Robot cleaner

A robot cleaner includes: a suction module configured to suck dust-included air; a cyclone module configured to separate dust from the dust-included air sucked through the suction module, and having a dust discharge opening; a first air flow guide and a second air flow guide spaced apart from each other, and connecting the suction unit to the cyclone unit; a dust box detachably coupled to the dust discharge opening of the cyclone module, and provided between the first and second air flow guides; a drive module provided between the first and second air flow guides; and a dust compressor provided in the dust box, and mechanically coupled to the drive module when the dust box is mounted to the cyclone module, and formed to be rotatable bi-directionally based on a driving force from the drive module such that dust collected in the dust box is pressed to have a deceased volume.

CROSS-REFERENCE TO RELATED APPLICATION

Pursuant to 35 U.S.C. §119(a), this application claims the benefit of earlier filing date and right of priority to Korean Application No. 10-2014-0169996, filed on Dec. 1, 2014, the contents of which is incorporated by reference herein in its entirety.

BACKGROUND

The present disclosure relates to a robot cleaner.

Generally, a robot has been developed for an industrial use, and has managed some parts of factory automation. As the robot is applied to various fields recently, not only medical robots and space robots, but also home robots are being developed. A representative of the home robot is a robot cleaner, a kind of home electronic appliance capable of performing a cleaning operation by sucking dust on a floor (including foreign materials) while autonomously moving on a predetermined region. Such a robot cleaner is provided with a chargeable battery, and is provided with an obstacle sensor for avoiding an obstacle while moving.

The robot cleaner is configured to suck dust-contained air, to filter dust from the dust-contained air by a filter, and to discharge filtered air to the outside. The filtered dust is accumulated in a dust box. The dust may scatter by flow of air generated when the robot cleaner is driven, thereby lowering cleaning performance. The dust may also scatter when discharged from the dust box, thereby causing discomfort to a user.

DETAILED DESCRIPTION

Referring toFIGS. 1 and 2, the robot cleaner100performs a function to clean a floor by sucking dust (including foreign materials) on the floor, while autonomously moving on a predetermined region. The robot cleaner100includes a cleaner body101for performing a moving function, a controller (not shown) and a moving unit110, e.g., a motorized wheel. The cleaner body101is configured to accommodate components therein, and to move on a floor by the moving unit110. The controller for controlling an operation of the robot cleaner100, a battery (not shown) for supplying power to the robot cleaner100, etc. may be mounted to the cleaner body101.

The moving unit110is configured to move (or rotate) the cleaner body101back and forth or right and left, and is provided with main wheels111and a supplementary wheel112. The main wheels111are provided at two sides of the cleaner body101, are configured to be rotatable to one direction or another direction according to a control signal. The main wheels111may be configured to be independently driven. For instance, each of the main wheels111may be driven by a different motor.

Each of the main wheels111may be composed of wheels111aand111bhaving different radiuses with respect to a rotation shaft. Under such a configuration, in a case where the main wheel111moves up on an obstacle such as a bump, at least one of the wheels111aand111bcontacts the obstacle. This can prevent idling of the main wheel111. The supplementary wheel112is configured to support the cleaner body101together with the main wheels111, and to supplement movement of the cleaner body by the main wheels111.

Referring toFIGS. 3 to 5, the robot cleaner100includes a suction unit or module130, a first guiding member141(or first air flow guide), a second guiding member142(or second air flow guide), a cyclone unit or module150and a fan unit or module170. The suction unit or module130is provided at a bottom portion of the cleaner body101, and is configured to suck dust or dirt contained air (dirty air) on a floor by the fan unit170. The suction unit130may be arranged at a front side of the cleaner body101, and may be detachably mounted to the cleaner body101. The position of the suction unit130is related to a moving direction of the robot cleaner100when the robot cleaner100is normally operated.

An obstacle sensor103electrically connected to the controller and configured to sense an obstacle while the robot cleaner100moves and a damper104formed of an elastic material and configured to absorb a shock when the robot cleaner100collides with an obstacle may be provided at the suction unit130. The obstacle sensor103and the damper104may be provided at the cleaner body101.

Referring toFIG. 5, the suction unit130includes a suction opening131, a roller132and a brush133. The suction opening131may be formed to extend in a lengthwise direction of the suction unit130. The roller132is rotatably installed at the suction opening131, and the brush133is mounted to an outer circumferential surface of the roller132. The brush133is configured to sweep up dust on a floor to the suction opening131. The brush133may be formed of various materials including a fibrous material, an elastic material, etc.

The first guiding member141and the second guiding member142may be provided between the suction unit130and the cyclone unit150, thereby connecting the suction unit130and the cyclone unit150to each other. The first guiding member141and the second guiding member142are spaced from each other. One ends of the first and second guiding members141and142coupled to the suction unit130may be fixed to the cleaner body101.

Air sucked through the suction unit130is introduced into the cyclone unit150in a diverged manner, through the first and second guiding members141and142. Such a configuration is advantageous in that air sucking efficiency is enhanced or improved, than in a case where a single guiding member is provided.

The first and second guiding members141and142may be disposed to be upward inclined toward the cyclone unit150, so as to extend from the suction unit130toward the cyclone unit150(specifically, a first suction opening150aand a second suction opening150bshown inFIG. 7A), where the cyclone unit150is arranged at a rear upper side of the suction unit130. The cyclone unit150may be provided with a cylindrical inner circumferential surface, and may be long-formed along a second direction (X1). The cyclone unit150may have an approximate cylindrical shape. The second direction (X1) may be a direction perpendicular to a moving (or first) direction of the robot cleaner100.

The cyclone unit150is configured to filter at least one of dust or dirt (hereinafter, collectively referred to as “dust”) from air sucked thereto through the suction unit130. Air sucked into the cyclone unit150is rotated along an inner circumferential surface of the cyclone unit150. During this process, dust is collected to a dust box or a storage chamber160communicated with a dust discharge opening150e(FIG. 7A), and dirty air is introduced into a first cyclone151and a second cyclone152.

