 30 at a lower portion thereof. The housing front 68 mates with an upper portion of the motor/filter housing 70 and the housing back 72. The primary support section further comprises the pre-motor filter assembly 64, the motor/fan assembly 30, a post-motor filter assembly 74, and an illumination assembly 76. [0036] The housing front 68 has two apertures 78, 80 formed on a lower front portion thereof. The first aperture 78 allows the pre-motor filter assembly 64 to be inserted into the motor/filter housing 70. The second aperture 80 allows access to the illumination assembly 76. The recess 62 for receiving the cyclone module assembly 16 is also preferably formed on the housing front 68. [0037] The pre-motor filter assembly 64 comprises a filter 82 and a drawer-like filter mount 84 that are slidingly received in the motor/filter housing 70. The filter 82 provides an additional stage of filtering the working air after it has exited the cyclone module assembly 16. The filter mount 84 comprises a filter supporting portion 86 and a filter cover 88. The supporting portion 86 has a perforated grill 90 to allow working air to flow from the filter 82 to the motor/fan assembly 30 and rails 92 formed on the outer side walls thereof. The filter cover 88 conceals the filter assembly 64 when it is received by the vacuum cleaner 10 and also functions as a handle for the user to grip to remove the filter mount 84 as needed, for example, when replacing the filter 82. [0038] The post-motor filter assembly 74 comprises a frame 94 integrally formed with the housing back 68, a filter 96, and a filter cover 98. The frame 94 includes a duct 100 in fluid communication with the motor/filter housing 70 and a filter support member 102 protruding from the inside of the duct 100. The filter 96 preferably comprises a HEPA-rated filter and provides a final filtering stage for the working air before it is exhausted from the vacuum cleaner 10. The filter 96 is removably mounted within the frame 94 by snap- or friction-fit. The filter cover 98 comprises a grill 104 to allow working air to flow from the filter 96 to the exterior of the vacuum cleaner 10, a pair of hinges 106 that are connected to the frame 94 along one side such that the filter cover 98 is moveable between an open and closed position, and a pair of latches 108 that are received in slots 110 on the frame 94 along the side opposite the hinges 106 to lock the filter cover 98 in the closed position. [0039] The illumination assembly 76 comprises a light bulb holder 112 on a front portion of the motor/filter housing 70, a light bulb 114, and a light bulb cover 116. The light bulb holder 112 is mounted within a recess 118 integrally formed on a front portion of the motor/filter housing 70 and comprises a socket for electrically coupling with the light bulb 114. A depression 120 is formed adjacent to the recess 118 for receiving the light bulb 114 when it is connected to the socket of the light bulb holder 112. At least a portion of the cover 116 is transparent or semi-transparent to allow light from the light bulb 114 to illuminate the area around the front of the base assembly 14 and is positioned over the second aperture 80 on the housing front 68 to conceal and protect the light bulb holder 112 and the light bulb 114. [0040] Referring additionally to FIGS. 5 and 6, the motor/filter housing 70 is a one-piece housing for both the motor/fan assembly 30 and the pre-motor filter assembly 64. The motor/filter housing 70 comprises a first chamber 122 for receiving the pre-motor filter assembly 64 and a front portion 124a of a second chamber 124 for receiving the motor/fan assembly 30. A rear portion 124b of the second chamber 124 is formed on the housing back 72. A first and second working air passage 126, 128 are also integrally formed on the housing back 72. The first working air passage 126 is in fluid communication with the conduit 66 connected to the cyclone outlet receiver 60 and the first chamber 122. The second working air passage 128 is in fluid communication with the second chamber 124 and the duct 100 of the post-motor filter assembly 74. [0041] The first chamber 122 comprises an insertion opening 130 for the pre- motor filter assembly 64, tracks 132 formed on the inner side walls that correspond to the rails 92 on the filter supporting portion 86 of the filter mount 84, a rear cross-brace 134 that functions as a stop for the filter mount 84 when it is inserted into the first chamber 122, and a plurality of perforations 136 providing fluid communication between the first chamber 122 and the second chamber 124. When the pre-motor filter assembly 64 is in place on the vacuum cleaner 10, the perforations 136 will be aligned with the grill 90 on the filter supporting portion 86. A sealing gasket 138 can be placed around the insertion opening 130 or alternately around the filter cover 88 to provide an air-tight seal between the first chamber 122 and the filter mount 84.

