SURFACE CLEANER

A surface cleaner includes a base including a suction inlet in fluid communication with a debris separator and a suction source. The base includes a housing having a channel extending around at least a portion of the suction inlet, the channel having a first sidewall offset from a second sidewall. The base further includes a soleplate configured to slide along the surface being cleaned, the soleplate including a suction inlet aperture that defines at least a portion of the suction inlet, the soleplate further including an inner rib, an outer rib, and a channel between the inner rib and the outer rib. The inner rib frictionally engages the first sidewall and the outer rib frictionally engages the second sidewall to create a seal between the soleplate and the housing.

BACKGROUND

The present disclosure relates to surface cleaners and more particularly to the connection between a soleplate of the surface cleaner and a base of the surface cleaner.

SUMMARY

In one embodiment a surface cleaner includes a suction source operable to generate a suction airflow configured to draw debris from a surface to be cleaned, a debris separator in fluid communication with the suction source, the debris separator operable to separate the debris from the suction airflow. The surface cleaner further includes a base including a suction inlet in fluid communication with the debris separator and the suction source such that a suction airflow path extends through the suction inlet, through the debris separator, and through the suction source to transport the suction airflow and the debris from the suction inlet and into the debris separator. The base includes a housing having a channel extending around at least a portion of the suction inlet, the channel having a first sidewall offset from a second sidewall. The base further includes a soleplate configured to slide along the surface being cleaned, the soleplate including a suction inlet aperture that defines at least a portion of the suction inlet, the soleplate further including an inner rib, an outer rib, and a channel between the inner rib and the outer rib. The inner rib frictionally engages the first sidewall and the outer rib frictionally engages the second sidewall to create a seal between the soleplate and the housing.

In another embodiment, a surface cleaner includes a fluid flow path extending from a suction inlet to a clean air outlet, a suction source operable to generate a suction airflow along the fluid flow path configured to draw debris from a surface to be cleaned into the suction inlet, and a debris separator positioned in the fluid flow path operable to separate the debris from the suction airflow. The surface cleaner further includes a nozzle assembly including a housing and a soleplate forming the suction inlet. The nozzle assembly has a joint between the housing and the soleplate, the joint extending around at least a portion of the suction inlet. The joint is formed by a channel in one of the housing and the soleplate extending around at least a portion of the suction inlet, the channel having a first sidewall offset from a second sidewall. The joint is also formed by an inner rib and an outer rib in the other of the housing and the soleplate extending around at least a portion of the suction inlet corresponding to the channel. The inner rib frictionally engages the first sidewall or the outer rib frictionally engages the second sidewall to create a seal between the soleplate and the housing.

DETAILED DESCRIPTION

FIGS.1and2illustrate a surface cleaner10. The surface cleaner10includes a suction source12and a debris separator14. The suction source12includes a motor and a fan and the suction source12is operable to generate a suction airflow to draw debris from a surface16being cleaned (e.g., floor, upholstery, etc.) and into the debris separator14. The debris separator14separates the debris from the suction airflow and retains the debris in the debris separator14. In one embodiment, the debris separator14includes a cyclonic separator. In some embodiments, the debris separator includes a filter, a filter bag, and/or any other suitable types of debris separators for a surface cleaner. Also, in the illustrated embodiment, the suction source12is downstream from the debris separator14. In other embodiments, the suction source12may be upstream or before the debris separator14along the suction airflow path.

The surface cleaner10includes a handle18and a base or nozzle assembly20. In the illustrated embodiment, the handle18is pivotally coupled to the base20and the handle18is operable to move the base20along the surface16. The debris separator14is coupled to the handle18for pivotal movement with the handle18. The handle18is pivotal relative to the base20between an upright storage position (FIG.1) and an inclined operating position. In the illustrated embodiment, the surface cleaner10is illustrated as a vacuum cleaner, specifically, an upright style vacuum cleaner. In other embodiments, the surface cleaner may be other types of surface cleaners, including utility vacuums, canister vacuums, wet floor cleaners, carpet extractors, robotic vacuum cleaners, and the like.

The base20includes a housing22and a suction inlet24. The suction inlet24is in fluid communication with the debris separator14and the suction source12. A fluid flow path extends through the suction inlet24, through the debris separator14, and through the suction source12to transport the suction airflow and the debris from the suction inlet24and into the debris separator14. The fluid flow path further extends through a clean air outlet25.

The illustrated base20further includes a brushroll26. The brushroll26is rotatable relative to the housing22about a brushroll axis28(FIG.6). The brushroll26includes bristles30that extend through the suction inlet24to contact the surface16. The illustrated surface cleaner10includes a belt32(FIG.3) that is operable to rotate the brushroll26about the brushroll axis28. The belt32is driven by a motor, which may include the motor of the suction source12in some embodiments. The housing22extends around a portion of the brushroll axis28to define a brushroll housing34. In some embodiments, the nozzle assembly includes a suction inlet without a brushroll or other rotatable agitator.

