Abstract:
A liquid extraction cleaner comprises a solution dispensing system, a liquid recovery system, and an agitation brush assembly. The solution dispensing system includes a cleaning solution supply tank affixed to the cleaner and fluidly connected to a solution spray nozzle through a trigger-operated manual solution spray pump. The supply conduit interconnecting the cleaning fluid supply tank and the spray nozzle traverses a passage formed integrally with the air-liquid separator housing, spray nozzle being mounted in the passage at a front portion of the cleaner. The liquid recovery system includes a air-liquid separator fluidly connected with a suction nozzle and a suction source for drawing liquid and debris into the air-liquid separator, and a recovery tank releasably mounted to the air-liquid separator for collecting recovered liquid. The agitation brush assembly is mounted in a lower forward portion of the cleaner for contact with a surface being cleaned.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional patent application Ser. No. 60/312,122, filed Aug. 14, 2001, entitled HAND HELD DEEP CLEANER. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of the Invention 
     This invention relates generally to extraction cleaners and more particularly to a portable, hand-held deep cleaner that applies cleaning fluid to a surface, agitates the surface, and then extracts the applied fluid therefrom. 
     2. Description of the Related Art 
     Portable, hand-held extraction cleaners having a cleaning solution supply tank and a recovery tank are known. These extraction cleaners typically have a vacuum motor that powers an impeller to create low pressure on one side of the impeller and higher pressure on the other side thereof. The recovery tank is typically positioned between the low-pressure side of the impeller and a fluid collection nozzle to remove fluid from a surface and deposit it in the recovery tank. It is also known to provide a separate cleaning fluid pump for directing cleaning fluid from the supply tank to the surface. 
     One hand-held deep cleaning device is disclosed in U.S. Pat. No. 4,788,738 issued to Monson et al. on Dec. 6, 1988. In this arrangement, a hand-held deep cleaner has a handle section removably joined to a lower discharge section. A collection chamber receives fluid from a surface through a nozzle opening that communicates with the intake side of a vacuum motor. The collection tank houses a hollow plenum chamber and a centrifugal separator attached to a vacuum blower. A cleaning fluid tank is pressurized by exhaust air from the outlet side of the rotating vacuum blower to force cleaning fluid under pressure from the cleaning fluid tank to a supply nozzle when a solution supply trigger is depressed to thereby apply cleaning fluid to a surface. 
     U.S. Pat. No. 5,367,740 issued to McCray on Nov. 29, 1994, discloses a hand-held deep cleaner that includes a housing, a handle, a body portion, and a nozzle with a suction opening. A collection tank is removably supported on the housing and is fluidly connected to a vacuum pump. The vacuum pump has an exhaust port and is powered by an electric pump motor. A solution tank is removably connected to the housing and is pressurized by a pressure pump that is also connected to the pump motor. A separate drive motor is coupled to a rotatable brush for scrubbing a surface to be cleaned. 
     U.S. Pat. No. 6,125,498 to Roberts et al. discloses a hand-held liquid extraction cleaner including a recovery tank mounted to the forward end of a cleaner housing with a suction nozzle and conduit on a front face of the recovery tank connected to an inlet opening in the recovery tank. A vacuum source is connected to the recovery tank through an exhaust conduit, integrally formed in the recovery tank, for drawing liquid and debris through the suction nozzle and the suction conduit and into the recovery tank. A removable cleaning fluid supply tank is mounted to a rear portion of the cleaner housing, an adjustable spray nozzle is mounted to the suction conduit and a pump is positioned in a supply conduit between the spray nozzle and the cleaning fluid supply tank for supplying pressurized cleaning fluid from the cleaning fluid supply tank to the spray nozzle. The pump includes an impeller which is positioned in an outlet opening of a reservoir in which the cleaning fluid is deposited from the cleaning fluid supply tank. 
     U.S. Pat. No. 4,776,058 to Garner et al. discloses a portable vacuum surface cleaning apparatus that includes an integrated suction nozzle and recovery tank removably mounted to a forward portion of a housing and a rotatably driven brush mounted to a rear portion of the housing. A cleaning solution tank at a rear portion of the housing has a discharge flow passage directed rearwardly adjacent the brush. An electrical vacuum source is mounted in the housing. 
     U.S. Pat. No. 5,507,068 to Fan et al. discloses a handheld fluid extractor having a suction nozzle at a front portion thereof, a fluid delivery tank mounted beneath the suction nozzle and a fluid recovery tank mounted beneath the solution tank. A chamber  68  is connected to the suction conduit  82  and separates the air from the recovered liquid which drops from the plenum chamber  68  into the recovery tank  28 . The fluid delivery tank and the fluid recovery tank are removable from the suction nozzle. 
     A commercially available form of the portable vacuum surface cleaning apparatus disclosed in the Garner et al. &#39;058 patent was manufactured and sold by Ryobi Motor Products under the trademark 1344 SPOT COP. The Ryobi SPOT COP extractor did not have a rotary-driven brush agitator and included a fluid dispenser adjacent to the suction nozzle at a front portion of the recovery tank. The cleaning solution was delivered to the spray nozzle from a cleaning solution tank at a rear portion of the housing through a pump. 
     Heretofore, a hand-held extractor has been manufactured and sold by Royal the mark DIRT DEVIL SPOT SCRUBBER. The Royal SPOT SCRUBBER is similar to the hand-held extraction cleaning machine disclosed in the Roberts et al. &#39;498 patent except that it has a hand pump adjacent to the handle to pump cleaning solution to a spray nozzle adjacent to the suction nozzle. In addition, a rotary brush is mounted to a main housing behind the suction nozzle and is driven about a vertical axis by a turbine motor which is connected to the suction source for the extractor. A valve alternately connects the suction source to the turbine motor and to the suction nozzle. 