The dust discharge opening150eis formed at a front side of the cyclone unit150. The dust discharge opening150emay be formed between the first suction opening150aand the second suction opening150b(or between the first cyclone151and the second cyclone152), i.e., at a central portion of the cyclone unit150. Under such a structure, dust included in air introduced into two sides of the cyclone unit150through the first and second suction openings150aand150b, rotates along an inner circumferential surface of the cyclone unit150, toward a central part from an end part of the cyclone unit150. The dust is collected or blown to the dust box160through the dust discharge opening150e.

The dust box160is connected to the cyclone unit150, and is configured to collect dust filtered by the cyclone unit150. In this embodiment, the dust box160is disposed between the suction unit130and the cyclone unit150. The dust box160is detachably mounted to the cyclone unit150so as to be separable from the cleaner body101. When a removable cover102coupled to the cleaner body101is opened, the dust box160may be in a separable state by being exposed to the outside. The dust box160may be configured to be exposed to the outside, thereby forming the appearance of the robot cleaner100together with the cleaner body101. In such a case, a user can check the amount of dust accumulated in the dust box160without opening the cover102.

The dust box160may include a dust box body or a dust storage chamber161and a dust box cover162. The dust box body161forms a space for collecting dust filtered by the cyclone unit150, and the dust box cover162is coupled to the dust box body161so as to open and close an opening of the dust box body161. For instance, the dust box cover162may be configured to open and close the opening of the dust box body161by being hinge-coupled to the dust box body161. The dust discharge opening150emay be provided at the dust box body161. However, the present disclosure is not limited to this. The dust discharge opening150emay be also formed at the dust box cover162according to a modified design.

As aforementioned, the dust box160connected to the cyclone unit150may be formed to have a predetermined depth, since the cyclone unit150is arranged at an upper side of the suction unit130. For efficient spatial arrangement, at least part of the dust box160may be accommodated in a space between the first guiding member141and the second guiding member142.

In this embodiment, the dust box body161includes a first portion161aand a second portion161bhaving different sectional areas. The first portion161amay communicate with the dust discharge opening150e, and at least part of the first portion161amay be disposed on the first and second guiding members141and142. As shown inFIG. 4, in this embodiment, two sides of the first portion161aare disposed on the first and second guiding members141and142.

The second portion161bis formed to extend to a lower side of the first portion161a, and to have a smaller sectional area than the first portion161a. At least part of the second portion161bis accommodated in a space between the first and second guiding members141and142. The first and second guiding members141and142may be formed such that at least part thereof is bent to enclose or support the second portion161bat two sides.

Based on such a structure, dust collected into the dust box160is firstly accumulated in the second portion161b. In a modified embodiment, an inclined portion or wall (not shown), inclined toward the second portion161bso that dust can move to the second portion161b, may be provided between the first portion161aand the second portion161b.

The dust box cover162may be arranged to be inclined so that at least part thereof can face the dust discharge opening150e. Based on such a structure, dust introduced into the dust box160through the dust discharge opening150ecan the dust box cover162to be collected in the dust box body161(mainly, the second portion161b).

The fan unit or module170is connected to the cyclone unit150. The fan unit170includes a motor175configured to generate a driving or suction force, and a first fan part171and a second fan part172connected to two sides of the motor part175and configured to generate a suction force. A detailed structure of the fan unit10will be explained later (see, e.g.,FIG. 9A).

The fan unit170may be fixed to the cleaner body101, and may be provided at a rear lower side of the cyclone unit150. For such an arrangement, the cyclone unit150is coupled onto the fan unit170(specifically, a first communication member173and a second communication member174), thereby being spaced from an inner bottom surface of the cleaner body101.

As shown inFIG. 5, an arbitrary line (L1), which connects two ends of the first guiding member141or the second guiding member142to each other, has an inclination angle (θ1), from an inner bottom surface (S) of the cleaner body101. An arbitrary line (L2), which connects the cyclone unit150and the fan unit170to each other, has an inclination angle (θ2), from the inner bottom surface (S) of the cleaner body101. As such inclination angles (θ1and θ2) are controlled, a volume of the dust box160may be variously changed.

FIG. 6is a side sectional view illustrating the cyclone unit150and the fan unit170separated from the robot cleaner100ofFIG. 3.FIG. 7Ais a perspective view of the cyclone unit150and the fan unit170ofFIG. 6. TheFIG. 7Billustrates a state where a second case154of the cyclone unit150ofFIG. 7Ahas been removed.

Referring toFIGS. 6 to 7Btogether with the aforementioned figures, the cyclone unit150is provided with the first suction opening150acommunicated with the first guiding member141, and the second suction opening150bcommunicated with the second guiding member142. The first suction opening150aand the second suction opening150bmay be formed at two sides of the cyclone unit150such that air introduced into the cyclone unit150through the first suction opening150aand the second suction opening150brotates along an inner circumferential surface of the cyclone unit150, toward a central part from an end part of the cyclone unit150.

The cyclone unit150may further include a first suction guide150a′ and a second suction guide150b′ configured to guide air sucked to the cyclone unit150through the first suction opening150aand the second suction opening150bto an inner circumferential surface of the cyclone unit150, respectively. The first suction guide150a′ is formed at the first suction opening150atoward an inner circumferential surface of the cyclone unit150, and the second suction guide150b′ is formed at the second suction opening150btoward an inner circumferential surface of the cyclone unit150.

The cyclone unit150is provided therein with the first cyclone151and the second cyclone152such that air and dust are introduced into the first cyclone151and the second cyclone152. The first cyclone151has a structure that an air passing hole151bis formed at a protruding member151ahaving a hollow inner space, and the second cyclone152has a structure that an air passing hole152bis formed at a protruding member152ahaving a hollow inner space. Dust of prescribed size cannot pass through the air passing holes151band152b, whereas air (with fine dust smaller than the prescribed size) can pass through the air passing holes151band152bto flow into the hollow inner spaces of the protruding members151aand152a.

