HK1117010B - Removable internal air diffuser - Google Patents

Description

Removable internal air diffuser

Background

Technical Field

The present invention relates generally to vacuum cleaners, and more particularly to vacuum cleaners having both a vacuum cleaner and a blower mode of operation.

Brief description of the related art

The collection of air during operation of the vacuum cleaner typically involves the generation of a high velocity airflow. Unfortunately, the noise associated with the generation and discharge of high velocity air streams can be annoying. To address this problem, many vacuum cleaners have been modified at their outlet port with mufflers to suppress noise. The gas flow is then discharged through the modified outlet port after encountering the muffler.

Some vacuum cleaners, such as wet/dry vacuum cleaners, operate in a blower mode using a high velocity airflow. A hose, wand, or other accessory item connected to the blower port is used to direct the airflow to the target. In many cases, when the vacuum cleaner is not used as a blower, for example during operation in a vacuum cleaner mode, the blower port is the same outlet port that is used to discharge the generated airflow. Thus, during operation in the vacuum cleaner mode, the blower port is encased to suppress noise. To operate in the blower mode, the muffler is removed to enable a hose, wand, or other accessory item to be connected to the blower port. In some instances, the muffler engages the blower port in a manner similar to a hose, wand, or other accessory item. As a result, the muffler projects out of the blower port, thereby becoming an inconvenient obstacle during operation in the vacuum cleaner mode.

In other past designs, vacuum cleaners have had additional outlet ports dedicated to handling the exhaust airflow. A dedicated exhaust port may be desirable if dust and other contaminates are not generated by the discharge airflow through the blower port. The dedicated exhaust port does not require a hose, wand, or other accessory item to be configured for operating the blower mode, and therefore, may be shaped and sized to diffuse the exhaust airflow. Scattering and diffusing the discharge airflow helps avoid the problem of dust generation because, with the port dedicated to vacuum discharge airflow, the blower port is typically blocked during operation in the vacuum cleaner mode.

To suppress noise generated at the dedicated exhaust port, a sound absorbing material is incorporated into the duct leading to the dedicated exhaust port. Placing the sound absorbing material within the delivery tube advantageously avoids the inconvenience caused by the muffler protruding outwardly from the port. Placement within the delivery tube limits or prevents access to the sound-absorbing material, which may be necessary in connection with replacement, cleaning, or other maintenance work.

Summary of The Invention

In accordance with one aspect, a vacuum cleaner has a housing defining a first port and a second port, and a cap assembly. The cap assembly includes a cap head (cap head) that closes the first port to direct the airflow to the second port via the flow path, and a sound-influencing material (sound-influencing material) secured to the cap head and disposed within the flow path to reduce noise caused by the airflow.

In one embodiment, the first port is a blower port and the second port is an exhaust port. The housing may include a lid assembly and a tub covered by the lid assembly, and the blower port and the exhaust port may be defined by the lid assembly.

The cap assembly may further include a frame coupled to the cap head to support the sound-influencing material within the flow path. The airflow may pass through the frame to allow the airflow to interact with the sound-influencing material. The cap head may include a plurality of locking slots and the frame may include a plurality of legs, each leg having a respective resilient projection to engage a corresponding locking slot of the plurality of locking slots, such that the cap head and the cap body may be separated to disassemble the cap assembly. The flow path may be defined by interior walls of the housing positioned to effect at least one air flow reversal (redirection) after the air flow passes through the frame and interacts with the sound-influencing material.

In some embodiments, the cap assembly is removably engaged with the first port during operation in the vacuum cleaner mode and is removed from the first port during operation in the blower mode.

The sound-influencing material may comprise reticulated foam to diffuse the airflow.