     SUMMARY OF INVENTION 
     According to the invention, a liquid extraction cleaner includes a housing with a liquid extraction system and a liquid dispensing system. The liquid extraction system includes a recovery tank, suction nozzle connected to the recovery tank, and a vacuum source. An air-liquid separator is integral with the housing and in fluid communication with the suction nozzle for separating air from liquid and debris. The vacuum source is in fluid communication with the recovery tank and the suction nozzle so that the vacuum source can draw liquid and debris through the suction nozzle toward the recovery air-liquid separator. The liquid dispensing system includes a cleaning fluid supply tank and a spray nozzle connected to the cleaning fluid supply tank. In one aspect of the invention, at least one agitator is mounted to the air-liquid separator adjacent to the suction nozzle for rotation about an axis and for scrubbing the surface to be cleaned. A motor is carried by the housing and is operably connected to the agitator to drive rotation of the agitator about the axis of rotation. 
     Preferably, the recovery tank is removably mounted to the air-liquid separator. The air-liquid separator is mounted to a front portion of the housing adjacent to the air-liquid separator suction nozzle. Typically, the recovery tank has visual indicia to indicate a maximum capacity of recovered liquid and debris. 
     In another aspect of the invention, the suction nozzle is elongated with a longitudinal axis and the agitator preferably rotates about an axis parallel to the longitudinal axis. The motor can be mounted to the air-liquid separator, and the motor can be operated independently of the vacuum source. In a preferred embodiment, the agitator has more than two rows of bristles. 
     Preferably, the liquid extraction cleaner according to the invention has at least two agitators rotatably mounted to the air-liquid separator next to the suction nozzle, with each agitator being rotatable in a direction opposite the other. In an alternative embodiment, the liquid extraction cleaner according to the invention can have at least one roller rotatably mounted to the housing next to the suction nozzle, with each roller having a plurality of flexible paddles extending radially therefrom. 
     In another aspect of the invention, the cleaning fluid supply tank is insulated. In one embodiment, a liquid extraction cleaner includes a supply conduit interconnecting the cleaning fluid supply tank and the spray nozzle. Preferably at least a portion of the supply conduit is insulated. In another embodiment, a double wall insulates the cleaning fluid supply tank with air disposed between the walls. 
     In yet another embodiment of the invention, a lamp assembly is mounted to a front portion of the housing and connected to a source of electrical energy for illuminating the surface to be cleaned. Preferably, the lamp assembly comprises a lamp, a reflector and a lens and the assembly is mounted to a front portion of the air-liquid separator. 
     In yet another aspect of the invention, a pump is connected to the cleaning fluid supply tank and operated by a trigger. The housing includes a handle at an upper portion thereof, and the trigger is located at an underside of handle. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       In the drawings: 
         FIG. 1  is a perspective view of a portable, hand-held deep cleaner according to the invention. 
         FIG. 2  is an exploded perspective view of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 3  is a cross section of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 4  is an exploded view of the solution supply tank and housing of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 5  is an exploded top perspective view of the solution supply tank of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 6  is an exploded perspective view of a portion of the fluid distribution system of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 7  is an enlarged exploded view of a solution pump assembly of the deep cleaner of  FIG. 1 . 
         FIG. 8  is an enlarged perspective view of a spray nozzle of the deep cleaner of  FIG. 1 . 
         FIG. 9  is an exploded view of the fluid recovery system of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 10  is an exploded view of the air-liquid separator assembly of the portable, hand held deep cleaner of  FIG. 1 . 
         FIG. 11  is another exploded view of a portion of the air-liquid separator assembly and recovery tank of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 12  is an exploded perspective view of the air-liquid separator assembly latch and lower brush housing of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 13  is a partial view of the air-liquid separator assembly rear flange and the housing of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 14  is an exploded view of the vacuum source, the air-liquid separator assembly, and the housing of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 15  is an enlarged perspective view of the vacuum motor assembly of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 16  is an exploded view of the rotating brush assembly of the portable, hand-held deep cleaner of  FIG. 1 . 
         FIG. 17  is a cross-sectional view of a solution tank assembly according to a further embodiment of the invention. 
         FIG. 18  is a cross-sectional view of a solution tank assembly according to a further embodiment of the invention. 
         FIG. 19  is an exploded partial perspective view of a hand-held deep cleaner housing according to a further embodiment of the invention. 
         FIG. 20  is a cross-sectional view like  FIG. 3  of a further embodiment of the hand-held deep cleaner, according to the invention. 
         FIG. 21  is a perspective view of a recovery tank according to another embodiment of the invention. 
         FIG. 22  is a perspective view of a recovery tank according to a further embodiment of the invention. 
         FIG. 23  is a perspective view of a brush assembly according to a further embodiment of the invention. 
         FIG. 24  is a perspective view of an end cap for the brush assembly of  FIG. 23 . 
         FIG. 25  is a perspective view of the end cap of  FIGS. 23–24  with an open brush belt access door. 
         FIG. 26  is a perspective view of a dual agitation brush assembly according to a further embodiment of the invention. 
         FIG. 27  is a perspective view of a further embodiment of the agitation brush according to the invention. 
         FIG. 28  is a perspective view of a further embodiment of the agitation brush according to the invention. 
         FIG. 29  is a perspective view of a further embodiment of the agitation brush according to the invention. 
