Patent Description:
Multi-surface floor cleaners are adapted for cleaning hard floor surfaces such as tile and hardwood and soft floor surfaces such as carpet and upholstery. Some multi-surface floor cleaners comprise a fluid delivery system that delivers cleaning fluid to a surface to be cleaned and a fluid recovery system that extracts spent cleaning fluid and debris (which may include dirt, dust, stains, soil, hair, and other debris) from the surface. The fluid delivery system typically includes one or more fluid supply tanks for storing a supply of cleaning fluid, a fluid distributor for applying the cleaning fluid to the surface to be cleaned, and a fluid supply conduit for delivering the cleaning fluid from the fluid supply tank to the fluid distributor. An agitator can be provided for agitating the cleaning fluid on the surface. The fluid recovery system typically includes a recovery tank, a nozzle adjacent the surface to be cleaned and in fluid communication with the recovery tank through a working air conduit, and a source of suction in fluid communication with the working air conduit to draw the cleaning fluid from the surface to be cleaned and through the nozzle and the working air conduit to the recovery tank. Other floor cleaners include "dry" vacuum cleaners which can clean different surface types, but do not dispense or recover liquid. Yet another floor cleaners include "wet" cleaners such as steam and hard floor cleaners that dispense cleaning fluid but may or may not apply suction to remove liquid and debris from the surface.

Certain components of floor cleaners, such as brushrolls and filters, may become dirty or wear out over time. To that end, it is helpful to design certain components as removable accessories for cleaning and/or replacement. However, a user may forget to reinstall the components or may reinstall them incorrectly, either of which will negatively impacting cleaning performance and can damage the floor cleaner. A user may also replace these components with low quality replacement versions that do not meet the requirements of the floor cleaner, again leading to poor cleaning performance or damage to the floor cleaner.

<CIT> provides an example of a cleaner with a replaceable filter but without any mechanism to detect correct insertion.

According to the invention there is provided, a filter assembly for a floor cleaner is provided and includes a filter having an intake side and an exhaust side, a filter housing including a frame having an open area through which air may pass, with the filter supported within the frame, a mesh screen on the intake side of the filter, the mesh screen having a pore size configured to filter a larger particle size than the filter, a door pivotally coupled with the filter housing, the door having an open grid and the mesh screen covering the open grid, a seal on the filter housing extending around the exhaust side of the filter, a handle projecting from the filter housing, and a permanent magnet disposed on the handle. The magnet is configured to be detected by a sensing component, such as a Hall Effect sensor, when the filter assembly is correctly installed on a floor cleaner.

The seal may comprise a perimeter seal portion surrounding the exhaust side of the filter and the permanent magnet may be disposed outward of the perimeter seal portion, such that the permanent magnet is configured to be disposed outside an air flow path of a floor cleaner.

According to an aspect not forming part of the invention, a method for controlling the operation of a floor cleaner comprises allowing operation of an electrically-powered component of the floor cleaner when a permanent magnet on an accessory component is detected by a sensing component and preventing operation of the electrically-powered component of the floor cleaner when a permanent magnet on an accessory component is not detected by the sensing component, wherein the permanent magnet on the accessory component is within the effective sensing zone of a sensing component when correctly installed on the floor cleaner, whereby the electrically-powered component the electrically-powered component is prevented from operating when the accessory component is missing from the floor cleaner, incorrectly mounted on the floor cleaner, or an accessory component that does not comprise a permanent magnet is installed on the floor cleaner.

The features and advantages of the present invention will become apparent from the following description of particular embodiments, when viewed in accordance with the accompanying drawings and appended claims.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as "at least one of X, Y and Z" is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

The invention generally relates to filter assemblies for floor cleaners for cleaning floor surfaces such as carpets, area rugs, wood, tile, and the like, and systems for detecting whether accessory components of the floor cleaner are present and properly installed.

<FIG> is a schematic view of a floor cleaner <NUM>. As discussed in further detail below, the floor cleaner <NUM> is provided with various features and improvements, including a replaceable brushroll <NUM> and a brushroll detection mechanism <NUM>, and a replaceable filter assembly <NUM> and a filter detection mechanism <NUM>.

The brushroll detection mechanism <NUM> can include a detectable component, such as a permanent magnet <NUM>, disposed on and carried by the brushroll <NUM> and a sensing component, such as a Hall Effect sensor <NUM> or a reed switch, disposed on the floor cleaner <NUM> in a position to sense the detectable component when the brushroll <NUM> is correctly installed in a brush chamber on the floor cleaner <NUM> that receives the brushroll <NUM>. The detectable component can be provided on a stationary or non-rotatable portion of the brushroll <NUM>.