In accordance with another aspect, a vacuum cleaner capable of operating in a blower mode and a vacuum cleaner mode is disclosed. The vacuum cleaner includes a housing defining a first port for outputting an airflow during operation in a blower mode, and a second port for discharging the airflow during operation in the vacuum cleaner mode. The vacuum cleaner further includes a diffuser cap that removably engages the first port during operation in the vacuum cleaner mode. The diffuser cap includes a cap for closing the first port to direct the exhaust gas flow to the second port via the flow path, and a diffuser material secured to the cap and disposed within the flow path for reducing noise caused by the exhaust gas flow. During operation in the blower mode, the diffuser cap is removed from the first port.

In one embodiment, the first port is a blower port and the second port is an exhaust port. The diffuser cap may include a cap assembly having a cap head and a cap body coupled to the cap head, wherein the cap includes the cap head to close the blower port, and wherein the cap body is disposed within the flow path such that the diffuser material is supported by the cap body. The housing may include a lid assembly and a bucket covered by the lid assembly, and the lid assembly may define a blower port, an exhaust port, and a flow path.

In another embodiment, the diffuser cap further includes a cap frame connected to the cap and disposed within the flow path to support the diffuser material within the flow path. An exhaust gas stream may pass through the cap frame to allow the exhaust gas stream to interact with the diffusion material. The cap may include a cap head having a plurality of locking slots, and the cap frame may include a plurality of legs, each leg having a respective resilient tab to engage a corresponding locking slot of the plurality of locking slots, such that the cap and the cap frame may be separated to disassemble the diffuser cap.

In accordance with yet another aspect, a vacuum cleaner includes a housing defining a blower port, an exhaust port, and a flow path between the blower port and the exhaust port. The vacuum cleaner further includes a removable cap assembly for the blower port to direct the discharge airflow via the flow path to the exhaust port. The removable cap assembly, in turn, includes a cap head that engages the blower port to close the blower port, and a cap body coupled to the cap head and inserted into the flow path, the cap body including a frame through which the discharge airflow passes. The removable cap assembly further includes a sound-influencing material supported within the flow path by the frame to reduce noise caused by the exhaust airflow.

Brief Description of Drawings

For a more complete understanding of the present invention, reference is now made to the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a vacuum cleaner according to one embodiment;

figure 2 is a top plan view of the vacuum cleaner of figure 1;

FIG. 3 is a cross-sectional view of the vacuum cleaner of FIG. 2, taken along line 3-3;

FIG. 4A is a perspective view of a vacuum cleaner cover assembly showing an exhaust airflow path or directional circuit, in accordance with one embodiment;

FIG. 4B is a perspective view of the vacuum cleaner cover assembly of FIG. 4A with the cover and handle removed, showing an exhaust airflow path or directional circuit;

FIG. 4C is a front view of the vacuum cleaner cover assembly of FIG. 4A;

FIG. 4D is a partial cross-sectional view of the vacuum cleaner assembly of FIG. 4C taken along line D-D showing the exhaust airflow path or directional lines;

FIG. 4E is a cross-sectional view of the vacuum cleaner assembly of FIG. 4D, taken along line E-E, showing the airflow path or directional lines;

FIG. 5A is a perspective view of a cap assembly of the vacuum cleaner of FIG. 1 in accordance with one embodiment; and the number of the first and second groups,

FIG. 5B is a disassembled perspective view of the cap assembly of FIG. 5A.

While the disclosed vacuum cleaner is susceptible of embodiments in various forms, there is illustrated in the drawings (and will hereinafter be described) specific embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification and is not intended to limit the invention to the specific embodiments illustrated and described herein.

Detailed description of the invention

The present invention relates generally to vacuum cleaners having a cap or cap assembly for an outlet port, the cap assembly including sound-influencing material to reduce noise caused by high velocity airflow generated during operation. The noise level may be reduced if, for example, the sound-influencing material acts as a diffuser for the high-velocity gas stream. The cap assembly may be useful in conjunction with a vacuum cleaner capable of operating in multiple modes, such as a blower mode and a vacuum cleaner mode. In this case, the outlet port engaged with the cap assembly may be a blower port of the vacuum cleaner.