         FIG. 30  is a perspective view of a further embodiment of the agitation brush according to the invention. 
         FIG. 31  is an exploded perspective view of a hand-held deep cleaner housing according to a further embodiment of the invention. 
         FIG. 32  is a reverse exploded perspective view of the hand-held deep cleaner housing of  FIG. 31 . 
         FIG. 33  is a perspective view of a further embodiment of the hand-held deep cleaner according to the invention with an illumination source. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIGS. 1 and 2 , a portable, hand-held deep cleaner  20  comprises a housing  22 , a cleaning fluid distribution system, a fluid recovery system, a rotatable agitator brush assembly  24 , and a battery pack  52  for supplying electrical power. 
     The housing  22  is formed by a first shell half  32  and a second shell half  34  that, when mounted together, houses a fluid distribution system and fluid recovery system. An air-liquid separator assembly  36  is mounted on a forward end  38  of the housing  22  and a solution tank assembly  40  is mounted to a rearward portion  44  of the housing  22 . 
     Each shell half  32 ,  34  includes a plurality of bosses  46  that are in alignment with corresponding bosses  46  in the other shell half. The shelf halves are preferably fastened together by installing threaded fasteners in the bosses in a well known manner to enclose elements of a fluid distribution system, a fluid recovery system, and a battery power source. Each shell half also includes an integrally molded handle portion  48  in the housing  22  that, when assembled together, form a unitary handle  23  having a grip lower surface  49  on the underside of the handle. The lower surface  49  of the handle  23  and an upper wall  64  together partially define a cavity  47  to accommodate a hand opening for hand carrying of the extractor. A switch  50  is connected between the battery pack  52  and an electric vacuum motor  54 , and an electric brush motor  56  for alternately starting and stopping the motors  54 ,  56 . In one embodiment, switch  50  is a 3-position switch having a center “off” position and two alternatively selectable “on” positions for activating one or the other of the motors  54 ,  56 . A switch cover  51  covers switch  50 . 
     Each shell half  32 ,  34  has a pair of spaced, parallel housing ribs  58 ,  70  that are integrally molded along three sides to a lower wall  60 , a sidewall  62 , and the upper wall  64  below the handle portion  48 . The housing ribs  58 ,  70  serve as reinforcement members for the shell halves  32 ,  34  and also define an internal impeller compartment  66  that houses a vacuum impeller assembly  268  (see  FIG. 15 ). Housing rib  70  includes a semi-circular opening  72  for fluidly connecting internal compartment  66  to air-liquid separator assembly  36 . Rib  58  also includes a semi-circular opening  59  that receives a bushing  73  receiving the front shaft  74  of the motor  54 . Preferably, the openings  59 ,  72  are collinear with each other. 
     A second internal compartment  67  is formed to the rear of rib  58  for holding vacuum motor  54 . Second internal compartment  67  includes additional rib  63  for positioning vacuum motor  54  in alignment with opening  59 . 
     A plurality of elongate exhaust apertures  76  extend through each shell half  32 ,  34  and communicate with the internal compartment  66  to permit exhaust air to escape from the internal compartment  66  when the vacuum motor assembly  68  is operating. A plurality of exhaust apertures  76  are also provided in the shell halves  32 ,  34  adjacent the second internal compartment  67  to vent compartment  67  and to prevent excessive heat build-up in the vacuum motor  54  during operation of the deep cleaner. The exhaust apertures  76  also serve to prevent excessive heat build-up in the housing  22  during recharging of the battery pack  52 . 
     The lower wall  60  of the housing  22  includes a hollow foot portion  78  that maintains the hand-held deep cleaner  20  in substantially horizontal position when not in use. Hollow foot portion  78  includes forwardly disposed open recess  79  adapted to receive a projection from a support base for mounting on a vertical surface. 
     A fluid distribution system is described comprising a solution tank assembly  40 , a solution pump assembly  80 , a trigger  82 , a plurality of solution supply conduits (not shown), and a spray nozzle assembly  86 . 
     As shown in  FIGS. 2–5 , the solution tank assembly  40  is mounted to an upper surface  42  of the rearward portion  44  of the housing  22 . The solution tank assembly  40  comprises a hollow tank body  88 , a lower wall  90  having a first opening  92  extending therethrough and in fluid communication with a fitting  96 , a filter screen mounted in the first opening  92 , a cap  114  and a seal  118 . 
     The tank body  88  is joined to the lower wall  90  at a peripheral seam  102 . A front wall  98  of the tank body  88  extends upwardly from the lower wall  90 , preferably at an obtuse angle with respect to the lower wall  90 . Front wall  98  further includes a T-shaped flange  100  extending therefrom. Lower wall  90  includes a generally circular depression surrounding first opening  92  and receiving filter screen  94 . Filter screen  94  prevents foreign particles in a solution from entering opening  92 . 
     A second opening  104  extends through an upper wall  106  of tank body  88  in the form of a neck portion  108  perpendicular to the upper wall  106 . Neck portion  108  includes external threads  112 . A generally circular cap  114  is formed with internal threads  116  that correspond with the external threads  112  on the neck portion  108 . A seal  118  having a central aperture  119  is positioned between the cap  114  and the top lip  122  of the neck portion  108  to thereby seal the second opening  104 . 
     A vent  124  is formed in a top surface of the cap  114  and serves to prevent a vacuum from forming in solution tank assembly  40  as solution is drawn from the tank by solution pump assembly  80 . 