The detectable component is configured to be detected by the sensing component within an effective sensing zone of the sensing component. Direct physical contact between the detectable component and sensing component is not required, as the effective sensing zone can detect the detectable component within a predetermined distance away from the sensing component. The predetermined distance can be a distance within which the detectable component is spaced from the sensing component when the brushroll <NUM> is correctly mounted in the brush chamber.

The brushroll detection mechanism <NUM> is configured to allow operation of an electrically-powered component of the floor cleaner <NUM> when the detectable component is detected by the sensing component and to prevent operation of the electrically-powered component when the detectable component is not detected by the sensing component. If the brushroll <NUM> is missing from the brush chamber, incorrectly mounted, or a brushroll that does not comprise a detectable component is mounted instead, the electrically-powered component is prevented from operating.

The brushroll detection mechanism <NUM> can include or be operably coupled with a switch configured to close and supply power to the electrically-powered component of the floor cleaner <NUM> when an authorized brushroll <NUM> is correctly mounted in the brush chamber. If the brushroll <NUM> is missing from the brush chamber, incorrectly mounted, or a brushroll lacking a detectable component is mounted instead, the switch is configured to open, so that no power is supplied to the component of the floor cleaner <NUM>.

The component controlled via the brushroll detection mechanism <NUM> may be a vacuum motor <NUM>, a brushroll motor <NUM>, or a pump <NUM>, or any combination thereof. Other components that may be powered depending upon whether the brushroll <NUM> is detected include a user interface <NUM>, a heater <NUM>, a controller <NUM>, a headlight <NUM>, and a speaker <NUM>.

If the sensing component is a Hall Effect sensor, the Hall sensor may be arranged to act as the switch configured to close and supply power to a component of the floor cleaner <NUM> when the brushroll <NUM> is correctly installed in the brush chamber. When a magnetic field experienced by the Hall Effect sensor exceeds a pre-determined value, the Hall Effect sensor can change state. The Hall Effect sensor will again change state if a magnetic field experienced by the Hall Effect sensor falls below the pre-determined value.

The floor cleaner <NUM> can include a controller <NUM> operably coupled with the various functional systems of the apparatus, including, but not limited to, the fluid delivery and recovery systems, for controlling its operation. The controller <NUM> can comprise a microcontroller unit (MCU) that contains at least one central processing unit (CPU). A user of the floor cleaner <NUM> can interact with the controller <NUM> via the user interface <NUM>.

The controller <NUM> detects the state of the switch, e.g. the state of the Hall Effect sensor <NUM>. The controller <NUM> is arranged selectively to allow or prevent the supply of power to the component depending upon the state of the switch. This in turn is dependent upon the distance between the Hall Effect sensor <NUM> and the permanent magnet <NUM>.

When a power button <NUM> is pressed, or another input control actuated, in an attempt to turn the floor cleaner <NUM> on, and the permanent magnet <NUM> is not detected by the Hall Effect sensor <NUM>, the Hall Effect sensor <NUM> can send a signal to the controller <NUM> to cause the floor cleaner <NUM> to provide a status update to the user. For example, the floor cleaner <NUM> can deliver a visual and/or audio warning message to the user. The warning message can indicate to the user that the brushroll <NUM> is missing from the brush chamber, incorrectly mounted, or a brushroll lacking a detectable component is mounted instead. The warning message may indicate to the user that the brushroll <NUM> must be correctly mounted before operating the floor cleaner <NUM>. The visual and/or audio warning can be issued for a predetermined period, such as for <NUM>-<NUM> seconds, and then cease. The warning may be repeated if the user again attempts to turn on the floor cleaner <NUM> when the permanent magnet <NUM> is still not detected by the Hall Effect sensor <NUM>.

To issue the warning message, power may be supplied to limited components of the floor cleaner <NUM>, such as to only those components required to issue the warning message. For example, the controller <NUM>, user interface <NUM>, speaker <NUM>, or a brushroll indicator light <NUM> may be powered temporarily to issue the warning message, and then automatically powered off.

In one embodiment, when the power button <NUM> is pressed and the permanent magnet <NUM> is not detected by the Hall Effect sensor <NUM>, the brushroll indicator light <NUM> flashes or is otherwise illuminated, and an audio warning sound is issued from the speaker <NUM>. The indicator light <NUM> may be an LED positioned near the brush chamber for the brushroll <NUM> so that a user's attention is drawn to the brush chamber. For example, for the embodiment shown in <FIG>, the brushroll indicator light <NUM> can be located on the base <NUM>.