As shown, the first cyclone151may be arranged close to the first suction opening150a, and the second cyclone152may be arranged close to the second suction opening150b. Under such a structure, air and dust sucked into the cyclone unit150through the first suction opening150ais mainly introduced into the first cyclone151, and air and dust sucked into the cyclone unit150through the second suction opening150bis mainly introduced into the second cyclone152. Dust may be efficiently filtered from the sucked air, and the dust-filtered air can be more efficiently discharged from the cyclone unit150.

The first and second cyclones151and152may be provided at two ends of the cyclone unit150in a facing manner. In this case, the first and second cyclones151and152may be formed to protrude from the same axis (X2). The axis (X2) may be perpendicular to a moving direction (forward or backward direction) of the robot cleaner100. The axis (X2) may be identical to the aforementioned a second direction (X1).

The first and second cyclones151and152may be arranged at central regions of two end portions of the cyclone unit150so as to have a preset separating distance from an inner circumferential surface of the cyclone unit150. Under such a structure, dust can rotate along an inner circumferential surface of the cyclone unit150, and dust-filtered air can be mainly introduced into the first and second cyclones151and152.

Referring toFIG. 8illustrating a modification example of the cyclone unit150ofFIG. 7A, a cyclone unit250may be configured so that air which has passed through first and second suction openings (not shown) can be introduced toward a central part of the cyclone unit250. Under such a structure, air introduced into the cyclone unit250can easily rotate toward a central part of the cyclone unit250from an end part of the cyclone unit250.

In the drawings, the cyclone unit250is arranged so that a region for accommodating a first cyclone251and a region for accommodating a second cyclone252have a preset angle therebetween. The preset angle viewed from a front side may be 180° or less.

The first and second suction openings may be formed toward a central part of the cyclone unit250such that air is introduced into the central part of the cyclone unit250. The first and second suction guides (not shown) aforementioned with reference to the aforementioned embodiment may be formed to extend toward the central part of the cyclone unit250.

Referring back toFIGS. 6 and 7B, the cyclone unit150may include a first case153and a second case154. The first case153is provided with the first and second suction openings150aand150band the first and second cyclones151and152, and is configured to be coupled to the first and second guiding members141and142. The second case154is provided with a dust discharge opening150, and is removably coupled to the first case153. For example, the second case154may be hinge-coupled to the first case153, and may be configured to open and close the first case153by being rotated.

Under such a configuration, as the second case154is separated from the first case153or rotated, and inside of the cyclone unit150may be exposed. This is advantageous in that dust or dirt, collected in the air passing holes151band152bof the first and second cyclones151and152without having passed therethrough, can be easily removed.

As shown inFIGS. 7B and 8, the cyclone unit150may further include a first discharge opening150cand a second discharge opening (opposite side of cyclone unit250C) communicated with inner spaces of the first and second cyclones151and152so that dust/dirt filtered air can be discharged. As shown, the first discharge opening150cand the second discharge opening (not shown) may be provided at two sides of the cyclone unit150. Although the second discharge opening is not visible in the drawings, the second discharge opening may be understood as a mirror image of the first discharge opening150cshown inFIG. 7A. The fan unit170may be connected to each of the first discharge opening150cand the second discharge opening, such that filtered air is discharged to the outside. As shown inFIG. 7B, the second discharge opening (similar to the first discharge opening) has a hollow interior in communication with the hollow interior of the second cyclone152.

FIG. 9Ais a perspective view of the fan unit170shown inFIG. 6,FIG. 9Billustrates a state where a first communication member173has been removed from the fan unit170ofFIG. 9A, andFIG. 9Cillustrates a state where a first fan cover175has been removed from the fan unit170ofFIG. 9B.FIG. 9Dillustrates a state where a first fan171b, a first motor housing175aand a second motor housing175bhave been removed from the fan unit170ofFIG. 9C.FIG. 9Eis a view taken along line ‘B-B’ in the fan unit170shown inFIG. 9D.

The fan unit170includes a motor part175, a first fan part171, a second fan part172, a first communication member173and a second communication member174. Although the second fan part172is not visible in the drawings, the second fan part172may be understood as a mirror image of the first fan part171shown inFIG. 9C.

The motor part or module175may be configured to generate a driving or a suction force, and may be provided at a central part of the fan unit170. The motor part175includes a motor175c, and a motor housing for accommodating the motor175ctherein. The motor175cmay be provided with rotation shafts at two sides thereof. The motor housing may be composed of a first motor housing175aand a second motor housing175bcoupled to each other to accommodate the motor175ctherein.

The first fan part or module171and the second fan part or module172are connected to two sides of the motor part175. The first fan part171includes a first fan171bconnected to a rotation shaft175c′ provided at one side of the motor175c, and a first fan cover171a configured to accommodate the first fan171b therein. And the second fan part172includes a second fan172bconnected to a rotation shaft provided at another side of the motor175c, and a second fan cover172aconfigured to accommodate the second fan172btherein.

The first and second fans171band172bare configured to generate a suction force by being rotated when the motor175cis driven, and to discharge filtered air to the outside. Each of the first and second fans171b and172bmay be a volute fan.

The first fan cover171ais provided with a first air inlet171d(FIG. 9B) in a direction of a rotation shaft of the first fan part171, and is provided with a first air outlet171e(FIG. 10) in a radius direction of the first fan part171. Likewise, the second fan cover172ais provided with a second air inlet in a direction of a rotation shaft of the second fan part172, and is provided with a second air outlet in a radius direction of the second fan part172. Although the second air inlet and the second air outlet are not visible in the drawings, the second air inlet may be understood as a mirror image of the first air inlet171dshown inFIG. 9B, and the second air outlet may be understood as a mirror image of the first air outlet171eshown inFIG. 10.

