Filter and accessory mount for upright vacuum cleaner exhaust port

Claim 2

A secondary air filter assembly for an upright vacuum cleaner, said upright vacuum cleaner comprising a body having an exhaust port for exit of air with which dirt is drawn into said vacuum cleaner, said air passing through a primary filter and depositing said dirt prior to exiting said exhaust port, said secondary air filter assembly comprising: a filter; a substantially rigid filter carrier; and a base for mounting on said body over said exhaust port; wherein: said base has: a double-sided adhesive closed-cell foam tape for attaching said assembly to said exhaust port, said foam tape surrounding said exhaust port and forming a seal between said exhaust port and said base for preventing air passing through said exhaust port from bypassing said secondary air filter assembly, at least one opening therein for the passage of exhaust air from said exhaust port through said base, and a first rib extending substantially continuously around said at least one opening therein and protruding toward said filter carrier; and said filter carrier has: at least one opening therein for the passage of exhaust air therethrough, and a second rib extending substantially continuously around said at least one opening therein and protruding toward said base; wherein: each of said base and said filter carrier has complementary releasable engagement structure, for releasably attaching said filter carrier to said base; and when said filter carrier is attached to said base: said first and second ribs extend substantially parallel to one another, separated by a separation distance, creating a separation space, said filter is captured between said base and said filter carrier, and edges of said filter are captured between said first and second ribs and are deformed into a tortuous path thereby for creating a seal in said separation space against passage of air through said separation space.

Claim 3

The secondary air filter assembly of claim 1 wherein: said base has a base plate; said filter carrier has a carrier plate; when said filter carrier is attached to said base said base plate and said carrier plate are separated by a plate gap distance; said filter is made of a lofty material having a compressed thickness; and at least one of said first and second ribs protrudes from said base plate by a protrusion distance less than said plate gap distance and at least about equal to a difference between said plate gap distance and said compressed thickness.

Claim 4

The secondary air filter assembly of claim 2 wherein said separation distance is at least equal to said compressed thickness.

Claim 5

The secondary air filter assembly of claim 1 wherein said filter is affixed to said filter carrier.

Claim 6

The secondary air filter assembly of claim 4 wherein at least portions of at least one edge of said filter are affixed to said filter carrier.

Claim 7

The secondary air filter assembly of claim 4 wherein: said filter comprises a plastic material; said filter carrier comprises a plastic material; and said filter is affixed to said filter carrier by ultrasonic welding.

Claim 8

The secondary air filter assembly of claim 1 wherein said filter comprises a high-efficiency, low-flow-resistance synthetic filter material.

Claim 9

The secondary air filter assembly of claim 7 wherein said filter material is an electrostatic filter material.

Claim 10

The secondary air filter assembly of claim 8, wherein said electrostatic filter material comprises two different fiber materials.

Claim 11

The secondary air filter assembly of claim 9 wherein one of said two different fiber materials is polypropylene fiber.

Claim 12

The secondary air filter assembly of claim 9 wherein one of said two different fiber materials is modacrylic fiber.

Claim 13

The secondary air filter assembly of claim 11 wherein the other of said two different fiber materials is polypropylene fiber.

Claim 14

The secondary air filter assembly of claim 1 wherein: said exhaust port comprises at least one exhaust port opening in said body, each said at least one exhaust port opening having at least one exhaust port edge; and said base further comprises a plurality of fingers for extending into said at least one exhaust port opening and engaging said at least one exhaust port edge.

Claim 15

The secondary air filter assembly of claim 13 further comprising a respective lip on each of at least two of said plurality of fingers, each said lip lockingly engaging said at least one exhaust port edge.

Claim 16

The secondary air filter assembly of claim 1 wherein said complementary releasable engagement structure comprises at least one tab on one of said base and said filter carrier, and at least one slot on the other of said base and said filter carrier for interengaging with said tab.

Claim 17

The secondary air filter assembly of claim 15 wherein at least one of said at least one tab comprises a lip for engaging an edge of at least one of said at least one slot.

Claim 18

The secondary air filter unit of claim 1 wherein said filter carrier comprises a deflector adjacent said at least one opening for adjusting direction of said exhaust air.

Claim 19

An upright vacuum cleaner comprising: a suction base; and a body, said body having therein a suction motor and a filter bag for filtering dirt from air drawn in by said suction motor, said body further having an exhaust port for exhausting air exiting from said filter bag, said upright vacuum cleaner further comprising a secondary air filter assembly affixed to said exhaust port, said secondary air filter assembly comprising: a filter; a substantially rigid filter carrier; and a base for mounting on said body over said exhaust port; wherein: said base has: a double-sided adhesive closed-cell foam tape for attaching said assembly to said exhaust port, said foam tape surrounding said exhaust port and forming a seal between said exhaust port and said base for preventing air passing through said exhaust port from bypassing said secondary air filter assembly, at least one opening therein for the passage of exhaust air from said exhaust port through said base, and a first rib extending substantially continuously around said at least one opening therein and protruding toward said filter carrier; and said filter carrier has: at least one opening therein for the passage of exhaust air therethrough, and a second rib extending substantially continuously around said at least one opening therein and protruding toward said base; wherein: each of said base and said filter carrier has complementary releasable engagement structure, for releasably attaching said filter carrier to said base; and when said filter carrier is attached to said base: said first and second ribs extend substantially parallel to one another, separated by a separation distance, creating a separation space, said filter is captured between said base and said filter carrier, and edges of said filter are captured between said first and second ribs and are deformed into a tortuous path thereby for creating a seal in said separation space against passage of air through said separation space.