In another embodiment, the switch can be separate from but operably coupled with the sensing component. It is further noted that in embodiments where power to multiple components is controlled based on whether the brushroll <NUM> is correctly installed in the brush chamber, multiple switches and/or controllers may be provided.

The filter detection mechanism <NUM> includes a detectable component, in the form of a permanent magnet <NUM>, disposed on and carried by the filter assembly <NUM> and a sensing component, such as a Hall Effect sensor <NUM> or a reed switch, disposed on the floor cleaner <NUM> in a position to sense the detectable component when the filter assembly <NUM> is correctly installed in the floor cleaner <NUM>, with a filter of the filter assembly <NUM> located in a recovery pathway of the floor cleaner <NUM>.

The recovery pathway can include at least a dirty inlet and a clean air outlet. The pathway can be formed by, among other elements, a suction source that includes the vacuum motor <NUM> and that is in fluid communication with the dirty inlet and a recovery tank or other collection container. The filter assembly <NUM> can be mountable at various locations on the floor cleaner <NUM> such that the filter is located in the recovery pathway, including anywhere in between the dirty inlet and the clean air outlet. For example, the filter assembly <NUM> can comprise a pre-motor filter installable in the recovery pathway upstream of the suction source that includes the vacuum motor <NUM>. The filter assembly <NUM> can be a post-motor filter installable in the recovery pathway downstream of the suction source that includes the vacuum motor <NUM>.

With the filter of the filter assembly <NUM> being located in the recovery pathway, working air passes through the filter. The detectable component on the filter assembly <NUM> can be provided outside the recovery pathway. By providing the detectable component outside the recovery pathway, the detectable component is not exposed to debris in the working air, is less likely to become dirty or damaged. Further features for protecting the detectable component and sensing component are described in further detail below.

The detectable component is configured to be detected by the sensing component within an effective sensing zone of the sensing component. Direct physical contact between the detectable component and sensing component is not required, as the effective sensing zone can detect the detectable component within a predetermined distance away from the sensing component. The predetermined distance can be distance within which the detectable component is spaced from the sensing component when the filter assembly <NUM> is correctly installed on the floor cleaner <NUM>.

The filter detection mechanism <NUM> is configured to allow operation of an electrically-powered component of the floor cleaner <NUM> when the detectable component is detected by the sensing component and to prevent operation of the electrically-powered component when the detectable component is not detected by the sensing component. If the filter assembly <NUM> is missing, incorrectly mounted, or a filter assembly that does not comprise a detectable component is mounted instead, the electrically-powered component is prevented from operating.

The filter detection mechanism <NUM> can include or be operably coupled with a switch configured to close and supply power to a component of the floor cleaner <NUM> when the filter assembly <NUM> is correctly mounted in the recovery pathway. If the filter assembly <NUM> is missing from the recovery pathway, incorrectly mounted, or a filter assembly lacking a detectable component is mounted instead, the switch is configured to open, so that no power is supplied to the component of the floor cleaner <NUM>.

The component controlled via the filter detection mechanism <NUM> may be the vacuum motor <NUM>, the brushroll motor <NUM>, or the pump <NUM>, or any combination thereof. Other components that may be powered depending upon whether the filter assembly <NUM> is detected include the user interface <NUM>, heater <NUM>, controller <NUM>, headlight <NUM>, and speaker <NUM>.

When the sensing component is a Hall Effect sensor, the Hall sensor may be arranged to act as the switch configured to close and supply power to a component of the floor cleaner <NUM> when the filter assembly <NUM> is correctly mounted in the recovery pathway. When a magnetic field experienced by the Hall Effect sensor exceeds a pre-determined value, the Hall Effect sensor can change state. The Hall Effect sensor will again change state if a magnetic field experienced by the Hall Effect sensor falls below the pre-determined value.

When a power button <NUM> is pressed, or another input control actuated, in an attempt to turn the floor cleaner <NUM> on, and the permanent magnet <NUM> is not detected by the Hall Effect sensor <NUM>, the Hall Effect sensor <NUM> can send a signal to the controller <NUM> to cause the floor cleaner <NUM> to provide a status update to the user. For example, the floor cleaner <NUM> can deliver a visual and/or audio warning message to the user. The warning message can indicate to the user that the filter assembly <NUM> is missing from the recovery pathway, incorrectly mounted, or a filter assembly lacking a detectable component is mounted instead. The warning message may indicate to the user that the filter assembly <NUM> must be correctly installed before operating the floor cleaner <NUM>. The visual and/or audio warning can be issued for a predetermined period, such as for <NUM>-<NUM> seconds, and then cease. The warning may be repeated if the user again attempts to turn on the floor cleaner <NUM> when the permanent magnet <NUM> is still not detected by the Hall Effect sensor <NUM>.