     The lower wall  90  of the solution tank assembly  40  has a bottom surface  134  including a number of flanges  128  extending toward each outboard edge of and parallel to the bottom surface  134 . The flanges  128  are adapted to fit against a mating surface  130  inside both shell halves  32 ,  34  of housing  22  as the bottom surface  134  is placed against the upper surface  42  formed in the top rearward portion  44  of the housing  22 . The T-shaped flange  100  extending from front wall  98  is likewise adapted to fit within housing  22  through a gap  125  in rear wall  126  of housing  22  as front wall  98  abuts rear wall  126 . 
     With solution tank assembly  40  assembled to housing  22 , fitting  96  is contained within housing  22 , fluidly connecting the interior of solution tank assembly  40  with the housing interior compartment  132 . The fitting  96  includes a barbed outer surface  136  that is frictionally retained in an end of a flexible solution tube  81 , the other end of which is fluidly connected to the solution pump assembly  80 . Solution tank assembly  40  is thereby fluidly connected to the solution pump assembly  80  from whence it can be pumped to the spray nozzle assembly  86  mounted on the forward face  138  of the air-liquid separator assembly  36 . 
     Referring to  FIGS. 2 ,  3 ,  4 ,  6  and  7 , the solution pump assembly  80  is captured by a pump cavity  140  integrally formed in the interior surface of the upper handle portion  48  of the housing halves  32 ,  34 . The solution pump assembly  80  is further aligned within the handle portion  48  of the deep cleaner  20  by a plurality of conforming ribs  158  for holding fluid chamber  142 , an alignment flange  156  on fluid chamber  142  and a trigger pivot boss  148 . Alternatively, the solution pump assembly  80  is attached to the first shell half  32  with screws (not shown) that extend through the solution pump assembly  80  and thread into bosses (not shown). The bosses are preferably integrally molded with a sidewall (not shown) of the solution pump assembly  80  and project forwardly therefrom. 
     The solution pump assembly  80  comprises a pump housing  141  including a fluid chamber  142 , a piston assembly  144  having a forward portion sealingly received in fluid chamber  142 , a compression spring  146 , a trigger assembly  82 , a pump inlet  150  and a pump outlet  152 . 
     Pump housing  141  further includes a cap  143  for sealing a rear portion thereof and holding piston assembly  144  within housing  141 . Cap  143  includes a central aperture for receiving pump inlet  150 . Housing  141  further includes a groove on a lower portion thereof for receiving an actuation arm  83  of trigger  82 . Referring to  FIG. 7 , the trigger  82  comprises a trigger lever  89 , which is offset from the actuation arm  83 . The trigger lever  89  is adapted to be pulled by a finger while a user&#39;s hand grasps the handle  23 . 
     The piston assembly  144  includes a check valve  153  comprising a seat  154  and a ball  155  that prevents the flow of solution from the fluid chamber  142  back through the pump inlet  150 . When the trigger lever  89  is pulled, the trigger  82  rotates about a trigger pivot hub  84  on trigger pivot boss  148  and actuation arm  83  moves the piston  144  into the fluid chamber  142 , overcoming the force of the compression spring  146  and forcing fluid in the chamber  142  through the pump outlet  152 . 
     As the trigger  82  is released, the compression spring  146  forces the piston  144  back to its original position. As the piston  144  moves back out of the chamber  142 , a vacuum is created within chamber  142 . A check valve in the spray nozzle assembly  86  prevents air from being drawn into the chamber  142  from pump outlet  152 . This vacuum thus causes the ball  155  to dislodge from seat  154  for fluid flow from the solution tank assembly  40  through pump inlet  150  and to fill the fluid chamber  142 . 
     The solution tank assembly  40  is in fluid communication with the solution pump assembly  80  via flexible tube  81  secured at one end to the barb  136  at the tank outlet fitting  96  and at the other end to the pump inlet  150  of the solution pump assembly  80 . A second flexible tube  85  fluidly connects the solution pump assembly outlet  152  and the spray nozzle assembly  86  located at the forward face  138  of the air-liquid separator assembly  36 . The second flexible tube  85  is encased by transparent conduit  164  attached to the forward face  138  of the air-liquid separator assembly  36 . 
     Referring now to  FIG. 8 , spray nozzle assembly  86  comprises a nozzle body  166  having an inlet  170  and an outlet  172  and a check valve  160  received within inlet  170 . Spray nozzle assembly  86  is fluidly connected to solution pump assembly  80  by the flexible tube  85  and is held to forward face  138  of air-liquid separator assembly  36  transparent conduit  164 . 
     The nozzle body  166  is preferably substantially cylindrical in cross section. A bore extends in a longitudinal orientation through the nozzle body  166  from a fluid inlet  170  to a fluid outlet  172 , and along the central axis. A barb  174  is formed at the inlet end  170  for connection to the flexible tube  85 . A fan-shaped nozzle opening  176  is formed at the outlet end  172  for normally delivering fluid in a fan-shaped pattern under pressure to a surface to be cleaned. The nozzle body also includes a nub  178  and a mounting block  180  projecting from an outer surface of the nozzle body  166 . The mounting block is adapted for attachment to the transparent conduit  164  ( FIGS. 2 ,  3  and  6 ) in order to secure the nozzle body against movement. 
     Check valve  160  received in inlet  170  of nozzle body  166  includes a valve seat  161  normally sealed by a ball  162  under force of a compression spring  163 . As the operator depresses trigger  82 , pressure developed in the solution pump assembly  80  overcomes the compression spring  163  to open the check valve  160  and fluid passes through nozzle assembly  86 . When trigger  82  is released and the pressure within solution pump assembly  80  decreases, compression spring  163  forces ball  162  back against seat  161  and check valve  160  thereby prevents air from being drawn toward solution pump assembly  80 . 