Claim 20

An upright vacuum cleaner comprising: a suction base; and a body, said body having therein a suction motor and a filter bag for filtering dirt from air drawn in by said suction motor, said body further having an exhaust port for exhausting air exiting from said filter bag, said upright vacuum cleaner further comprising a secondary air filter assembly affixed to said exhaust port, said secondary air filter assembly comprising: a filter; a substantially rigid filter carrier; and a base for mounting on said body over said exhaust port; wherein: said base has: a double-sided adhesive closed-cell foam tape for attaching said assembly to said exhaust port, said foam tape surrounding said exhaust port and forming a seal between said exhaust port and said base for preventing air passing through said exhaust port from bypassing said secondary air filter assembly, at least one opening therein for the passage of exhaust air from said exhaust port through said base, and a first rib extending substantially continuously around said at least one opening therein and protruding toward said filter carrier; and said filter carrier has: at least one opening therein for the passage of exhaust air therethrough, and a second rib extending substantially continuously around said at least one opening therein and protruding toward said base; wherein: each of said base and said filter carrier has complementary releasable engagement structure, for releasably attaching said filter carrier to said base; and when said filter carrier is attached to said base: said first and second ribs extend substantially parallel to one another, separated by a separation distance, creating a separation space, said filter is captured between said base and said filter carrier, and edges of said filter are captured between said first and second ribs and are deformed into a tortuous path thereby for creating a seal in said separation space against passage of air through said separation space.

Claim 21

The upright vacuum cleaner of claim 18 wherein: said base has a base plate; said filter carrier has a carrier plate; when said filter carrier is attached to said base said base plate and said carrier plate are separated by a plate gap distance; said filter is made of a lofty material having a compressed thickness; and at least one of said first and second ribs protrudes from said base plate by a protrusion distance less than said plate gap distance and at least about equal to a difference between said plate gap distance and said compressed thickness.

Claim 22

The upright vacuum cleaner of claim 19 wherein said separation distance is at least equal to said compressed thickness.

Claim 23

The upright vacuum cleaner of claim 18 wherein said filter is affixed to said filter carrier.

Claim 24

The upright vacuum cleaner of claim 21 wherein at least portions of at least one edge of said filter are affixed to said filter carrier.

Claim 25

The upright vacuum cleaner of claim 21 wherein: said filter comprises a plastic material; said filter carrier comprises a plastic material; and said filter is affixed to said filter carrier by ultrasonic welding.

Claim 26

The upright vacuum cleaner of claim 18 wherein said filter comprises a high-efficiency, low-flow-resistance synthetic filter material.

Claim 27

The upright vacuum cleaner of claim 24 wherein said filter material is an electrostatic filter material.

Claim 28

The upright vacuum cleaner of claim 25 wherein said filter material comprises two different fiber materials.

Claim 29

The upright vacuum cleaner of claim 26 wherein one of said two different fiber materials is polypropylene fiber.

Claim 30

The upright vacuum cleaner of claim 26 wherein one of said two different fiber materials is modacrylic fiber.

Claim 31

The upright vacuum cleaner of claim 28 wherein the other of said two different fiber materials is polypropylene fiber.

Claim 32

The upright vacuum cleaner of claim 18 wherein: said exhaust port comprises at least one exhaust port opening in said body, each said at least one exhaust port opening having at least one exhaust port edge; and said base further comprises a plurality of fingers for extending into said at least one exhaust port opening and engaging said at least one exhaust port edge.

Claim 33

The upright vacuum cleaner of claim 30 further comprising a respective lip on at least two of said plurality of fingers, each said lip lockingly engaging said at least one exhaust port edge.

Claim 34

The upright vacuum cleaner of claim 18 wherein said complementary releasable engagement structure comprises at least one tab on one of said base and said filter carrier, and at least one slot on the other of said base and said filter carrier for interengaging with said tab.

Claim 35

The upright vacuum cleaner of claim 32 wherein at least one of said at least one tab comprises a lip for engaging an edge of at least one of said at least one slot.

Claim 36

The upright vacuum cleaner of claim 18 wherein said filter carrier comprises a deflector adjacent said at least one opening for adjusting direction of said exhaust air.