To issue the warning message, power may be supplied to limited components of the floor cleaner <NUM>, such as to only those components required to issue the warning message. For example, the controller <NUM>, user interface <NUM>, speaker <NUM>, or a filter indicator light <NUM> may be powered temporarily to issue the warning message, and then automatically powered off.

In one scenario, when the power button <NUM> is pressed and the permanent magnet <NUM> is not detected by the Hall Effect sensor <NUM>, the filter indicator light <NUM> flashes or is otherwise illuminated, and an audio warning sound is issued from the speaker <NUM>. The indicator light <NUM> may be an LED positioned near the brush chamber for the filter assembly <NUM> so that a user's attention is drawn to the filter receiver. For example, for the embodiment shown in <FIG>, the filter indicator light <NUM> can be located on the carry handle <NUM>.

In another scenario, the switch can be separate from but operably coupled with the sensing component. It is further noted that in situations where power to multiple components is controlled based on whether the filter assembly <NUM> is correctly mounted in the recovery pathway, multiple switches and/or controllers may be provided.

It is noted that the brushroll detection mechanism <NUM> and the filter detection mechanism <NUM> may be used together or separately, and may be combined in any order or combination. For example, a floor cleaner could comprise the filter detection mechanism <NUM> and not the brushroll detection mechanism <NUM>. While the brushroll detection and the filter detection may be applied separately, the systems and methods discussed herein are not mutually exclusive. For example, by supplementing brushroll detection with filter detection, an authorized brushroll and an authorized filter must both be correctly mounted in their respective compartments or the floor cleaner <NUM> will not operate.

While the floor cleaner <NUM> of <FIG> is shown as including the vacuum motor <NUM>, the brushroll motor <NUM>, the pump <NUM>, the user interface <NUM>, the heater <NUM>, the headlight <NUM>, the speaker <NUM>, the brushroll indicator light <NUM>, and the filter indicator light <NUM>, it is understood that the different components may be used in combination with each other as desired, or may be used separately. That one floor cleaner is illustrated herein as having all of these components does not mean that all of these features must be used in combination, but rather done so here for brevity of description.

The functional systems of the floor cleaner <NUM> can be arranged into any desired configuration, such as an upright device having a base and an upright body for directing the base across the surface to be cleaned, a canister device having a cleaning implement connected to a wheeled base by a vacuum hose, a portable device adapted to be hand carried by a user for cleaning relatively small areas, or a commercial device. Any of the aforementioned cleaners can be adapted to include a flexible vacuum hose, which can form a portion of the working air conduit between a nozzle and the suction source.

<FIG> show an version of the floor cleaner <NUM> in the form of an upright multi-surface wet/dry vacuum cleaner having a housing that includes an upright handle assembly or body <NUM> and a cleaning foot or base <NUM> mounted to or coupled with the upright body <NUM> and adapted for movement across a surface to be cleaned. As used herein, the term "multi-surface wet vacuum cleaner" includes a vacuum cleaner that can be used to clean hard floor surfaces such as tile and hardwood and soft floor surfaces such as carpets and area rugs. The replaceable brushroll <NUM> is disposed on and removable from the base <NUM>. The replaceable filter assembly <NUM> is disposed on and removable from the upright body <NUM>, but in other embodiments may be removable from other portions of the floor cleaner <NUM>.

For purposes of description related to the figures showing the upright multi-surface wet/dry vacuum cleaner, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," "inner," "outer," and derivatives thereof shall relate to the cleaner as oriented in <FIG> from the perspective of a user behind the floor cleaner <NUM>, which defines the rear of the floor cleaner <NUM>. However, it is to be understood that the item may assume various alternative orientations, except where expressly specified to the contrary.

The upright body <NUM> can comprise a handle <NUM> and a frame <NUM>. The frame <NUM> can comprise a main support section at least partially supporting a supply tank <NUM> and a recovery tank <NUM>, and may further support additional components of the upright body <NUM>. The floor cleaner <NUM> can include a fluid delivery or supply pathway, including and at least partially defined by the supply tank <NUM>, for storing cleaning fluid, e.g. cleaning liquid, and delivering the cleaning fluid to the surface to be cleaned and a recovery pathway, including and at least partially defined by the recovery tank <NUM>, for removing liquid and debris from the surface to be cleaned and storing the liquid and debris until emptied by the user.

The handle <NUM> can include a hand grip <NUM> and a trigger <NUM> mounted to the hand grip <NUM>, which controls fluid delivery from the supply tank <NUM> via an electronic or mechanical coupling with the supply tank <NUM>. Other actuators, such as a thumb switch instead of the trigger <NUM>, can be provided for controlling fluid delivery. A carry handle <NUM> can be disposed on a front side of the frame <NUM>, below the stick handle <NUM>, and can facilitate manual lifting and carrying of the floor cleaner <NUM>.