When the high-speed airflow encounters the capped blower port, the sound-influencing material reduces the noise and directs or diverts the high-speed airflow to another outlet port of the vacuum cleaner. Such diversion may further reduce noise and reduce other inconveniences, as other outlet ports may be configured for discharging the airflow in a non-directed or diffuse manner.

Typically, the sound-influencing material is supported by the cap assembly within the flow path leading to the other outlet ports, as will be further described herein. The removable nature of the cap assembly provides convenient access to the sound-influencing material which may require replacement, cleaning or other servicing. To this end, the cap assembly may be disassembled to facilitate removal of the sound-influencing material. Thus, although the sound-influencing material is inserted within the flow path via the engagement of the cap assembly and the outlet port, it is both easily accessible and replaceable.

The features and principles of the disclosed vacuum cleaner are particularly well suited for vacuum cleaners capable of generating high velocity air streams, such as wet/dry vacuum cleaners. Although the disclosed vacuum cleaner is shown and described herein in connection with a wet/dry vacuum cleaner, practice of the disclosed vacuum cleaner is not limited to this type of vacuum cleaner. On the contrary, the features and principles of the disclosed vacuum cleaner are applicable to related devices other than wet/dry vacuum cleaners, as well as related devices that generate airflow at any speed. Further, the features and principles disclosed herein are applicable to a variety of wet/dry vacuum cleaners, including, for example, those having a pump for disposing of liquid, or a detachable blower, etc.

Referring now to fig. 1-3, an exemplary vacuum cleaner is indicated generally at 10. The vacuum cleaner 10 includes a housing, generally indicated at 12, which in turn includes a bucket 14 for debris collection during operation, and a lid assembly, generally indicated at 16, that covers an open end 17 (fig. 1 and 3) of the bucket 14. Although the vacuum cleaner 10 is of various types such as a canister or a bucket, embodiments of the present invention are not limited thereto and may include various types of vacuum cleaners. Bucket 12 is mounted on wheels (not shown) that are connected to bucket 12 on pivots or posts 18 (fig. 1) disposed within respective wheel supports 20 (fig. 1 and 3), and respective wheel covers (not shown) are attachable to wheel supports 20.

The lid assembly 16 includes a lid 22 and a latching region 24 (not shown) for latching to detachably secure the lid 22 to the pail 14 at the open end 17 of the pail 14. The lid assembly 16 further includes a motor cover 26 and a handle 28 for lifting the lid assembly 16 after separation from the tub 14. The bucket 14 also includes a handle 30 (best shown in fig. 1), and a power cord wrap extension 32 (fig. 1 and 2) projecting from the cover 22.

The motor cover 26 has a number of apertures 34 to allow cooling air to reach a motor 36 (fig. 3) disposed within the housing 12 and, more particularly, within the shroud assembly 16. As best shown in fig. 3, the aperture 34 communicates with a motor cavity 38 defined in part by an inner wall 40 of the shroud assembly 16. During operation, the motor 36 drives a shaft 42, which in turn drives an impeller 44 having a plurality of impeller blades 46. The impeller 44 may be relied upon to generate a high velocity airflow for use in both the vacuum cleaner and blower modes of operation. In alternative embodiments, the vacuum cleaner 10 may have an additional impeller for blower mode operation.

With continued reference to the exemplary embodiment of fig. 3, the impeller blades 46 rotate within a cavity defined by an upper impeller housing 48 and a lower impeller housing 50. The lower impeller housing 50 has an inlet or opening 52 through which air is drawn during operation. The opening 52 communicates with the interior of the tub 14. The air passes through a filter assembly, generally indicated at 54, connected to the lower portion of the hood assembly 16 before reaching the opening 52. The filter assembly 54 has a cage 56 surrounding the opening 52, with a filter 58 supported by the cage 56, and, in some embodiments, a float (not shown) disposed within the cage 56. The filter 58 removes debris and other matter from the airflow that is drawn into the bucket via the inlet port 60 (fig. 1) of the bucket, thereby preventing such matter from reaching or contacting the impeller 44. The float may serve to block the opening 52 to prevent the drum 14 from filling to the extent that liquid would otherwise pass through the opening 52 to be acted upon by the impeller 44.