A mechanism to suck and discharge air according to such a structure will be explained in more detail. Dust-filtered air is introduced into the first fan cover171athrough the first air inlet171dby a suction force due to rotation of the first fan part171. The air is moved to a side direction by rotation of the first fan part171implemented as a volute fan, and is discharged out through the first air outlet171e. Such a mechanism may be equally applied to processes to suck and discharge air by rotation of the second fan part172.

The first communication member173is configured to connect the first discharge opening150cof the cyclone unit150with the first fan part171, and thus to guide air introduced into the inner space of the first cyclone151into the first fan part171. Likewise, the second communication member174is configured to connect the second discharge opening of the cyclone unit150with the second fan part172, and thus to guide air introduced into the inner space of the second cyclone152into the second fan part172.

As aforementioned (refer toFIGS. 6 to 7B), in a case where the cyclone unit150includes the first case153and the second case154, the first case153may be provided with the first discharge opening150cand the second discharge opening, and may be coupled to each of the first and second communication members173and174.

A first coupling member155for coupling with the first communication member173, and a second coupling member156for coupling with the second communication member174may be provided at two sides of the first case153.

For instance, each of the first and second coupling members155and156may include a hook and an elastic member. More specifically, the hooks are rotatably coupled to two sides of the first case153, and are locked by the first and second communication members173and174. The elastic members are configured to elastically press the hooks so that a locked state of the hooks to the first and second communication members173and174can be maintained. The first and second communication members173and174may be provided with locking protrusions173aand174aconfigured to lock the hooks so that the first case153can be prevented from being separated from the first and second communication members173and174.

Coupling of the first case153with the first and second communication members173and174is not limited to the above coupling. That is, the first case153may be coupled with the first and second communication members173and174in various manners without an additional coupling member, e.g., by using a locking structure or by bonding.

Fine dust filters173band174b, configured to filter fine dust from dust-filtered air, may be mounted to the first and second communication members173and174. As the fine dust filters173band174b, HEPA filters may be used. For replacement, the fine dust filters173band174bmay be configured to be exposed to the outside when the cyclone unit150is separated from the first and second communication members173and174.

When the motor175cof the fan unit170and the first and second fans171b,172bare driven, vibrations occur from the robot cleaner. If a suction force is increased for enhancement of a cleaning function, the motor175cand the first and second fans171b,172bare rotated more rapidly. This may cause severe vibrations.

To solve such problems, a supporting unit180configured to support the fan unit170may be disposed between an inner bottom surface of the cleaner body101and the fan unit170. The supporting unit180is formed of an elastic material (e.g., rubber, urethane, silicone, etc.) so as to absorb vibrations generated from the fan unit170. The supporting unit180is configured to elastically support the motor part175, the first fan part171and the second fan part172which are the main components where vibrations occur. The supporting unit180includes a motor supporting member183configured to elastically support the motor part175, and first and second fan supporting members181,182configured to elastically support the first and second fan parts171,172.

The motor supporting member183is installed on an inner bottom surface of the cleaner body101, and is formed to enclose or surround at least part of the motor part175. Referring toFIGS. 9D and 9E, the motor supporting member183is formed to enclose an outer circumference of the motor housings175a,175b.

Referring toFIG. 9E, the motor supporting member183may include a base part183ainstalled on the inner bottom surface of the cleaner body101, and an extending part183bupward extending from the base part183aso as to enclose at least part of the motor part175. The base part183aand the extending part183bmay be integrally formed with each other by injection molding.

Coupling holes183care formed at the motor supporting member183, and coupling members184(e.g., fasteners) to the inner bottom surface of the cleaner body101through the coupling holes183c, thereby fixing the motor supporting member183to the cleaner body101. In the drawings, the coupling holes183care formed at two sides of the motor supporting member183.

A plurality of ribs protrude from an outer circumference of the first motor housing175a, and a plurality of ribs175b′ (FIG. 9E) protrude from an outer circumference of the second motor housing175b. The ribs175b′ are provided therein a coupling structure. For instance, the ribs of the first motor housing175aare provided with protrusions, and the ribs175b′ of the second motor housing175bare provided with accommodation grooves175b″ for accommodating the protrusions therein. As the protrusions are fitted into the accommodation grooves175b″, the first motor housing175aand the second motor housing175bmay be coupled to each other.

An inner side of the extending part183bmay be formed to correspond to an outer circumference of the motor part175, so as to enclose at least part of the motor part175. The extending part183bmay be formed to cover at least one of the aforementioned plurality of ribs175b′. In this case, an accommodation groove183b′ is formed in the extending part183b, in correspondence to the at least one rib. With such a configuration, as the rib175b′ is accommodated in the accommodation groove183b′, the motor part175may be fixed to the motor supporting member183more stably.

A hollow part183dmay be formed between the base part183aand the extending part183b, thereby reducing vibrations from being transmitted to the base part183afrom the extending part183b. In the drawings, the hollow part183dis formed at the motor supporting member183in plurality.

The first and second fan supporting members181,182are configured to elastically support the first and second fan covers171a,172a, respectively. In the drawings, protruding parts171a′,172a′ protrude from the first and second fan covers171a,172a, so as to face the inner bottom surface of the cleaner body101. The first and second fan supporting members181,182are disposed between the inner bottom surface of the cleaner body101and the protruding parts171a′,172a′.

The first and second fan supporting members181,182may be fixed to the protruding parts171a′,172a′. For instance, referring toFIGS. 6 and 9A, a protrusion171a″ may be formed to protrude from the protruding part171a′, toward the inner bottom surface of the cleaner body101. An insertion groove181a configured to insert the protrusion171a″ may be formed at the first fan supporting member181. The first and second fan supporting members181,182may be coupled to the protruding parts171a′,172a′, respectively, by another coupling structure, e.g., a coupling structure using screws, a bonding coupling structure, etc.

The first and second fan supporting members181,182may be fixed to the inner bottom surface of the cleaner body101, or may be supported on the inner bottom surface of the cleaner body101in a non-fixed state. In the case where the first and second fan supporting members181,182are fixed to the inner bottom surface of the cleaner body101, a coupling structure using screws may be used.