A moveable joint assembly <NUM> can be formed at a lower end of the frame <NUM> and moveably mounts the base <NUM> to the upright body <NUM>. The upright body <NUM> can pivot up and down about at least one axis relative to the base <NUM>. The joint assembly <NUM> can alternatively comprise a universal joint, such that the upright body <NUM> can pivot about at least two axes relative to the base <NUM>. Wiring and/or conduits can optionally supply electricity, air and/or liquid (or other fluids) between the base <NUM> and the upright body <NUM>, or vice versa, and can extend though the joint assembly <NUM>. The upright body <NUM> can pivot, via the joint assembly <NUM>, to an upright or storage position, an example of which is shown in <FIG>, and a reclined or use position (not shown), in which the upright body <NUM> is pivoted rearwardly relative to the base <NUM> to form an acute angle with the surface to be cleaned. In this position, a user can partially support the apparatus by holding the hand grip <NUM>.

The floor cleaner <NUM> can include one or more user interfaces (UI) through which a user can interact with the floor cleaner <NUM>. The UI can enable operation and control of the floor cleaner <NUM> from the user's end, and can provide feedback information from the floor cleaner <NUM> to the user. The UI can be electrically coupled with electrical components, including, but not limited to, circuitry electrically connected to various components of the fluid delivery and recovery systems of the floor cleaner <NUM>, as described in further detail below. The UI includes one or more input controls, such as but not limited to buttons, triggers, toggles, keys, switches, or the like, operably connected to systems in the floor cleaner <NUM> to affect and control its operation.

In the illustrated embodiment, the floor cleaner <NUM> includes a first input control on the carry handle <NUM> and a second input control <NUM> on the hand grip <NUM>. In one embodiment, first input control is a power button <NUM> that controls the supply of power to one or more electrical components of the floor cleaner <NUM>, in conjunction with the brushroll detection mechanism and/or filter detection mechanism as described herein. The other input control <NUM> includes a cleaning mode button that cycles the floor cleaner <NUM> between different cleaning modes. Some examples of cleaning modes include a hard floor cleaning mode and an area rug or carpet cleaning mode. In one example, in each cleaning mode the vacuum motor <NUM>, the pump <NUM>, and the brushroll motor <NUM> are activated, with the vacuum motor <NUM> operating at a lower power level and the pump <NUM> operating at a lower flow rate in the hard floor mode. Those rates increase in the area rug cleaning mode. Other cleaning modes are possible.

Electrically-powered components of the floor cleaner <NUM> can be powered by a power cord <NUM> plugged into a household power supply. Alternatively, the floor cleaner <NUM> can be powered by a battery, preferably a rechargeable battery, for cordless operation.

The fluid delivery system is configured to deliver cleaning fluid from the supply tank <NUM> to a surface to be cleaned, and can include, as briefly discussed above, a fluid delivery or supply pathway. The supply tank <NUM> includes a supply chamber for holding cleaning fluid. The cleaning fluid can comprise one or more of any suitable cleaning liquids, including, but not limited to, water, compositions, concentrated detergent, diluted detergent, etc., and mixtures thereof. For example, the liquid can comprise a mixture of water and concentrated detergent. Alternatively, supply tank <NUM> can include multiple supply chambers, such as one chamber containing water and another chamber containing a cleaning agent. As yet another alternative, the floor cleaner <NUM> can comprise multiple supply tanks. It is noted that while the floor cleaner <NUM> described herein is configured to deliver a cleaning liquid, the invention may be applicable to floor cleaner that deliver steam. Thus, the term "cleaning fluid" may encompass both liquid and steam unless otherwise noted.

The recovery system is configured to remove liquid and debris from the surface to be cleaned and store the liquid and debris on the floor cleaner <NUM> for later disposal, and can include, as briefly discussed above, a recovery pathway <NUM>. The recovery pathway <NUM> can include at least a dirty inlet and a clean air outlet. The pathway can be formed by, among other elements, a suction nozzle <NUM> defining the dirty inlet, a suction source <NUM> in fluid communication with the suction nozzle <NUM> for generating a working air stream, the recovery tank <NUM>, and at least one exhaust vent <NUM> defining the clean air outlet.