[0042] The motor/filter housing 70 and the housing back 72 can further comprise integrally formed bearings 140 aligned along a shaft of the motor/fan assembly 30 for pivotally mounting the upright assembly 12 to the base assembly 14. The each bearing 140 is formed in two parts, with a front portion 140a formed on each side of the motor/filter housing 70 and a rear portion 140b formed on each side of the housing back 72.

[0043] The working air path through the primary support section 18 will now be described with reference to FIGS. 7 and 8. Working air initially enters the cyclone module assembly 16 through the suction nozzle 32 due to suction force created by the motor/fan assembly 30. The cyclone module assembly 16 separates and collects dirt and debris from the working air stream for disposal after the cleaning operation is complete. The working air then exits the cyclone module assembly 16 and enters the working air conduit 66 through the cyclone outlet receiver. The working air passes through the working air conduit 66, as indicated by arrow A, and enters the first working air passage 126 formed in the housing back 126 of the primary support section 18, as indicated by arrow B. From the first working air passage 126, the working air enters the first chamber 122 of the motor/filter housing 70 where it passes through the filter 82 of the pre-motor filter assembly 64, as indicated by arrow C. After passing through the filter 82, the working air enters the second chamber 124 through the aligned grill 90 of the filter mount 84 and the perforations 136 of the first chamber 122, as indicated by arrow D. The working air in the second chamber 124 through and around the motor/fan assembly 30, as indicated by arrow E and is discharged through the second working air passage 128, as indicated by arrow F. From the second working air passage 128, the working air enters the duct 100 of the post-motor filter assembly 74, where the working air passes through filter 96, as indicated by arrow G before being exhausted from the vacuum cleaner through the grill 104, as indicated by arrow H.

[0044] The one-piece motor/filter housing 70 can easily be assembled with the housing back 72 to simplify the installation of the motor/fan assembly 30 and the pre- motor filter assembly 64 in the vacuum cleaner 10. Assembly is greatly simplified because all of the working air path connections are formed in two parts (70, 72) and are fluidly mated in a single assembly step. In addition, the assembled vacuum cleaner housing is limited to only one mating surface that minimizes air leaks and enhances filtering performance. [0045] Referring to FIG. 9, an alternate embodiment of the primary support section 18 ' is illustrated, where like element are referred to by the same reference numerals bearing a prime (') symbol. The primary support section 18' comprises a motor cavity 142 formed at a lower end thereof, between the housing front 68' and the housing back 72'. The motor cavity 142 receives a motor/filter housing 144 that is formed by a front housing 146 and a rear housing 148 and positions the motor/fan assembly 30' within the vacuum cleaner. The rear housing 148 further includes an integral working air inlet 150 that is in fluid communication with the suction nozzle 38' and a working air outlet 152 that is in fluid communication with the post-motor filter assembly 74'. The front housing 146 further includes an integral chamber in which the pre-motor filter assembly 64' is removably received as well as an integrally formed duct fluidly communicating with the inlet to the motor/fan assembly 30'. The post-motor filter assembly 74' is positioned adjacent to or maybe integral with the motor/filter housing 144 and is in fluid communication with the exhaust air flow from the motor/fan assembly 30' through the working air outlet 152. The recess 62' for receiving a cyclone module assembly is formed integrally with the housing front 68'. The bearings 140' for pivotal mounting of the base assembly are integrally formed with the housing front 68'and the housing back 72' in two parts, with a front portion 140a' formed on each side of the housing front 68' and a rear portion 140b' formed on each side of the housing back 72'.

[0046] Referring back to FIG. 3, the primary support section 18 is modular in nature and can receive one of a number of cyclone module assemblies 16, 16', 16", base assemblies 14, 14', and upper handle assemblies 20, 20'. The primary support section 18 receives one of a number of possible cyclone module assemblies 16, 16', 16" in a receiving portion 58. The cyclone module assemblies 16, 16', 16" separate and collect debris from a working air stream for disposal after the cleaning operation is complete. As shown herein, the vacuum cleaner 10 has a single stage cyclone module assembly 16, a concentric two-stage cyclone module assembly 16', and a side- by-side two-stage cyclone module assembly 16'. The primary support section 18 also receives one of a number of possible base assemblies 14, 14' such that the base assembly is pivotally coupled thereto. The vacuum cleaner 10 further has a base assembly 14 having a height adjustment mechanism that is actuated by a foot-operated height adjustment actuator 48 on one side of the base assembly 14, and a base assembly 14' having a height adjustment mechanism that is actuated by a hand- operated height adjustment actuator 48' on the upper housing 34 of the base assembly 14'. The primary support section 18 further receives one of a number of possible upper handle assemblies 20, 20' by coupling the yoke 22, 22' with an upper portion of the primary support section 18. The vacuum cleaner 10 is provided with an upper handle assembly 20 having a closed-loop grip 26 and an upper handle assembly 20' having a generally straight or stick-like grip 26'. Additional cyclone module assemblies, base assemblies, and upper handle assemblies can be provided and other possible configurations and differences are contemplated. Moreover, while the vacuum cleaner 10 is illustrated herein as having a plurality of cyclone-type separators, it is contemplated than other dirt separation assemblies, such as bag dirt separators can be provided as well.