Generally, the vacuum cleaner 10 is capable of operating in multiple modes, such as a blower mode and a vacuum cleaner mode. In the vacuum cleaner mode, the vacuum cleaner 10 may be connected to the inlet port 60 of the bucket with any number of tools, implements or accessories for collecting dry or wet material. In the blower mode, the airflow generated by the impeller 44 is not used for collection, but is used to direct the airflow to a target for cleaning and other purposes. In some embodiments, the motor cover 26 and other associated components are separable to enable portable blower mode operation. More generally, the housing 12 defines a plurality of outlet ports dedicated to exhausting the exhaust gas flow or providing the output gas flow. In the exemplary embodiment shown in the figures, the blower mode of operation generates an airflow at a blower port, generally indicated at 62. In fig. 1-3, the blower port 62 is shown as closing or capping the blower port 62 with a blower port cap 64 when the vacuum cleaner 10 is operating in the vacuum cleaner mode. As will be described in greater detail below, during operation in the vacuum cleaner mode, when the cap 64 engages the blower port 62, the airflow is discharged through one or more exhaust ports 66 (fig. 2). The exemplary embodiment shown in fig. 2 has two exhaust ports 66 symmetrically disposed on each side of the blower port 62. More generally, covering the blower port 62 with the cap 64 directs or redirects the airflow to the exhaust port 66, so the exhaust airflow generated during operation in the vacuum cleaner mode may be diffused and otherwise treated to reduce noise. The blower port 62 is designed to support a strong, directed airflow, whereas the exhaust port, and the passages or flow paths leading to the exhaust port, may be designed to diffuse the airflow prior to discharge.

Figures 4A-4E show an exemplary design and flow path or direction of airflow during operation in the vacuum cleaner mode. For convenience in illustration, elements common to the various figures of fig. 4A-4E are identified with like reference numerals to illustrate the shroud assembly 16 of the vacuum cleaner 10 without the bucket 14. Fig. 4A shows the exhaust port 66 in greater detail. Specifically, each passageway, generally indicated at 68, leads to the exhaust port 66 and has a side wall 70 that diverges as the exhaust (exhaust) airflow 72 approaches the exhaust port 66. For ease of illustration, the exhaust airflow 72 is schematically illustrated via directional lines, it being understood that the diverging nature of the sidewalls 70 diffuses or scatters the exhaust airflow 72. Other airflow paths or directions identified herein are similarly simplified for ease of illustration. Directing the exhaust airflow 72 to a plurality of outlet ports and allowing the exhaust airflow 72 to expand reduces the noise level, directionality, and strength of the exhaust airflow 72.

Referring now to fig. 4B, the hood assembly 16 is shown without the motor cover 26 and handle 28, and with portions of the hood 22 removed to further reveal the flow path or direction of the exhaust airflow 72 and its interaction with the blower port cap 64. The flow path to the exhaust port 66 or the blower port 62 depends on the mode of operation, as the same airflow is utilized for both vacuum cleaner and blower modes of operation. This particular passage is responsible for this transfer, which will be described below in connection with the exemplary embodiment, but the housing 12 may be designed in many ways to provide or manipulate airflow for both modes of operation. In general, the airflow path may include features that reduce noise without significant detrimental performance effects.

The interaction of the airflow and the blower port cap 64 will now be described. The blower port cap 64 provides further noise reduction functionality by, for example, diffusing the exhaust airflow 72 before the airflow reaches the passage 68. Accordingly, the blower port cap 64 may be referred to herein as a diffuser cap, although the cap 64 may provide alternative or additional sound-influencing functionality, as will be described below in connection with alternative embodiments.