The recovery tank <NUM> is a working air treatment assembly, and removes liquid and debris from the working airstream and collects the liquid and debris for later disposal. A portion of the recovery tank <NUM> can define a portion of the recovery pathway <NUM>. It is understood that other types of working air treatment assemblies for removing and collecting debris and/or liquid from the working airstream for later disposal can be used, such as a cyclonic separator, a centrifugal separator, a bulk separator, a filter bag, or a water-bath separator. The type of working air treatment assembly may depend on the type of floor cleaner, whether the apparatus performs dry cleaning, wet cleaning, or both, and so on.

In the illustrated cleaner, the suction source <NUM> and recovery tank <NUM> are provided on the upright body <NUM>, although other locations are possible. At least a portion of the recovery pathway <NUM> between the suction nozzle <NUM> and the recovery tank <NUM> can be formed by a conduit <NUM> extending through the joint assembly <NUM>, from the base <NUM> to the upright body <NUM>. Thus it is noted that, for the illustrated cleaner, the recovery pathway <NUM> is defined by portions of the suction nozzle <NUM>, conduit <NUM>, recovery tank <NUM>, and suction source <NUM>, with the brushroll <NUM> being disposed in the recovery pathway <NUM> at the suction nozzle <NUM> and a filter of the filter assembly <NUM> being disposed in the recovery pathway <NUM> downstream of the recovery tank <NUM>. Other arrangements for the recovery pathway <NUM>, the brushroll <NUM>, and the filter assembly <NUM> are possible, as described in further detail below.

The suction nozzle <NUM> can be provided on the base <NUM> can be adapted to be adjacent the surface to be cleaned as the base <NUM> moves across a surface, and is in fluid communication with the recovery tank <NUM>, for example through conduit <NUM>. The replaceable brushroll <NUM> can be disposed in suction nozzle <NUM>, and therefore in the recovery pathway <NUM>, with the brushroll <NUM> agitating the surface to be cleaned so that the debris is more easily ingested into the suction nozzle <NUM>. The suction nozzle <NUM> positioned to recover liquid and debris indirectly from the floor surface via the brushroll <NUM>. In other cleaners, the brushroll <NUM> can be outside the recovery pathway, for example to mop the floor surface, with the suction nozzle <NUM> positioned to recover liquid and debris directly from the floor surface.

While a single horizontally-rotating brushroll <NUM> is shown herein, dual horizontally-rotating brushrolls, one or more vertically-rotating brushrolls, or a stationary brush can instead be provided on the floor cleaner <NUM>.

The suction source <NUM>, which can be a motor/fan assembly including the vacuum motor <NUM> and a fan <NUM>, is provided in fluid communication with the recovery tank <NUM>. The suction source <NUM> can be positioned within the frame <NUM>, such as above the recovery tank <NUM>, and is fluidly downstream of the recovery tank <NUM>. At least a portion of the recovery pathway <NUM> between the recovery tank <NUM> and the suction source <NUM> can be formed by a chamber <NUM> in the upright body <NUM>.

The embodiment of filter assembly <NUM>, is a pre-motor filter assembly and is provided in the recovery pathway <NUM> downstream of the recovery tank <NUM> and upstream of the suction source <NUM>. The floor cleaner <NUM> can also be provided with one or more additional filters upstream or downstream of the recovery tank <NUM> and/or the suction source <NUM>.

Referring to <FIG>, the base <NUM> can comprise a base housing <NUM> and the suction nozzle <NUM> can comprise a nozzle cover <NUM> coupled to the base housing <NUM>. As shown in <FIG>, the nozzle cover <NUM> can be removable from the base housing <NUM> to access the brushroll <NUM>, which is removable from a brush chamber <NUM> of the base <NUM>. The brush chamber <NUM> may be formed by the base housing <NUM> and/or another portion of the base <NUM>, with the nozzle cover <NUM> closing the brush chamber <NUM> to capture the brushroll <NUM> therein. Accordingly, the nozzle cover <NUM> is removed from the base housing <NUM> prior to removing the brushroll <NUM>. The brushroll <NUM> and brush chamber <NUM> can instead be configured so that prior removal of a nozzle cover is not required, such as by having the brushroll <NUM> removable through lateral side of the base <NUM> or from the underside of the base <NUM>.

The fluid delivery system can comprise a flow control system for controlling the flow of cleaning fluid from the supply tank <NUM> to a distributor <NUM> configured to distribute or dispense the fluid. In one configuration, the flow control system can comprise the pump <NUM>, which pressurizes the system. The pump <NUM> can be positioned within the base <NUM>, and is in fluid communication with the supply tank <NUM>, for example via conduit (not shown) that may pass interiorly to joint assembly <NUM>. In another configuration, the pump <NUM> can be eliminated and the flow control system can comprise a gravity-feed system having a valve fluidly coupled with an outlet of the supply tank <NUM>, whereby when valve is open, cleaning fluid will flow under the force of gravity to the distributor <NUM>.