As aforementioned, the first fan part171is connected to the first communication member173, and the second fan part172is connected to the second communication member174. Accordingly, vibrations generated from the first and second fan parts171,172may be transmitted to the first and second communication members173,174and noise may occur as the components come in contact with each other.

For reduction of such noise, a first connection member185, formed of an elastic material so as to absorb vibrations generated from the first fan part171, may be disposed between the first fan part171and the first communication member173. Likewise, a second connection member (not shown), formed of an elastic material so as to absorb vibrations generated from the second fan part172, may be disposed between the second fan part172and the second communication member174.

Referring toFIG. 9B, the first connection member185may be formed to have a ring shape so as to enclose the first air inlet171dof the first fan cover171a. The first connection member185is pressurized when the first fan part171and the first communication member173are coupled to each other, thereby being fitted to the first fan part171and the first communication member173. The second connection member may be also formed to have a ring shape so as to enclose the second air inlet, in correspondence to the first connection member185. The second connection member is formed to seal a gap occurring when the second communication member174and the second fan part172are coupled to each other.

The fan unit170may be a main component of the robot cleaner100where noise occurs. Moreover, since the robot cleaner100of the present disclosure is provided with the plurality of fan parts171,172corresponding to the plurality of cyclones151,152, noise occurs. Hereinafter, a structure for reducing noise generated from the fan unit170will be explained.

Referring toFIGS. 9A to 9EwithFIG. 6, a noise reducing member190is disposed above the fan unit170so as to reduce noise. As shown, the noise reducing member190extends toward two sides of the motor part175, thereby covering the first and second fan parts171,172. If necessary, the noise reducing member190may more extend to cover the first and second communication members173,174.

For smooth exhaustion, the noise reducing member190is formed not to cover the first air outlet171eof the first fan cover171aand the second air outlet of the second fan cover172a. The noise reducing member190extends to a lower side of the fan unit170from an upper side of the fan unit170. In this case, the noise reducing member190may extend up to an upper side of the first and second air outlets, or may be provided with exhaustion holes at parts corresponding to the first and second air outlets.

As the noise reducing member190is disposed to cover an upper side of the fan unit170, noise generated from the motor175cand the first and second fans171b,172bmay be prevented from being transmitted to the upper side of the fan unit170. As noise is concentrated or directed into the inner bottom surface by the noise reducing member190, a user may receive noise of a low level.

The noise reducing member190may reduce noise by irregularly reflecting or absorbing noise generated from the fan unit170. For diffused reflection of noise, an inner side surface of the noise reducing member190, which faces the fan unit170, may have a concavo-convex structure. For absorption of noise, a noise absorbent configured to absorb at least part of noise may be attached to the inner side surface of the noise reducing member190, which faces the fan unit170. The noise absorbent may be formed of a porous material such as a sponge.

The noise reducing member190is disposed to cover most regions of the upper side of the fan unit170. However, in some cases, the noise reducing member190may be disposed to cover a partial region of the upper side of the fan unit170. Referring toFIG. 5, the cyclone unit150is connected to a front upper side of the fan unit170. In this case, the noise reducing member190may be installed at the fan unit170so as to cover a rear upper side of the fan unit170.

Since the noise reducing member190is configured to reduce noise generated from the motor175cand the first and second fans171b,172b, the noise reducing member190may be installed at the fan unit170. In the drawings, the noise reducing member190is mounted to the first and second communication members173,174. However, the installation position of the noise reducing member190is not limited to the fan unit170. That is, the noise reducing member190may be mounted to any region adjacent to the fan unit170, e.g., the cyclone unit150, the inside of the cleaner body101, etc. For instance, the noise reducing member190may be installed at the first case153of the cyclone unit150, and may extend from the first case153toward the fan unit170so as to cover an upper side of the fan unit170.

An installation structure of the noise reducing member190will be explained in more detail. A coupling boss173cfor coupling with the noise reducing member190protrudes from each of the first and second communication members173,174. Referring toFIGS. 5 and 9A, a first coupling boss173c′ and a second coupling boss173c″, which protrude toward the noise reducing member190, are provided at the first communication member173. The noise reducing member190is spaced apart from the fan unit170, in a supported state by the first and second coupling bosses173c′,173c″. Coupling members194are coupled to the first and second coupling bosses173c′,173c″ via coupling holes of the noise reducing member190, thereby fixing the noise reducing member190to the first communication member173.

The noise reducing member190extends along a direction, so as to cover the motor part175and the first and second fan parts171,172disposed at two sides of the motor part175. The noise reducing member190may extend toward a lower side of the fan unit170, from an upper side of the fan unit170.

For instance, as shown, the noise reducing member190includes a base part or plate192and an extending or plate part193. The base part192and the extending part193may have a flat shape, and may be connected to each other in a bent manner. The base part192is disposed to cover an upper side of the fan unit170, and is mounted to the first coupling bosses173c′ of the first and second communication members173,174by the coupling members194. The extending part193downward extends from the base part192in a bent manner, thereby covering a rear upper side of the fan unit170. The extending part193is mounted to the second coupling bosses173c″ of the first and second communication members173,174by the coupling members194. For smooth exhaustion, the extending part193is disposed not to cover the first air outlet171eof the first fan cover171a, and the second air outlet of the second fan cover172a.

A noise absorbent, configured to absorb at least part of noise generated from the fan unit170, may be attached to the inside of at least one of the base part192and the extending part193. The noise reducing member190may be formed to have a rounded shape corresponding to the appearance of the fan unit170, so as to enclose at least part of the fan unit170. For instance, the noise reducing member190may be formed in a semi-circular shape, and may be disposed to cover a rear upper side of the fan unit170.

For noise reduction and air volume increase when the first and second fan parts171,172are driven, the following structure may be applied. This will be explained in more detail with reference toFIG. 10.FIG. 10is an enlarged view of part ‘C’ shown inFIG. 5.