More generally, the cap 64 forms part of a removable cap assembly, generally indicated at 74, that engages the blower port 62 to direct or redirect the discharge airflow generated during operation in the vacuum cleaner mode. More specifically, the cap assembly 74 closes or caps the blower port 62 during operation in the vacuum cleaner mode and is removed during operation in the blower mode. To this end, the cap assembly 74 may include a retention strap 76 connected or attached to the cap head 78 and/or to a cover 79 of the cap head 78, e.g., via screw fasteners 80. The retaining strap 76 is in turn connected or attached to a ring 81 (as best shown in fig. 5A and 5B), the ring 81 being held in place by a retaining ridge 82 (fig. 4E). The ring 81 has a circumference that prevents the ring 81 from traversing the ridge (ring)82 so that the retainer strap 76 and the ring 81 prevent the cap assembly 74 from being lost or misplaced during operation in the blower mode.

One embodiment of the cap assembly 74 is shown engaged with the blower port 62 in fig. 4B, 4D, and 4E, and in greater detail separately in fig. 5A and 5B. Referring to the exemplary embodiment shown in these figures, the cap assembly 74 generally includes elements (e.g., the cap head 78) for closing or covering the blower port 62, as well as elements for treating the airflow to reduce the level of noise caused thereby. While alternative embodiments may have a more permanent arrangement of components to be readily changed in accordance with the present invention, in this embodiment, the components of the cap assembly 74 may be separated or disassembled to allow for easy replacement, cleaning or other maintenance. Typically, some of the elements of the cap assembly 74 are disposed in the flow path leading to the exhaust port 66. Positioning the components within the flow path provides for interaction with the airflow, while alternative embodiments may have components arbitrarily positioned at different locations relative to the blower port 62.

The cap assembly 74 includes a cap body 84 that is coupled to the cap head 78 and inserted into a flow path (described below) leading to the exhaust port 66. Typically, the cap 84 is inserted into the flow path to support placement of the sound-influencing material within the flow path, that is, positioning the sound-influencing material within the flow path ensures that the air flow impinges upon or otherwise encounters the material. In contrast to the cap head 78, the cap body 84 may, but need not, serve as the element of the cap assembly 74 responsible for closing the blower port 62. Alternatively, the cap body 84 may be generally sized for convenient insertion through the blower port 62 and deep into the flow path leading to the exhaust port 66, as opposed to insertion that creates an airtight seal. The cap 84 may have a variety of shapes to accommodate the sound-influencing material, which in turn may also be freely custom shaped or sized. In the exemplary embodiment shown in the figures, the sound-influencing material is presented within the flow path as a roll 86 of foam or foam-like material. Thus, the cap 84 includes a frame 88 that holds the foam roll 86 in place despite the high velocity air flow present in the flow path. The frame 88, in turn, includes a support base 90 and a plurality of brackets 92 extending therefrom. The base 90 substantially prevents the foam roll 86 from undesirably displacing within the flow path while still allowing airflow through or against the foam material. Thus, the base 90 may have any of a variety of shapes and is not limited to the embodiment shown in FIGS. 5A and 5B, wherein a pair of concentric circular portions 94, 96 are connected by a radial arm 98. The base 90 and frame 88 are more generally shaped to define a plurality of spaces to facilitate airflow through the foam roll 86. Further, the individual elements of the frame 88 may also define spaces in a manner such that, for example, each bracket 92 may include a pair of spaced apart prongs 99.

While the cap frame 88 portion may be integrally formed as, for example, a molded component, the cap assembly 74 may be separated or disassembled in some embodiments to provide access to the foam roll 86 or other components for replacement, cleaning, or other servicing. To this end, and in accordance with the exemplary embodiment best shown in fig. 5A and 5B, the cap head 78 includes a plurality of locking slots 100 for respectively engaging resilient projections 102 projecting from the ends of the frame legs 92. Each slot 100 may also include a resilient tab 104 that forms a snap-fit (snap-fit) mechanism with a corresponding tab 102 of the frame bracket 92. The manner in which the frame 88 is coupled to the cap head 78 may utilize other different locking, snap-fit, or other fastening mechanisms known to those skilled in the art.