The trigger <NUM> (<FIG>) can be operably coupled with the flow control system such that pressing the trigger <NUM> will deliver cleaning fluid to the distributor <NUM>. For example, the delivery system can include a valve (not shown) in the fluid pathway extending between the pump <NUM> and the distributor <NUM>, and the trigger <NUM> can selectively open the valve to permit fluid to flow out of the distributor <NUM>.

The distributor <NUM> can comprise spray tips on the base <NUM> positioned to deliver cleaning fluid to the brushroll <NUM>, thereby indirectly providing cleaning fluid to the floor surface, or can be positioned to deliver cleaning fluid directly to the floor surface. Other configurations of the distributor <NUM> are possible, such as a spray manifold having multiple outlets or a spray nozzle configured to spray cleaning liquid outwardly from the base <NUM> in front of the floor cleaner <NUM>.

In the cleaner shown, the spray tips are provided on an interior or brush-facing side of the nozzle cover <NUM>. The spray tips can be fed through channels of the nozzle cover <NUM> that terminate at connector ports <NUM> that couple with spray connectors <NUM> on the base housing <NUM> when the nozzle cover <NUM> is installed on the base housing <NUM>. The spray connectors <NUM>, in turn, are supplied with cleaning fluid via the pump <NUM> or other flow control system of the floor cleaner <NUM>.

Optionally, a heater (not shown) can be provided for heating the cleaning liquid prior to delivering the cleaning liquid to the surface to be cleaned. In one example, an in-line heater can be located downstream of the supply tank <NUM>, and upstream or downstream of the pump <NUM>. Other types of heaters can also be used. In yet another example, the cleaning liquid can be heated using exhaust air from a motor cooling air path for the suction source <NUM> of the recovery system. Where the floor cleaner comprises a heater, the heater can be controlled via the brushroll detection mechanism <NUM> and/or the filter detection mechanism <NUM> as described above with reference to <FIG>.

The brushroll <NUM> can be operably coupled to and driven by a drive assembly including the brushroll motor <NUM> in the base <NUM>. The coupling between the brushroll <NUM> and the brushroll motor <NUM> can comprise one or more belts, gears, shafts, pulleys or combinations thereof. Alternatively, the vacuum motor <NUM> (<FIG>) can be configured to provide both vacuum suction and brushroll rotation.

Referring to <FIG>, the brushroll is positioned in brush chamber <NUM> and rotates in a direction R about brushroll axis <NUM>. The base <NUM> can comprise an interference wiper <NUM> and/or a squeegee <NUM>. The wiper <NUM> can be mounted at a forward portion of the brush chamber <NUM> and interfaces with a wetted portion of the rotating brushroll <NUM> to scrape excess liquid off before reaching the surface to be cleaned. The squeegee <NUM> can be disposed behind the brushroll <NUM> and contacts the surface as the base <NUM> to wipe residual liquid, thereby leaving a moisture and streak-free finish on the surface to be cleaned.

Referring to <FIG>, a brushroll <NUM> including the detectable component, e.g. permanent magnet, is shown. The brushroll <NUM> can be a hybrid brushroll suitable for use on both hard and soft surfaces, and for wet or dry cleaning. The brushroll <NUM> may comprises a brush bar <NUM> supporting at least one agitation element.

The brushroll <NUM> includes a rotatable portion that is configured to rotate about the brushroll axis <NUM> and a stationary or non-rotatable portion that does not rotate about the brushroll axis <NUM>. The brushroll axis <NUM> can be defined by the brush bar <NUM> and can extend longitudinally through a center of the brush bar <NUM>. The rotatable portion includes at least the brush bar <NUM> and at least one agitation element.

The permanent magnet <NUM> is disposed on the non-rotatable portion of the brushroll <NUM>, and can forms the detectable component of the brushroll sensing mechanism. In being disposed on a non-rotatable portion of the brushroll <NUM>, the permanent magnet <NUM> is located in a section of the brushroll <NUM> that does not rotate during operation of the brushroll motor <NUM>. Thus, the permanent magnet <NUM> does not move relative to the brushroll axis <NUM>, but rather remains at a fixed point relative to the brushroll axis <NUM> and to the rotating brush bar <NUM>.

The brush bar <NUM> has a first and second lateral ends <NUM>, <NUM>, and a cylindrical outer surface <NUM> extending from the first lateral end <NUM> to the second lateral end <NUM>. The at least one agitation element generally projects outwardly form the outer surface <NUM> of the brush bar <NUM>.