[0047] The modular nature of the vacuum cleaner 10 provides flexibility in manufacturing so that a variety of different models with different features and options can be assembled from any combination of cyclone module assemblies 16, 16', 16', base assemblies 14, 14', and upper handle assemblies 20, 20' on to the common primary support section 18. An entire product line that varies from low end models with very few features to high end models with many features and improved separation efficiencies to be produced in a cost effective manner with this flexible design. Moreover, since the primary support section 18 houses the motor/fan assembly 30, the pre-motor filter assembly 64, the post-motor filter assembly 74, and the necessary ducting for fluid communication of these components with the base assemblies 14, 14' and cyclone module assemblies 16, 16', 16', vacuum cleaner assembly is greatly simplified. [0048] Referring to FIGS . 10 and 11 , a multi-purpose upholstery tool 270 comprises a tool housing 272 and an air conduit 274 in fluid communication with a suction surface 276. A plurality of coarse agitators 278 are integrally formed around the perimeter of the suction surface 276. An engagement rib 280 is formed on at least three sides of the housing 272. An interchangeable bristle block 282 is selectively attached to the tool housing 272 with a sliding motion via a groove 284 formed in an inner side wall of the bristle block 282 and the engagement rib 280. The bristle block 282 further comprises a plurality of upper bristle tufts 286 and lower bristle tufts 288. As can be appreciated, the number of bristles used to form each tuft 286, 288 , the number of tufts, and a number of tuft rows can all be varied to create an optimum upholstery tool 270. The tufts 286, 288 can be of any material, shape, and size, however in the preferred embodiment the upper set of tufts 286 are comprised of shorter, stiffer bristles for scrubbing while the lower bristle tufts 288 are comprised of longer, softer bristles suitable for dusting purposes. Alternatively, any of the tufts 286, 288 can be rubber or plastic devices suitable for pet hair removal. The air conduit 274 is sized to provide a removable friction fit with the hose grip 52 on the live hose 50.

[0049] In operation, the user removes the hose grip 52 from the hose receiver 42 and mounts the upholstery tool 270 to the hose grip 52. The user then orients the bristle block 282 so that the desired tufts 286, 288 are oriented toward the surface to be cleaned and slides the bristle block 282 on to the tool housing 272 so that the rib 280 engages the groove 284. The friction between the bristle block 282 and the tool housing 272 provide the engagement force necessary to keep the upholstery tool 270 joined during the cleaning operation. When it is desired to used the coarse agitators 278, the upholstery tool 270 can be used without the bristle block 282. The upholstery tool 270 is preferably stored on the vacuum cleaner 10 when not in use, such as on a rear portion of the upper handle assembly 20, as shown in FIG. 2. [0050] Referring to FIGS. 12-14, where like elements are identified by the same reference numeral bearing a prime (') symbol, an alternate multi-purpose upholstery tool 270' comprises a tool housing 272' as previously described, however substituting the U-shape bristle block 282 for an enclosed ring bristle block 282' having only one set of bristle tufts 286'. The bristle block 282' includes a groove 284' that engages both a corresponding rib 280' formed on an outer side wall of the tool housing 272' and the coarse agitators 278' formed around the perimeter of the suction surface 276', so that the bristle block 282' can be removably attached to the tool housing 272'. The bristle tufts 286' are arranged on a lower surface around the perimeter of the bristle block 282'. [0051] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the forgoing description and drawings without departing from the spirit of the invention.

Claims

CLAIMSWhat is claimed is:

1. A vacuum cleaner comprising: a base assembly having a suction nozzle and a working airpath; an upright assembly pivotally mounted to the base assembly; a dirt separation assembly mounted to the upright assembly and in fluid communication with the suction nozzle; a suction source mounted in the upright assembly adapted to establish and maintain a dirt-containing airstream from the base assembly through the dirt separation assembly; an integrally formed first casing that at least partially houses a pre- motor filter assembly and partially houses the suction source; and a second casing that is mated with the first casing and that partially houses the suction source.