Referring toFIG. 10, a gap may be maintained between an inner circumferential surface of the first fan cover171a, and an inner portion of the first fan171bdisposed close to the inner circumferential surface of the first fan cover171a. Likewise, a gap may be maintained between an inner circumferential surface of the second fan cover172a, and an inner portion of the second fan172bdisposed close to the inner circumferential surface of the second fan cover172a.

The first fan cover171amay be provided with a first exhaustion guide (r) and the second fan cover172amay be provided with a second exhaustion guide, each exhaustion guide for guiding smooth exhaustion of dust-separated air. This will be explained in more detail with reference to the first exhaustion guide (r). The first exhaustion guide (r) may extend from an inner circumferential surface of the first fan cover171atoward the first air outlet171e, in a rounded manner. Although the second exhaustion guide is not visible, the second exhaustion guide may be understood as a mirror image of the first exhaustion guide (r) shown inFIG. 10.

A first exhaustion hole (not shown) corresponding to the first air outlet171e, and a second exhaustion hole (not shown) corresponding to the second air outlet may be formed at the cleaner body101.

For exhaustion of cleaner air, a fine dust filter171cmay be mounted to at least one of the first fan cover171a and the cleaner body101. As the fine dust filter171c, a HEPA filter may be used to filter fine dust smaller than the prescribed size. The fine dust filter171cis mounted to cover at least one of the first air outlet171eand the first exhaustion hole, and is configured to filter fine dust from dust-separated air. Likewise, the fine dust filter171cmay be mounted to at least one of the second fan cover172aand the cleaner body101.

As aforementioned, in the robot cleaner100, dirty air is sucked through the suction unit130, and dust is separated from the dirty air through the cyclone unit150. The dust-separated air is discharged to the outside through the fan unit170. The filtered dust is accumulated in the dust box160. The dust may be blown by flow of air generated when the robot cleaner100is driven, thereby lowering cleaning performance. The dust may be also blown when discharged from the dust box160, thereby causing discomfort to a user.

The present disclosure provides the following structure, in order to prevent scattering of dust accumulated in the dust box160, and in order to provide a user's convenience during a dust discharge process.FIG. 11illustrates a view of part ‘D’ inFIG. 5, which is viewed from a bottom surface.FIG. 12illustrates a view when the dust box160has been removed in order to explain a driving mechanism of a driving unit105and a pressing unit120shown inFIG. 5.

Referring toFIGS. 11 and 12withFIGS. 3 and 5, the dust box160is detachably mounted to the cyclone unit150so as to be communicated with the dust discharge opening150e. The dust box160may be coupled to the cyclone unit150so as to be communicated with the dust discharge opening150eformed at a front side of the cyclone unit150, thereby being disposed between the suction unit130and the cyclone unit150. The dust discharge opening150emay be communicated with a central part of the dust box160such that dust is uniformly discharged to the inside of the dust box160.

Based on such a structure, one region of the dust box160may be provided on the first and second guiding members141,142. Two sides of the first portion161amay be provided on the first and second guiding members141,142. Another region of the dust box160may be provided between the first and second guiding members141,142. At least part of the second portion161bdownward-extending from the first portion161ais accommodated between the first and second guiding members141,142.

The driving unit or module105may be provided between the first and second guiding members141,142. Referring toFIG. 5, the driving unit105includes a motor105aand a driving gear105b.FIG. 11illustrates only the driving gear105b, excluding the motor105a, for convenience. The motor105ais electrically connected to the controller, and is rotatable according to a control signal applied thereto in two directions (i.e., clockwise or counterclockwise). The motor105amay be mounted to an inner bottom surface of the cleaner body. The driving gear105bis connected to a rotation shaft of the motor105a, and is configured to transmit a driving force of the motor105aby being engaged with a driven gear123of the pressing unit120to be explained later.

The pressing unit or dust compressor120may be installed at the dust box160, and the pressing unit120is rotatable in two directions by receiving a driving force from the driving unit105. Rotation of the motor105amay be controlled such that such a bidirectional rotation of the pressing unit120is repeatedly performed. Dust collected in the dust box160is pressed by the bidirectional rotation of the pressing unit120, thereby having a decreasing volume of the collected dirt.

The pressing unit120may include a rotation shaft121, a pressing member or plate122and a driven gear123. The rotation shaft121is installed to pass through a bottom surface of the dust box160. One part of the rotation shaft121is inserted into the dust box160, and another part of the rotation shaft121protrudes from the bottom surface of the dust box160. A sealing structure for sealing a gap between the rotation shaft121and the dust box160may be provided between the rotation shaft121and the dust box160.

The pressing member122is installed at the rotation shaft121inserted into the dust box160, and is rotatable in the dust box160based on the rotation of the rotation shaft121rotates. Dust collected in the dust box160is moved to one side of the dust box160by the rotation of the pressing member122.

To prevent idling of the pressing member122when the rotation shaft121rotates, a fixing structure may be provided at the rotation shaft121and the pressing member122. For instance, a groove122′ may be formed at the pressing member122, and a protrusion162a(seeFIG. 13A) corresponding to the groove may be formed on the cover162. The rotation shaft121may be formed in a shape other than a circular shape, e.g., a “D”-shape, to correctly orient the pressing member122. The inside of the pressing member122, where the rotation shaft121is inserted, may have a shape corresponding to the shape of the rotation shaft121.

The pressing member122may be formed to have a flat shape, and a plurality of protruding parts or protrusions122″ may be provided from at least one surface of the pressing member122. The plurality of protruding parts122″ are configured to restrict dust from being adhered to the pressing member122, or to press dust collected at one side of the dust box160in a non-uniform manner. The plurality of protruding parts122″ may have a dome shape.

As aforementioned, the dust box body161may include the first portion161aand the second portion161bhaving different sectional areas. Similarly, the pressing member122may include a first pressing portion plate122aand a second pressing portion or plate122bhaving different sectional areas.