The cap head 78 and frame 88 may also include a number of projections 106, 108 and 110 that support the foam roll 86 and otherwise maintain its position in the flow path. In the exemplary embodiment best shown in fig. 5A and 5B, the tab 106 is pie-shaped extending from the cap head 78, and the tab 108 is extending from the portion 94 of the support base 90 of the frame 88. The projections 106, 108, and 110 need not be similarly sized or shaped. For example, the projections 110 extend from the portion 96 of the support base 90 to face the respective legs 92 of the frame 88. To provide mating inner and outer support to the foam roll 86, the projections 110 may have a width similar to the width of each bracket 92. More generally, the projections 106, 108 and 110 may be shaped and sized to optimally support the foam roll 86 while reducing obstruction of the airflow through the frame 88.

With continued reference to fig. 5A and 5B, the cap head 78 may have a threaded inner wall 112 that engages mating threads 114 (fig. 4E) of the blower port 62. Alternatively, the inner wall of the cap head 78 may have a ring (not shown) that engages a corresponding ring of the blower port 62 to snap the cap assembly 74 into place via a press-fit mechanism. Other mechanisms may be used to detachably secure the cap assembly 74 in place while covering the blower port 62.

The foam roll 86 of the cap assembly 74 may comprise or consist of any sound-influencing material, wherein the term "influencing" is used in a broad sense to include treatment of the air flow, wherein noise or sound may be diffused, absorbed, dampened, scattered, or otherwise reduced, or any combination of the foregoing. In one embodiment, the drum 86 is made of reticulated foam that diffuses the airflow by allowing it to substantially pass through the drum 86 to reduce the noise level. The roller 86 may comprise other porous materials in addition to or instead of reticulated foam. Other suitable materials may alternatively or additionally include impact absorption or suppression. Furthermore, the sound-influencing material need not consist of a rectangular piece of rolled foam, but rather may be custom shaped and positioned in accordance with the mechanism by which noise reduction is achieved. For example, the sound-influencing material may alternatively be formed as a flat pad of any suitable thickness disposed at the distal end of the cap head 78. As shown in fig. 5A and 5B, for the purpose of ensuring that the sound-influencing material is inserted within the flow path at the proper depth or position, the cap head 78 may include an inner tube or other portion 116 that extends from the end defining the cap 64 to the end that is coupled to the frame 88. Portion 116 of cap head 78 may similarly be used to position the pad of sound-influencing material at an appropriate depth or location.

Referring to fig. 4B, 4D, and 4E, the flow paths taken by the exhaust gas flow 72 are shown. Before describing the exemplary embodiments shown in these figures, it should be noted that the airflow through the housing 12 and, more generally, through the vacuum cleaner 10 may vary widely, depending on design choices and alternatives of the vacuum cleaner 10 known to those skilled in the art. Moreover, while the airflow 72 is related to the exhaust airflow generated during operation in the vacuum cleaner mode, the flow path taken by the output airflow generated during operation in the blower mode is substantially similar, with the exception of the flow path in which the cap assembly 74 is inserted. For this reason, only the exhaust airflow path is illustrated herein, in which case, in the blower mode, airflow is directed to the blower port 62 instead of the exhaust port 66 due to insertion of a tube or other accessory item (not shown) into the blower port 62 instead of the cap assembly 74. The solid nature of the accessory item blocks the flow path otherwise leading to the exhaust port 66 rather than allowing airflow to pass through (frame 88 and foam roll 86).