2. The vacuum cleaner according to claim 1 wherein the second casing at least partially houses a post-motor filter assembly.

3. The vacuum cleaner according to claim 2 wherein the second casing is integrally formed.

4. The vacuum cleaner according to claim 3 wherein the second casing at least partially houses the pre-motor filter assembly.

5. The vacuum cleaner according to claim 2 wherein the second casing comprises a first integrally formed duct fluidly communicating the cyclone module assembly with the pre-motor filter assembly.

6. The vacuum cleaner according to claim 5 wherein the second casing further includes a second integrally-formed duct fluidly communicating an outlet of the suction source with the post-motor filter assembly.

7. The vacuum cleaner according to claim 1 wherein at least one of the first and second casings at least partially forms an exterior wall of the upright assembly.

8. The vacuum cleaner according to claim 1 and further comprising a third casing that mates with the first and second casings.

9. The vacuum cleaner according to claim 8 wherein the third casing at least partially forms a pocket for removably mounting the dirt separation assembly.

10. The vacuum cleaner according to claim 9 wherein the dirt separation assembly is a cyclone separation assembly.

11. The vacuum cleaner according to claim 10, and further comprising at least two cyclone separation assemblies of different configurations that are each adapted to be selectively mounted to the upright assembly within the pocket.

12. The vacuum cleaner according to claim 11 wherein the first casing at least partially forms the pocket along with the third casing.

13. The vacuum cleaner according to claim 1 wherein the first and second casings have integrally formed bearings for pivotally mounting the upright assembly to the base assembly.

14. A vacuum cleaner comprising: a primary support platform comprising: a dirt separation assembly receiving portion including a first opening, adapted to receive dirt-laden air from a suction nozzle and connected to one end of a working air duct, and a second opening connected to an exhaust conduit; a plurality of different dirt separation assemblies, each of which is adapted to be removably mounted in the dirt separation assembly receiving portion, has an inlet opening adapted to be fluidly coupled with the first opening in the receiving portion and has an outlet opening adapted fluidly coupled to the second opening in the receiving portion; a suction source mounted in the primary support platform and adapted to establish and maintain a dirt-containing airstream from the suction nozzle through one of the dirt separation assemblies; and a base assembly pivotally mounted to the primary support platform and adapted to be moved along a surface to be cleaned.

15. The vacuum cleaner according to claim 14 wherein the dirt separation assembly receiving portion forms a socket for mounting one of the plurality of different dirt separation assemblies.

16. The vacuum cleaner according to claim 14 wherein at least one of the plurality of different dirt separation assemblies is cyclone separation assembly.

17. The vacuum cleaner according to claim 14 wherein at least two of the plurality of different dirt separation assemblies include a single-stage cyclone separator, a concentric two-stage cyclone separator, a non-concentric two-stage cyclone separator, and a two-stage cyclone separator with a plurality of second stage cyclones.

18. The vacuum cleaner according to claim 14 wherein the base assembly comprises a suction nozzle that is fluidly connected to the suction source through an inlet opening.

19. The vacuum cleaner according to claim 18, and further comprising a plurality of different interchangeable base assemblies, each of which is adapted to be pivotally mounted to the primary support platform and further includes a suction nozzle adapted to be fluidly connected to the suction source through an inlet opening.

20. The vacuum cleaner according to claim 19, and further comprising a plurality of different interchangeable handle assemblies adapted to be connected to an upper portion of the primary support platform.

21. The vacuum cleaner according to claim 20 wherein the plurality of different handle assemblies comprise different grips for a user to grasp to maneuver the vacuum cleaner over a surface to be cleaned.

22. An accessory tool for a vacuum cleaner comprising: a housing having a suction nozzle and an air conduit adapted to be connected to a source of suction for generating a working air flow from the suction nozzle through the housing; a first agitator formed on the housing adjacent to the suction nozzle; and an attachment having a second agitator that is different from the first agitator and that is selectively mounted to the housing such that the second agitator is in fluid communication with the suction nozzle.

23. An accessory tool for a vacuum cleaner according to claim 22 wherein the attachment further has a third agitator that is different from the first and second agitators and the attachment is selectively mounted to the housing so that the second agitator is in fluid communication with the suction nozzle.