The first pressing portion122amay be provided in the first portion161aso as to compress dust inside the first portion161a. The second pressing portion122bdownward-extends from the first pressing portion122a, and may be provided in the second portion161bso as to compress dust inside the second portion161b. As shown, the second pressing portion122bmay be formed to have a smaller area than the first pressing portion122ain correspondence to an area of the second portion161b.

The driven gear123may be provided at the rotation shaft121which protrudes from the dust box160, thereby rotating the rotation shaft121. Since the pressing member122is connected to the rotation shaft121, the pressing member122is rotated, when the driven gear123is rotated. To prevent idling of the rotation shaft121when the driven gear123is rotated, a fixing structure may be provided at the driven gear123and the rotation shaft121. Detailed explanations of the fixing structure will be replaced by the fixing structure between the rotation shaft121and the pressing member122.

The driven gear123is configured to transmit a driving force received from the motor105ato the pressing member122, by being engaged with the driving gear105bof the driving unit105. Since the driven gear123is provided at the dust box160, the engaged state between the driving gear105band the driven gear123is released, if the dust box160is separated from the cyclone unit150for removal of dust. When the dust box160is re-coupled to the cyclone unit150, the driving unit105is connected to the pressing unit120. In order to facilitate accommodation of a tooth of one gear into two teeth of another gear, an upper end of teeth105b′ of the driving gear105bmay be inclined from a lower end of teeth of the driven gear123.

As shown inFIG. 12, the driving gear105bmay be provided with a supporting portion or plate105b″ configured to support the driven gear123when the teeth of the driven gear123are engaged with the teeth105b′ of the driving gear105b. The supporting portion105b″ protrudes more than the teeth105b′ of the driving gear105bin a side direction, so as to support the teeth of the driven gear123engaged with the teeth105b′ of the driving gear105b. The supporting portion105b″ may have a disc shape having the rotation shaft of the motor105aas a center.

Referring toFIGS. 11 and 13A, an accommodation portion or housing161b′ is configured to accommodate therein another part of the driven gear123such that only part of the driven gear123engaged with the driving gear105bis exposed to the outside, and may be formed at a lower side of the dust box160. In the drawings, the accommodation portion161b′ protrudes from a bottom surface of the dust box160, more specifically, a bottom surface of the second portion161b.

Based on such a structure, a part of the driven gear123is accommodated in the accommodation portion161b′, and introduction of foreign materials into the driven gear123and damage of the driven gear123may be prevented. Considering that the other part of the driven gear123is exposed to the outside when the dust box160is detached from the cleaner body101, such structure is more effective because the part of the driven gear123is accommodated in the accommodation portion161b′.

As illustrated inFIGS. 13A and 13B, the dust box160includes the dust box body161and the dust box cover162. The pressing member122is accommodated in the dust box body161, and is configured to move dust collected in the dust box160to one side of the dust box160by being rotated. The dust box cover162is coupled to the dust box body161, and is configured to open and close an opening of the dust box body161. The dust box cover162may be hinge-coupled to the dust box body161, and is configured to open and close the opening of the dust box body161by being rotated.

As shown inFIGS. 12 and 13, a groove122′ and a protrusion162aallow for more stable rotation of the pressing member122. The groove122′ recessed toward the rotation shaft121is formed at an upper end of the pressing member122. The groove122′ may be formed on the rotation shaft121if the rotation shaft extends to the top of the pressing member122. A protrusion162a, formed to be insertable into the groove122′ of the pressing member122, protrudes from an inner side of the dust box cover162. As shown inFIG. 13A, the opening of the dust box body161is exposed, the protrusion162ais separated from the groove122′ of the pressing member122.

On the other hand, as shown inFIG. 13B, if the dust box cover162is the opening of the dust box body161, the protrusion162ais inserted into the groove122′ of the pressing member122. The pressing member122is connected to each of the rotation shaft121and the protrusion162a, and rotates centering around the rotation shaft121and the protrusion162a. Based on such a structure, if the pressing member122is rotated as the rotation shaft121rotates, the protrusion162ainserted into the groove122′ serves to fix a rotation center of the pressing member122for more stable rotation.

Referring toFIG. 14, the pressing unit120is configured to be rotatable in two directions by receiving a driving force from the driving unit105. The pressing member122is rotated in the dust box160in two directions, thereby moving dust (D) introduced through the dust discharge opening150eto two sides. In the drawings, the dust (D) is collected at two sides of the dust box160as the pressing member122is rotated in two directions.

The rotation of the motor105amay be controlled such that bidirectional rotation of the pressing member122is repeatedly performed. For instance, if a repulsive force is applied to the motor105awhich is being rotated in an opposite direction to the rotation direction, the motor105amay be rotated in the opposite direction. If the pressing member122is rotated in one direction to press dust (D) collected at one side of the dust box160to some degree, the motor105ais rotated to another direction to compress dust (D) collected at another side of the dust box160.

If the amount of the dust (D) is very small, the motor105amay be rotated in an opposite direction, by receiving a repulsive force occurring when the pressing member122collides with one side wall of the dust box160, or a repulsive force occurring due to a stopper structure provided inside or outside the pressing member122. Alternatively, the controller may control bidirectional rotation of the pressing member122to be repeatedly performed, by applying a control signal to the motor105asuch that a rotation direction of the pressing member122is changed at predetermined time periods.

In the present disclosure, since the dust box is disposed between the suction unit and the cyclone unit, a compact design may be implemented. Further, effective air flow (having a flow change more than 90°) can be generated for separation of dust.

In the robot cleaner of the present disclosure, since a plurality of cyclones are provided in a single cyclone unit, dust can be efficiently separated from sucked air. For enhanced separation of dust, a plurality of guiding members are provided in correspondence to the plurality of cyclones. Air sucked through the suction unit is introduced into the cyclone unit in a divided manner, and the fan unit discharges air having passed through the plurality of cyclones to the outside. With such a structure, dust is separated from sucked air in a more efficient manner, and the dust-separated air is discharged to the outside. This can enhance cleaning performance of the robot cleaner.