     With reference also to  FIGS. 2 ,  3 , and  9 – 16 , the fluid recovery system includes a air-liquid separator assembly  36 , a recovery tank  186 , a working air conduit  188 , and a vacuum source. 
     The air-liquid separator assembly  36  includes a rear chamber section  192  attached to a front chamber section  194 , a deflector  196 , and a channel cover  198 . The air-liquid separator assembly  36  includes bosses located on rear chamber section  192  for attachment to housing  22 . A brush cavity  195  is located at a forward lower section of front chamber section  194  for mounting of the rotating brush assembly  24 . 
     The front chamber section  194  has a bottom wall  200 , a pair of sidewalls  202  and a sloping front face  204 . A channel  206  is formed in the front face  204 . An inlet opening  217  is formed at an upper portion of channel  206  and fluidly connects channel  206  with an interior chamber  212  of front chamber section  194 . A generally square shaped electrical conduit  215  comprising an outer wall  211  spans the interior chamber  212  to enclose electrical wiring running from the switch  50  to the brush motor  56 . A locating recess  213  is located at an upper portion of the sloping front face  204  and serves to locate the transparent conduit  164 . The channel cover  198  fits snugly over the channel  206  to enclose channel  206  and form an elongated suction nozzle opening  208  at a lower portion of channel  206 . Suction nozzle  208  is thereby fluidly connected with inlet opening  217  of the air-liquid separator assembly  36 . The suction nozzle opening  208  is elongated and has a longitudinal axis. A generally rectangular opening  214  is formed in bottom wall  200  of front chamber section  194  for fluidly connecting to the recovery tank assembly  186 . 
     Deflector  196  is attached to front chamber section  194  over inlet opening  217  to deflect airs liquids, and debris downwardly within the interior chamber  212 . The deflector  196  is an integrally molded one-piece assembly including an arcuate upper portion  216  adjacent the inlet opening  217  to the interior chamber  212  and a depending portion  218  extending downwardly into the interior chamber  212 . Both portions  216 ,  218  include curved sides to form a generally concave deflector  196  about the inlet opening  217  to channel recovered fluid toward a lower portion of the interior chamber  212 . 
     The rear chamber section  192  comprises an outer shell  220  and an integrally molded conduit  222 . A locating boss  227  is formed on a rearward portion of outer shell  220  to provide alignment between air-liquid separator  36  and housing  22  during assembly. Conduit  222  comprises an outer wall  221 , a working air inlet  223  positioned inside the interior chamber  212 , and, at a second end, a working air outlet  224  intersecting the outer shell  220  at an integrally molded collar  225 . The collar  225  is adapted to be received in the semi-circular openings  72  of front housing ribs  70  to fluidly connect interior chamber  212  of the air-liquid separator assembly  36  with internal compartment  66  of the housing  22 . 
     The air-liquid separator assembly  36  is seated against a forward end  38  formed of the housing  22  with collar  225  retained in semi-circular openings  72  of front housing ribs  70 . The rectangular opening  214  in the bottom wall  200  of front chamber section  194  is in fluid communication with the recovery tank assembly  186 . The air-liquid separator assembly  36  is essentially integral with the housing  22  in the sense that it is inseparable from it. Preferably, the air-liquid separator assembly  36  is adhesively bonded to the forward end  38  of the housing  22 . 
     Referring now to  FIGS. 2 ,  3 ,  9  and  11 – 13 , recovery tank assembly  186  comprises a lower tank portion  228 , an upper tank portion  230 , a seal  244  and a latch  246 . Lower tank portion  228  and upper tank portion  230  form together a substantially enclosed tank having a single rectangular opening  232  with latch  246  attached at a forward portion thereof. 
     The upper tank portion  230  has a preferably rectangular opening  232  located at the forward end  234  for fluid communication with a corresponding preferably rectangular opening  214  in the front chamber section  194  of air-liquid separator assembly  36 . Seal  244  surrounds rectangular opening  214  to form a watertight seal between upper tank portion  230  and air-liquid separator assembly  36 . A pair of arcuate recesses  249  are located on a rearward portion of upper tank  230  to provide a bearing surface with the shell halves  32 ,  34 . 
     Lower tank portion  228  includes two sidewalls  236  each including a depression  238  with nubs  240  extending therefrom to facilitate handling the recovery tank assembly  186  during removal and installation thereof with respect to the portable hand-held deep cleaner  20 . Lower tank portion  228  further includes a slot  250  at a forward portion thereof for receiving latch  246 . A flange  260  projects outwardly from a rearward wall  258  of lower tank portion  228 . 
     As shown in  FIGS. 11–13 , latch  246  includes a base portion  248  for receipt in slot  250  integrally formed with a resilient arm  242  having a projection  247 . Projection  247  cooperates with a lip  256  on a rearward face  252  of a lower brush housing  284  to retain recovery tank assembly  186  against the lower face of air-liquid separator assembly  36 . 
     Recovery tank assembly  186  is pivotally mounted to housing  22  by inserting flange  260  into a groove  262  formed in forward end  38  of housing  22 . Recovery tank assembly  186  is rotated upwardly so that projection  247  bears against lip  256  and resilient arm  242  is depressed until projection  247  overcomes lip  256 . Tank assembly  186  is thus releasably retained against the air-liquid separator assembly  36  by projection  247  beneath lip  256 . 