In both the vacuum cleaner and blower modes of operation, an airflow is initiated at the inlet port 60 of the tub. After the airflow travels along a path or direction 120, through the filter 58, across the shroud 56, and through the opening 52, the impeller 44 draws the air into a cavity 122 defined by an inner wall 124, as shown in FIG. 4E. Finally, the airflow is directed out of the cavity 122 into the passage 126 defined by the inner walls 128 and 130. After continuing along path 132 within passage 126, the airflow is directed by inner walls 136 and 138 to a substantially different direction 134. The airflow then enters the cavity 140 leading to the cap assembly 74. The cavity 140 is defined by walls 142 and 144 of the shroud assembly 16 that encourage the airflow to change direction otherwise. Each of these changes in direction is designed to reduce the level of noise before being handled by the cap assembly 74, with the airflow then encountering the cap assembly 74 after being dispersed within the cavity 140, as schematically shown by the three airflow paths or directions 146A-146C in fig. 4E. As a result of this spreading, the airflow encounters the cap assembly 74 from many directions, passing over the foam roll 86 or other sound-influencing substance to varying extents and at different locations. At least some of the airflow passes through the frame 88 into the cylindrical space defined by the drum 86. Because the cap head 78 effectively closes off the other end of the cylindrical space, the air flow is forced in a radially outward direction past the foam roll 86 between the legs 92 of the frame 88. The other portion of the air flow passes through the frame 88 between the portions 94 and 96 and over the end of the foam roll 86.

Regardless of where the airflow encounters the foam roll 86, or the direction of the airflow at the point of encounter, the airflow is generally directed through the flow path in which the foam roll 86 is disposed, causing the airflow to interact with the foam roll 86 (or other sound-influencing material). As best shown in fig. 4B and 4E, the airflow is directed via a flow path by a wall 150 defining an opening, generally indicated at 152, through which the airflow flows. The airflow through the opening 152 is schematically shown in fig. 4B and 4D as airflow direction 154, it being understood that the airflow direction 154 is only one of many directions in which the airflow may take through the opening 152. For example, additional airflow directions 156 after having passed through the opening 152 are also shown in fig. 4B and 4D. Each such air flow, or direction of air flow, constitutes a flow path in which the foam roll 86 is disposed to diffuse or otherwise reduce noise caused by the air flow.

As best shown in fig. 4B and 4D (partial cross-sectional view taken along line D-D of fig. 4C), airflow, schematically represented as directions 154 and 156, is directed to the exhaust port 66 after emanating from the side of the cap assembly 74 and passing generally diffusely through the opening 152, respectively. These airflows are then caused to flow along a flow path that includes one or more further turns defined by symmetrical, inner wall pairs 158 and 160 that may extend downwardly from the motor cover 26 or, in an alternative embodiment, from the hood 22. The pair of walls 158 and 160 define a cavity in which the steering occurs, the cavity being further defined by a wall comprising a U-shaped slot wall 162 into which a wall (not shown) extending downwardly from the motor cover 26 is inserted. Following these turns, the airflows take respective paths or directions schematically shown as 164 and the corresponding exhaust airflows 72 (FIG. 4B) are for discharge via the exhaust ports 66.

The foregoing description is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the invention may be apparent to those having ordinary skill in the art.

Claims (20)

1. A vacuum cleaner comprising:

a housing defining a first port and a second port; and the number of the first and second groups,

a cap assembly, comprising:

a cap head for closing the first port such that gas flow is directed to the second port via a flow path; and the number of the first and second groups,

a sound-influencing material secured to the cap head and disposed within the flow path to reduce noise caused by the airflow, the sound-influencing material defining a space;

wherein an air flow flows through the space defined by the sound-influencing material and the flow path to the second port.

2. The vacuum cleaner of claim 1, wherein the first port comprises a blower port and the second port comprises an exhaust port.

3. The vacuum cleaner of claim 2, wherein the housing includes a lid assembly and a bucket covered by the lid assembly, and wherein the blower port and the exhaust port are defined by the lid assembly.

4. The vacuum cleaner of claim 1, wherein the cap assembly further comprises a frame coupled to the cap head to support the sound-influencing material within the flow path.

5. The vacuum cleaner of claim 4, wherein the airflow passes through the frame to allow the airflow to interact with the sound-influencing material.