The base20further includes a soleplate36adjacent the suction inlet24and the soleplate36slides along or is directly above the surface16being cleaned. Referring toFIGS.3and4, the soleplate36includes a suction inlet aperture38that defines at least a portion of the suction inlet24. The soleplate36includes a front edge40and a back edge42spaced rearward of the front edge40. The soleplate36further includes a first side edge44that extends from the front edge40to the back edge42and a second side edge46that extends from the front edge40to the back edge42. In the illustrated embodiment, the front edge40is parallel to the back edge42and the first and second side edges44,46are perpendicular to the front and back edges40,42. In the illustrated embodiment, the suction inlet aperture38is bound by the front edge40, the back edge42, the first side edge44, and the second side edge46such that the soleplate36extends all the way around the perimeter of the suction inlet24and the suction inlet aperture38of the soleplate36defines the suction inlet24.

The soleplate36may include a brush48(FIG.6) or a wiper or squeegee (not shown) to direct the debris toward the suction inlet24as the base20moves along the surface16. Also, the soleplate36may include ribs50that are disposed below the brushroll26and extend across the suction inlet aperture38to inhibit ingestion of the power cord or other large objects.

Referring toFIGS.4,5, and10, the soleplate36further includes an inner rib52and an outer rib54, offset from the inner rib52, that facilitates coupling the soleplate36to the housing22and to create a seal between the housing22and the soleplate36. In one embodiment, the inner rib52is generally concentric with the outer rib54. The seal inhibits the suction airflow from traveling through the interface between the soleplate36and the housing22and bypassing the suction inlet24. The inner rib52is adjacent the suction inlet aperture38of the soleplate36and extends parallel to the outer rib54. Longitudinal portions of the inner and outer ribs52,54extend along the brushroll axis28, parallel to the brushroll axis28in the illustrated embodiment. The inner and outer ribs52,54extend upwardly in a direction away from the surface16. The inner rib52and the outer rib54extend along the length of the front and back edges40,42that define the suction inlet aperture38. In the illustrated embodiment, the inner rib52and the outer rib54extend along the entire length of the front edge40and the back edge42. In other embodiments, the inner and outer ribs52,54, may extend only along a portion of the length of the front and back edges40,42. The inner rib52and the outer rib54extend along at least a portion of the first side edge44and the second side edge46that define the suction inlet aperture38. In one embodiment, the inner rib52and the outer rib54extend around a majority of the perimeter of the suction inlet aperture38of the soleplate36.

Referring toFIG.10, a channel56is between the inner rib52and the outer rib54. The channel56or space between the inner rib52and the outer rib54allows the inner and outer ribs52,54to flex and move slightly into the channel56in the direction of arrows58inFIG.10. This results in a force in the direction of arrows60inFIG.10that facilitates coupling the soleplate36to the housing22and creating the seal between the soleplate36and the housing22. The housing22includes a channel62that opens downward toward the surface16. As shown inFIG.9, the channel62extends around the perimeter of the suction inlet24at corresponding or adjacent locations to the inner and outer ribs52,54of the soleplate36(FIG.4). For example, the longitudinal length of the ribs52,54corresponds to the length of the channel62but the length of the channel62and the length of the ribs52,54are not necessarily the same length. Longitudinal portions of the channel62extend along the brushroll axis28, parallel to the brushroll axis28in the illustrated embodiment.

Referring toFIG.10, the channel62has an open end64and an inside end66. The channel62also includes a first sidewall67and a second sidewall69. The channel62has a first width68, measured between the first sidewall67and the second sidewall69, adjacent the open end64and a second width70, measured between the first sidewall67and the second sidewall69, adjacent the inside end66. The second width70is less than the first width68and a transition or taper72is located between the first width68and the second width70. The inner and outer ribs52,54have a first end74and a second end76. A first rib width78is defined at the first end74and a second rib width80is defined at the second end76. The rib widths78,80are the sum of the thicknesses of the ribs52,54and the width of the channel56. The second rib width80is greater than the first rib width78. A rib height is defined as the distance between the first end74and the second end76. The ribs52,54may have different ribs heights. A channel depth is defined as the distance from the open end64of the channel62to the inner end66of the channel62. In one embodiment, the height of the ribs52,54is less than the depths of the channel62. Also, in one embodiment, the amount of flex of the ribs52,54, discussed above, at the first end74of the ribs52,54is in a range between 0.1% and 2% of the height of the ribs or depth of the channel62. In other embodiments, the amount of flex of the ribs52,54at the first end74of the ribs52,54is in a range between 0.2% and 1.5% of the height of the ribs or depth of the channel62. In yet other embodiments, the amount of flex of the ribs52,54at the first end74of the ribs52,54is in a range between 0.3% and 1% of the height of the ribs or depth of the channel62. In yet other embodiments, the amount of flex of the ribs52,54could be in other ranges depending on the application.