     Recovery tank assembly  186  is removed from housing  22  by pressing against resilient arm  242  until projection  247  clears lip  256  and then rotating tank assembly  186  downwardly about flange  260  until tank assembly  186  is clear of housing  22 . As shown in  FIGS. 11 and 13 , the rear flange  260  includes a flat defining an interior edge  266 . The flange  260  seats in the groove  262  with the edge  266  blocking dislocation from the groove  262  and providing a pivot point for rotation of the recovery tank assembly  186  relative the groove  262  of housing  22 . It will be apparent that the recovery tank assembly  186  is removable without also removing the air-liquid separator assembly  36 , which remains fixed to the housing  22 . 
     Referring again to  FIGS. 2 ,  3 ,  9 ,  14  and  15  the front impeller assembly  268  includes a front curved plate  270  having an air inlet  272 , a rear plate  274  spaced from the front plate  270  with an opening  276  for receiving the front shaft  74  of the motor  54 , and a plurality of arcuate vanes  280  positioned between the front and rear plates  270 ,  274 . Preferably, each vane  280  curves radially outwardly from the air inlet  272  to draw air into the inlet  272  from the air-liquid separator assembly  36 , as represented by direction arrows A in  FIG. 3 , and expels the air from between the plates. The air expelled from the impeller assembly  268  is exhausted from the housing  22  through the exhaust apertures  76 . The air inlet  272  in the front plate  270  is in fluid communication with the working air outlet  224  of the air-liquid separator assembly  36 . Working air outlet  224  is sealingly attached to front housing rib  70  by integrally molded collar  225 . Impeller compartment  66  is thus fluidly connected with the air-liquid separator assembly  36  at front housing rib  70 , and is substantially fluidly isolated from vacuum motor compartment  67  by bushing  73 . The vacuum motor shaft  74  passes through bushing  73  into impeller compartment  66 . Impeller assembly  268  is mounted on shaft  74  for rotational movement within impeller compartment  66 . 
     A vacuum motor  54  is located within the housing  22  within the internal compartment  67  defined behind the rib  58  defining a rear wall of impeller compartment  66  on the interior of the housing  22 . A front portion of the motor  54  is substantially supported by shaft  74  and bushing  73 , with a rear portion of the motor supported by a motor mounting base  75  held by internal ribs of the housing formed for that purpose. The aforementioned front impeller assembly  268  is connected to the shaft  74  of the vacuum motor  54  for rotational movement within the impeller compartment  66 . The vacuum motor  54  is electrically connected to a power source such as a battery  52  through a switch  50  located in the upper handle portion  48  of the housing  22 . 
     Referring to  FIG. 3 , a working air conduit comprises a fluid pathway from the suction nozzle opening  208  through the exhaust apertures  76 . The working air conduit begins at the suction nozzle opening  208 , extends through the front face channel  206 , into the interior chamber  212  of the air-liquid separator assembly  36 , and through the conduit  222  to the impeller compartment  66  and the exhaust apertures  76 . 
     Water and other debris is separated from the flow of air as the combined flow is first diverted downwardly by deflector  196  and is then diverted again to enter the working air inlet  223 . The dirt and water contained in the working air flow will be separated from the air and will settle to the bottom of the interior chamber  212  of the air-liquid separator assembly  36  and will drain through the rectangular opening  232  into the recovery tank  186 . Working air continues through an upper portion of the air-liquid separator assembly  36 , into the working air inlet  223 , through the conduit  222 , through the working air outlet  224 , into the impeller assembly  268 , and out a plurality of exhaust apertures  76  in the side of the housing halves  32 ,  34 . Airflow is indicated by arrows in  FIG. 3 . 
     Referring to  FIGS. 2 ,  3 ,  12  and  16 , an agitator in the form of a rotating brush assembly  24  is mounted to the air-liquid separator assembly  36  and positioned adjacent to the rear of suction nozzle opening  208 . The brush assembly  24  comprises upper and lower brush housings  286 ,  284 , first and second end caps  288 ,  290 , the electric brush motor  56 , a brush roll  292  and associated connecting members as will be furthered described. Lower brush housing  284  further comprises a cavity  285  in which brush roll  292  is free to rotate. The brush roll  292  rotates about an axis parallel to the longitudinal axis of the suction nozzle opening  208 . 
     Lower brush housing  284  and upper brush housing  286  form an internal compartment  310  therebetween. The compartment  310  includes a plurality of ribs  308  adapted to mount electric brush motor  56 . Electric brush motor  56  has a shaft  295  mounting a first gear  296 . A sidewall  309  of compartment  310  includes an opening  297  for receiving shaft  295  and separating compartment  310  from a second internal compartment  312 . With shaft  295  received in opening  297 , first gear  296  is in second internal compartment  312 . 
     A second gear  298  rotatably mounted on a shaft  300  is also mounted within second internal compartment  312 , and includes a first set of gear teeth  299  intermeshed with first gear  296 . A second set of teeth  301  project through an opening  314  to the outside of lower housing  284 . Electric brush motor  56  and second gear  298  are held within upper and lower brush housings  286 ,  284  which are mounted together by fasteners such as screws (not shown) in cooperation with a plurality of bosses  306 . 
     Brush roll  292  is positioned between the first and second end caps  288 ,  290 . A plurality of bristles  325  are located in a generally V-shaped configuration on opposing sides of the brush roll  292  in the longitudinal axis. 