6. The vacuum cleaner of claim 4, wherein the cap head includes a plurality of locking slots, and wherein the frame includes a plurality of brackets, each bracket having a respective resilient projection to engage a corresponding locking slot of the plurality of locking slots to allow the cap head to be separated for disassembly of the cap assembly.

7. The vacuum cleaner of claim 4, wherein the flow path is defined by interior walls of the housing positioned to effect at least one turn of the airflow after the airflow passes through the frame and interacts with the sound-influencing material.

8. The vacuum cleaner of claim 1, wherein the cap assembly is removably engaged with the first port during operation in the vacuum cleaner mode, and wherein the cap assembly is removed from the first port during operation in the blower mode.

9. The vacuum cleaner of claim 1, wherein the sound-influencing material comprises reticulated foam to diffuse the airflow.

10. A vacuum cleaner operable in a blower mode and a vacuum cleaner mode, the vacuum cleaner comprising:

a housing defining a first port for outputting an airflow during operation in a blower mode and a second port for discharging an airflow during operation in a vacuum cleaner mode; and the number of the first and second groups,

a diffuser cap removably engaged with the first port during operation in a vacuum cleaner mode, the diffuser cap comprising:

a cap head to close the first port such that the exhaust gas flow is directed to the second port via a flow path; and the number of the first and second groups,

a diffuser material secured to the cap head and disposed within the flow path to reduce noise caused by exhaust gas flow;

wherein the diffuser cap is removed from the first port during operation in blower mode;

wherein the gas flow flows to the second port through a space defined by the diffusion material and the flow path.

11. The vacuum cleaner of claim 10, wherein the first port comprises a blower port and the second port comprises an exhaust port.

12. The vacuum cleaner of claim 11, wherein the housing includes a shroud assembly and a bucket covered by the shroud assembly, and wherein the shroud assembly defines the blower port, the exhaust port, and the flow path.

13. The vacuum cleaner of claim 10, wherein the diffuser cap further comprises a cap frame coupled to the cap head and disposed within the flow path to support the diffuser material within the flow path.

14. The vacuum cleaner of claim 13, wherein the exhaust airflow passes through the cap frame and a space defined by the diffuser material to allow the exhaust airflow to interact with the diffuser material.

15. The vacuum cleaner of claim 13, wherein the diffuser cap includes a cap head having a plurality of locking slots, and wherein the cap frame includes a plurality of legs, each leg having a respective resilient tab to engage a corresponding locking slot of the plurality of locking slots, such that the cap head is separable from the cap frame for disassembly of the diffuser cap.

16. The vacuum cleaner of claim 13, wherein the diffusing material comprises a reticulated foam roll disposed within the cap frame to diffuse the exhaust airflow.

17. A vacuum cleaner comprising:

a housing defining a blower port, an exhaust port, and a flow path between the blower port and the exhaust port; and the number of the first and second groups,

a removable cap assembly for the blower port to direct a discharge airflow to the exhaust port via the flow path, the removable cap assembly comprising:

a cap head engaged with the blower port to close the blower port;

a cap body coupled to the cap head and inserted into the flow path, the cap body including a frame through which the exhaust airflow passes; and the number of the first and second groups,

a sound-influencing material supported by the frame within the flow path to reduce noise caused by the exhaust airflow;

wherein the sound-influencing material defines a space and the airflow passes through the frame of the cap and the space defined by the sound-influencing material to allow the airflow to interact with the sound-influencing material.

18. The vacuum cleaner of claim 17, wherein the housing includes a shroud assembly and a bucket covered by the shroud assembly, and wherein the shroud assembly defines the blower port, the exhaust port, and the flow path.

19. The vacuum cleaner of claim 17, wherein the cap head includes a plurality of locking slots, and wherein the frame includes a plurality of brackets, each bracket having a respective resilient projection to engage a corresponding locking slot of the plurality of locking slots to allow the cap head to be separated from the cap body for disassembly of the cap assembly.

20. The vacuum cleaner of claim 17, wherein the sound-influencing material comprises a reticulated foam roll disposed within the cap frame to diffuse the exhaust airflow.