Referring toFIGS.8and10, a joint81is formed between the housing22and the soleplate36, which extends around a majority of a perimeter of the suction inlet24. In one embodiment, the joint81extends around at least 50% of the perimeter of the suction inlet24. In other embodiments, the joint81extends around at least 75% of the perimeter of the suction inlet24. In yet other embodiments, the joint81extends around 90% to 100% of the perimeter of the suction inlet24. A longitudinal portion of the joint81extends along the brushroll axis26. In the illustrated embodiment, the joint81is formed by the inner rib52and the outer rib54being received in the channel62of the housing22to couple the soleplate36to the housing22and to create a seal between the soleplate36and the housing22. It should be understood that the term seal as used herein is not necessarily a perfect air-tight seal but rather that the seal inhibits air from entering the suction airflow through the joint81instead of through the suction inlet24. The inner rib52frictionally engages the first sidewall67and the outer rib54frictionally engages the second sidewall69to create a seal between the soleplate36and the housing22. In the illustrated embodiment, there are no gaskets (e.g., rubber gasket) between soleplate36and the housing22. The soleplate36directly contacts the housing22to create the seal. The width70at the inside end66of the channel62is less than the first rib width78to facilitate assembly of the soleplate36with the housing22. During assembly, the inner rib52and the outer rib54flex into the channel56of the soleplate36when the inner rib52and the outer rib54are received in the channel62of the housing22. This flexing forms an interference fit that couples the soleplate36to the housing22and creates a seal between the soleplate36and the housing22around the suction inlet24. Also, the inner rib52and the outer rib54directly contact the housing22inside the channel62of the housing22to create a friction fit between the soleplate36and the housing22to couple the soleplate36to the housing22. In one embodiment, the soleplate36and the housing22are formed from different materials. Referring toFIG.3, in the illustrated embodiment, threaded fastener82are utilized to also secure and couple the soleplate36to the housing22of the base20. In the illustrated embodiment, fewer threaded fasteners82are employed than was required for certain prior art compression seals because the seal in the joint81is formed along the sidewalls67,69with lower reactionary forces in the vertical direction than a compression seal would generate. Also, while the illustrated embodiment has been described with the ribs52,54flexing, in other embodiments, one or both of the sidewalls67,69of the channel62may flex to form the interference fit, and/or a combination of one or more ribs52,54flexing with one or more sidewalls67,69flexing. Also, while in the illustrated embodiment, both ribs52,54are described as flexing, in other embodiments, only one of the ribs52,54may flex and/or the ribs52,54may flex at different rates or have different stiffnesses, as well as the sidewalls67,69may flex at different rates or have different stiffnesses.

Referring toFIGS.11and12, the base20includes a belt housing portion84through which the belt32extends. The belt32drives the brushroll26. The belt housing portion84includes a cover86that is removable to allow a user to access the belt32to replace the belt32. In the illustrated embodiment, the soleplate36forms portions of the belt housing portion84along with portions of the housing22of the base20. In other embodiments, the soleplate36may not form a portion of the belt housing portion84yet the belt housing portion still includes the joint81. The joint81extends around at least a portion of the belt housing portion84. For example, the inner rib52and the outer rib54extend around portions of the belt housing portion84and are received in channels and described above to create the coupling, seal structure, and friction fit discussed above.

In the illustrated embodiment ofFIGS.1-12, the joint81has been illustrated with the soleplate36including the inner rib52and the outer rib54and the housing22of the base20including the channel62in which the ribs52,54are received. In other embodiments, the housing22of the base20may include the inner rib52and the outer rib54and the soleplate36includes the channel62in which the ribs52,54are received.

Also,FIG.13illustrates an alternative embodiment of the joint81described above. The joint81ofFIG.13includes features similar to the joint81ofFIGS.1-12and only some differences will be discussed below and like components have been given the same reference number. In the embodiment ofFIG.13, there is an opening90adjacent the second ends76of the ribs52,54. And, there is a wall92that extends between the first ends74of the ribs52,54. When the ribs52,54are received in the channel62, the sidewalls67,69flex and/or the ribs52,54flex adjacent the opening90to facilitate the friction fit and seal between the ribs52,54and the sidewalls67,69of the channel62.

Certain interference seals in the prior art, such as U.S. Pat. Nos. 6,101,669 and 8,695,161, are configured to press one rib into one corresponding channel. The prior art interference seals created manufacturing challenges for product designs that desired such a seal between large parts, or to surround a large area. Variations in shrinkage between parts during plastic molding could cause misalignments of the single rib and the corresponding channel, resulting in difficulty in assembly, improper part fit, and possibly reduced effectiveness in sealing. The need to match the single rib to its corresponding channel required more attention to molding processes and inspection, and could cause higher scrap rates of improperly fitting parts or require use of higher priced plastics with lower, more predictable shrink rates. The presently disclosed joint81accommodates more variation in shrinkage between parts, larger tolerances in part sizing, and accommodates misalignments by providing the channel56between the ribs52,54to enable the ribs to flex in the channel62during assembly while maintaining a seal along at least one of the sidewalls67,69. The presently disclosed joint81enables lower priced resins with higher shrink rates to be molded, for example, polyolefins, while maintaining assembly of the joint81at a lower cost.