     Brush roll  292  includes a first end  303  including a brush roll gear  304  and a second end  305 . Second end  305  is adapted to receive a brush shaft  324  and brush bushing  322  for receipt in a bearing surface  294  on second end cap  290 . First brush end  303  also receives a brush end  324  and brush bushing  322  for receipt in first end cap  288 , and is further adapted to be operably connected to second gear  298  by a brush drive belt  302  engaging second set of teeth  301  and brush roll gear  304 . First and second end caps  288 ,  290  are removably mounted to respective sides of upper and lower belt housings  286 ,  284  through use of a threaded fastener received in bosses  317  on the side of lower housing  284 . 
     Referring again to  FIG. 16 , first and second end caps  288 ,  290  are attached to opposite ends of the brush motor lower brush housing  284 . Each end cap includes a recess  316  that is in alignment with bosses  317  on the lower brush housing  284 . In the preferred embodiment, the end caps  288 ,  290  are constructed of a transparent material to allow for visual inspection of the brush roll  292  contained therein. 
     The end caps  288 ,  290  are preferably fastened to the lower brush housing  284  by installing threaded fasteners in the bosses in a well known manner to secure the end caps to the lower brush housing  284 . An interior surface of the end caps  288 ,  290  creates the bearing surface  294 . The bearing surface  294  communicates with the brush bushing  322 , which is in communication with the brush shaft  324 . 
     The brush shaft  324  is in communication with a cavity on the end of the brush roll  292  coaxially oriented with the brush roll gear  304 . The brush drive belt  302  can be accessed for replacement or any other required maintenance by removing first end cap  288  from lower brush housing  284 , performing the required maintenance, and replacing first end cap  288 . 
     Referring to  FIGS. 2 ,  3 ,  14  and  15 , battery pack  52  is located within a cavity defined by the plurality of ribs  58  on the interior of the housing  22 . The battery pack  52  is electrically connected to a recharging circuit  57  comprising a printed circuit board and associated commonly known electrical components for supplying a recharging current to the battery pack  52 . The battery  52  is further selectively electrically connected to the electric vacuum motor  54  and the electric brush motor  56  through a switch  50  located in the upper handle portion  48  of the housing  22 . 
     In operation, fluid is delivered to the surface to be cleaned when the solution pump assembly trigger  82  is engaged. Fluid is drawn from the solution tank assembly  40  and through the solution pump assembly  80 . The solution pump assembly  80  forces fluid through a tube  85  and exits the spray nozzle  86  in a fan-shaped pattern. 
     In an alternate embodiment (see  FIGS. 19 and 20 ), fluid is delivered when the trigger is depressed, simultaneously energizing an electric solution pump and opening a valve in the supply conduit to deliver pressurized solution to the spray nozzle. 
     The suction nozzle opening  208 , the suction channel  206 , the interior chamber  212  of the air-liquid separator assembly  36 , and the conduit  222  are in fluid communication with each other and the vacuum source  68  created by the front impeller  268  to draw air and entrained liquid and debris from the surface being cleaned and deposit the liquid and debris in the interior of the recovery tank when the vacuum motor  54  is operating. 
     In the preferred embodiment, the recovery tank is designed to have a capacity of about 20 ounces, whereas the solution tank has a capacity of about 8 ounces. It is contemplated that with normal use of the hand-held deep cleaner, the liquid collected in the recovery tank will be eight ounces or less before emptying. Further, if the deep cleaning machine is held vertically for cleaning vertical surfaces for example, the liquid will collect principally in the recovery tank assembly  186  and ordinarily will not enter the air inlet  272  in the air conduit. The recovery tank assembly  186  is disengaged from the portable hand-held deep cleaner  20  by depressing the latch  246  on the forward end  234  of the recovery tank assembly  186 . The recovery tank assembly  186  is then free to rotate on the back flange  260  until the flange clears the groove  262  in the housing  22  and allows the recovery tank assembly  186  to be removed. It will be apparent that the recovery tank assembly  186  is removable without also removing the air-liquid separator assembly  36 , which remains fixed to the housing  22 . 
     Referring to  FIG. 17 , a further embodiment of the solution tank  40  shown in  FIG. 5  comprises an exterior wall  330  and an interior wall  331  forming a double wall construction. The solution tank further comprises an insulator  326  between the interior wall  331  and the exterior wall  330 . Interior wall  331  defines an interior chamber  328  of the solution tank. In one embodiment, the solution tank is formed from a single blow-molded material. The insulator  326  may be comprised of air or a solid insulating material. 
     In a further embodiment and referring to  FIG. 18 , the interior chamber  328  is formed by a single injection-molded element. The interior chamber  328  is spaced from the solution tank exterior wall  330  by a plurality of ribs  332  extending in a perpendicular fashion from the exterior surface of the interior chamber to form an air space  334  between the interior chamber  328  and the exterior wall  330 . The resulting air space  334  insulates the warm solution contained in the solution tank and impedes heat transfer from the inner chamber  328  to the exterior wall  330 . 
     Referring to  FIGS. 19–20 , in a further embodiment of the pump  80  as shown in  FIGS. 2 ,  3 ,  6 , and  7 , an electric pump motor  336  drives a solution pump  338  to provide pressurized solution to the system. The electric pump motor  336  is activated by a microswitch  340  that closes a circuit between the battery pack  52  and the electric pump motor  336 . The microswitch  340  is located in a cavity formed in the upper handle housing  48 . A tang  342  on the trigger  344  is oriented to operate the microswitch  340  when depressed. The trigger  344  simultaneously operates a solution valve  346  to fluidly connect the solution pump  338  to the nozzle  86 . When the trigger  344  is depressed, the solution valve  346  opens and the electric pump motor  336  is simultaneously energized which operates the solution pump  338  and provides a flow of pressurized solution from the solution tank  40  to the nozzle  86 . 