Further, in the present disclosure, there are provided the suction guide for guiding sucked air to an inner circumferential surface of the cyclone unit, and the exhaustion guide extending from an inner circumferential surface of the fan cover toward the air outlet in a rounded manner. With such a structure, the robot cleaner can reduce noise occurring when air is sucked and discharged to the outside.

Further, since dust having a large particle size is firstly filtered by the cyclone unit, and then fine dust is filtered by the fine dust filter provided on at least one of the suction side and the exhaustion side of the fan unit. This can allow cleaner air to be discharged to the outside of the robot cleaner.

In the present disclosure, the cyclone unit having the plurality of cyclones is disposed on the rear upper side of the suction unit, and the plurality of connection members are formed with an inclination angle so as to connect the suction unit and the cyclone unit to each other. The fan unit is disposed on the rear lower side of the cyclone unit. With such a new structure and arrangement, the robot cleaner can have efficient spatial arrangement and enhanced cleaning performance.

Further, when at least part of the dust box is accommodated in a space between the plurality of connection members, the dust box may have a larger capacity within the restricted space.

Noise of the robot cleaner is mainly generated from driving of the motor and the fan. Considering this, the noise reducing member is disposed above the fan unit to prevent noise generated from the fan unit from being transmitted to the upper side. This can allow the robot cleaner to have low noise.

Further, in the present disclosure, the motor supporting member configured to elastically support the motor part, and the first and second fan supporting members configured to elastically support the first and second fan parts are provided. This can reduce vibrations and noise generated from the fan unit.

In the present disclosure, the pressing unit is configured to press dust separated through the cyclone unit and to reduce a volume of the dust, by being rotated in two directions. Thus, dust collected in the dust box can be prevented from scattering, and scattering of the dust can be reduced when the dust is discharged to the outside. This can provide a user's convenience.

Further, if the dust box cover is disposed to cover the opening of the dust box body, the protrusion inside the dust box cover is inserted into the groove of the pressing member. This can allow the pressing member to be rotated in a more stable manner.

Further, the dust box is disposed between the suction unit and the cyclone unit, and the driving unit is disposed between the first guiding member and the second guiding member. With such a new structure and arrangement, the robot cleaner can implement a more efficient spatial arrangement.

The disclosed robot cleaner may be capable of preventing scattering of dust accumulated in a dust box, and providing a user's convenience during a dust discharge process.

A robot cleaner may have a structure to enhance a dust collection function of a dust box, and an efficient spatial arrangement with other components.

A robot cleaner may include a suction unit configured to suck dust-included air; a cyclone unit configured to separate dust from the dust-included air sucked through the suction unit by using a centrifugal force, and having a dust discharge opening; a first guiding member and a second guiding member spaced apart from each other, and configured to connect the suction unit and the cyclone unit with each other; a dust box detachably mounted to the cyclone unit so as to be communicated with the dust discharge opening, and disposed on the first and second guiding members at least partially; a driving unit disposed between the first and second guiding members; and a pressing unit provided at the dust box, and mechanically connected to the driving unit when the dust box is mounted to the cyclone unit, and formed to be rotatable in two directions by receiving a driving force from the driving unit such that dust collected in the dust box is pressed to have a deceased volume.

In an embodiment of the present disclosure, the pressing unit may include a rotation shaft disposed to pass through a bottom surface of the dust box; a pressing member installed at the rotation shaft inserted into the dust box, and rotatable in the dust box; and a driven gear installed at the rotation shaft protruding from the dust box, and connected to the driving unit.

The driving unit may include a motor provided at a cleaner body; and a driving gear connected to a rotation shaft of the motor, and configured to transmit a driving force to the pressing unit by being engaged with the driven gear.

The driving gear and the driven gear may be engaged with each other when the dust box is mounted to the cyclone unit.

The driving gear may include a supporting portion configured to support the driven gear when teeth of the driven gear are engaged with teeth of the driving gear.

An accommodation portion, configured to accommodate therein another part of the driven gear such that only part of the driven gear engaged with the driving gear is exposed to the outside, may be formed at a lower side of the dust box.

The motor may be configured to be rotated in an opposite direction, if a repulsive force is applied to the motor being rotated, in the opposite direction to a rotation direction.

The dust box may include a dust box body which forms a space for collecting dust filtered by the cyclone unit, and configured to accommodate therein the pressing member; and a dust box cover coupled to the dust box body and configured to open and close an opening of the dust box body.

A groove recessed toward the rotation shaft may be formed at an upper end of the pressing member. A protrusion, configured to support rotation of the pressing member by being inserted into the groove, may protrude from an inner side of the dust box cover.

The dust box cover may be rotatably coupled to the dust box body, and the protrusion may be inserted into the groove when the dust box cover is disposed to cover the opening of the dust box body.

The dust box body may include a first portion communicated with the dust discharge opening; and a second portion formed to extend to a lower side of the first portion, having a smaller sectional area than the first portion, and accommodated between the first and second guiding members at least partially.

Two sides of the first portion may be disposed on the first and second guiding members.

The pressing member may include a first pressing portion disposed in the first portion so as to compress dust inside the first portion; and a second pressing portion downward-extending from the first pressing portion, and disposed in the second portion so as to compress dust inside the second portion. The second pressing portion may be formed to have a smaller area than the first pressing portion.

An upper side of the dust box may form upper appearance of the cleaner body.

The dust box may be formed of a transmissive material such that a user views an inner side of the dust box.

This application relates to U.S. application Ser. Nos. 14/952,760 filed on Nov. 25, 2015, and 14/956,205 filed on Dec. 1, 2015, which are hereby incorporated by reference in their entirety. Further, one of ordinary skill in the art will recognize that features disclosed in these above-noted applications may be combined in any combination with features disclosed herein.