     In a further embodiment of the supply tubes  81 ,  85  as shown in  FIG. 3 , are covered with an insulating jacket  347  to impede the loss of heat from a hot solution. 
     Referring to  FIGS. 21–22  in a further embodiment of the recovery tank  186  as shown in  FIGS. 1–3 , capacity indicia are formed into the sidewall  236 . In one embodiment shown in  FIG. 21 , the lower portion of the sidewall  236  is textured to form an opaque finish  348 . The sidewall top portion  350  is transparent, thus enabling a user to visually inspect the recovery tank contents. 
     Referring to  FIG. 22  in a further embodiment of the recovery tank  186  as shown in  FIGS. 1–3 , the capacity indicia comprise a horizontal line  352  molded into the sidewall  236 . In this embodiment, the entire surface of the sidewall  236  is transparent. 
     The recovery tank  186  is constructed of thermoplastic materials that are resistant to the high heat and humidity encountered in a commonly known dishwashing appliance. 
     Referring to  FIGS. 23–25  in a further embodiment of the brush end caps  288 ,  290  as shown in  FIG. 16 , an access panel  356  is located in the face  358  of the first end cap  288 . The access panel  356  comprises a living hinge  360  on an upper surface  362  and a tab  364  on the lower surface. The tab  364  engages a recess  366  in the first end cap  288 . A screw head recess  357  is formed in the access panel. Screw boss  317  is in alignment with recess  357 . Access panel  356  is secured in place with a screw (not shown) through the recess  357  and into the boss  317 . When the screw is removed and the tab  364  is released from the recess  366 , the access panel  356  rotates about the living hinge  360  providing clear access to the brush belt  302 . 
     In a further embodiment, the access panel and the first end cap  288  comprise complementary tongue and groove elements arranged so that the access panel is removed by lateral movement parallel to the face  358  of end cap  288  to provide access to the brush belt  302 . 
     Referring to  FIG. 26 , a further embodiment of the brush assembly as shown in  FIG. 16  comprises two brush rolls  370  and  374  with bristles  325  located parallel to one another. The brush belt  302  passes from the brush motor gear  298 , under the first brush roll gear  368  on the first brush roll  370 , then under the second brush roll gear  372  of the second brush roll  374 , to an idler pulley  376  and then back to the brush motor gear  298 . The brush rolls are thus caused to rotate in opposite directions, towards each other, such that debris is agitated and lifted from the surface. 
     Referring to  FIG. 27  in a further embodiment of brush roll  292  as shown in  FIG. 16 , a single brush roll  400  consists of a plurality of bristle tufts  402  arranged in more than two rows  403  at an angle to the longitudinal axis of the brush roll  400 . 
     In a further embodiment of brush roll  292  shown in  FIG. 16  and referring to  FIG. 28 , a brush roll  404  comprises a plurality of flexible paddles or wipers  406  arranged at an angle to the longitudinal axis of the brush roll  404  in a similar orientation to the bristle tufts described in the previous embodiment. 
     In a further embodiment of brush roll  292  shown in  FIG. 16  and referring to  FIG. 29 , a brush roll  408  comprises a combination of bristle tufts  402  and flexible paddles or wipers  406  arranged about the brush roll  408 . 
     In a further embodiment of brush roll  292  shown in  FIG. 16  and referring to  FIG. 30 , a brush roll  412  in the form of a twist-wire brush comprises a continuous helix of bristles  414  bound together by a twist-wire spindle  416 . 
     In a further embodiment of the battery pack  52  as shown in  FIGS. 2 ,  3 ,  14 , and  15 , and referring to  FIGS. 31–32 , the battery pack  52  rests in a tray  378 . The tray slides on rails  380  formed by ribs  382  on the interior surface of the housing  384 . An end panel  386  is integrally formed on the tray  378  and is configured to conform to the exterior surface  388  of the housing  22  over the battery pack area. A screw (not shown) retains the battery tray  378  to the housing through a boss. The interior of the tray contains a cathode and an anode surface that corresponds with the battery pack terminals. A compression spring  390  maintains engagement of the battery terminals with the tray cathode and anode. An external battery charger is provided to charge the battery pack when the battery pack is not in use in the deep cleaner. 
     Referring to  FIG. 33 , in a further embodiment of the portable hand-held deep cleaner of  FIG. 1 , an illumination system is provided. An incandescent lamp  392  is positioned in a reflectorized housing  394  at the top forward portion of the first air-liquid separator  36 . The lamp  392  is selectively electrically connected to battery pack  52  through switch  50  located in the upper handle portion  48  of the housing halves  22 ,  24 . The solution tube and transparent conduit  164  are located below the reflectorized housing  394 . A transparent lens  396  covers housing  394  to protect lamp  392  from contamination and to provide an external surface for the cleaner  20 . When activated, illumination from the lamp  392  is directed through the transparent lens  396  to an area forward of the deep cleaner to illuminate the surface being cleaned. 
     While various alternative embodiments have been described in  FIGS. 17–33  with respect to the general embodiment of  FIGS. 1–16 , it will be understood that one, all, or various subcombinations of the features shown in  FIGS. 17–33  can be added to the general embodiment of  FIGS. 1–16  without departing from the scope of this invention. 
     Reasonable variation and modification are possible within the spirit of the foregoing specification and drawings without departing from the scope of the invention which is defined in the appended claims.