The agitation element can comprise a plurality of bristles <NUM> and microfiber material <NUM> provided on the brush bar <NUM>, with the microfiber material <NUM> arranged between the bristles <NUM>.

Bristles <NUM> can be tufted or unitary bristle strips and constructed of nylon, or any other suitable synthetic or natural fiber. The brush bar <NUM> can have a plurality of radial bores <NUM> spaced along the length of the cylindrical outer surface <NUM> that receive tufts of bristles <NUM>. The bores <NUM> may be arranged in one or more lines or rows. The bristles <NUM> may be arranged in any desirable pattern, such as helical, with the rows of bores <NUM> accordingly wrapping at least partially about the circumference of the cylindrical outer surface <NUM>.

The microfiber material <NUM> can be constructed of polyester, polyamides, or a conjugation of materials including polypropylene or any other suitable material known in the art from which to construct microfiber.

The brush bar <NUM> can be constructed of a polymeric material such as acrylonitrile butadiene styrene (ABS), polypropylene or styrene, or any other suitable material such as plastic, wood, or metal. The brush bar <NUM> can have a solid core or a hollow core.

The non-rotatable portion of the brushroll <NUM> can comprise an end cap <NUM> disposed at one end of the brush bar <NUM>. The end cap <NUM> is configured to mount one end of the brushroll <NUM> in the base <NUM>, as described in further detail below.

To rotatably support the brushroll <NUM> in the base <NUM>, the brushroll <NUM> can include an end assembly at the first lateral end <NUM> of the brush bar <NUM>. The end assembly can, for example, include a stub shaft <NUM> extending from the first lateral end <NUM> of the brush bar <NUM> and a bearing <NUM> having an inner race press fitted on the stub shaft <NUM> and an outer race fixed in the end cap <NUM>.

To accommodate the end cap <NUM> and the stub shaft <NUM>, a cavity <NUM> may extend from the first lateral end <NUM> of the brush bar <NUM> laterally inwardly along the brushroll axis <NUM>. The first lateral end <NUM> of the brush bar <NUM> may accordingly have an increased diameter for accommodating the end cap <NUM>, with sufficient clearance for the brush bar <NUM> to rotate about the end cap <NUM>.

The brushroll <NUM> can include a ferrule <NUM> on the first lateral end <NUM> of the brush bar <NUM> and the end cap <NUM> is inserted through the ferrule <NUM> into the cavity <NUM>. Other configurations for insertion of the end cap <NUM> into the brush bar <NUM> are possible, including inserting the end cap <NUM> into a hole drilled or otherwise formed in the end of the brush bar <NUM>. The ferrule <NUM> can be integrally molded with the brush bar <NUM>, or can be formed separately and attached to the first lateral end <NUM> of the brush bar <NUM>.

Referring to <FIG>, the brushroll <NUM> can include a second or drive end cap <NUM> that couples with a drive assembly or transmission <NUM>, which can comprise one or more belts, gears, shafts, pulleys or combinations thereof. The drive end cap <NUM> is integrally formed with the brush bar <NUM>, although the drive end cap <NUM> can be separate feature that is connected or joined to the brush bar <NUM>. In any event, the drive end cap <NUM> and the brush bar <NUM> are formed or joined together such that upon drive input to the drive end cap <NUM>, the brush bar <NUM> rotates. In being integrally formed, the drive end cap <NUM> and the brush bar <NUM> are be integrated into a single part both supporting the agitation element (e.g. bristles <NUM> and/or microfiber materials <NUM>) and coupleable with the transmission <NUM>.

The drive end cap <NUM> can have a splined drive connection <NUM> with a drive head <NUM> of the transmission <NUM> operably connecting the brushroll motor <NUM> to the brushroll <NUM>. The drive head <NUM> can be provided at an end of the brush chamber <NUM> opposite the end comprising the Hall Effect sensor <NUM>. Other drive connections between the brushroll <NUM> and transmission <NUM> are possible.

Referring to <FIG>, <FIG>, and <FIG>, the brushroll <NUM> can be secured in the brush chamber <NUM> by a brushroll latch. Various configurations for the brushroll latch are possible. A portion of the latch is provided on the end cap <NUM>, with a mating portion provided in the brush chamber <NUM>. Particularly, the end cap <NUM> can have a latch member <NUM> that is received by a latch receiver <NUM> in the brush chamber <NUM>. The base housing <NUM> can include spaced first and second walls <NUM>, <NUM> which at least partially define the brush chamber <NUM>. The first and second walls <NUM>, <NUM> can be lateral sidewalls that form a portion of the brush chamber <NUM> therebetween, such as by enclosing open lateral ends of the nozzle cover <NUM>. The latch receiver <NUM> can be provided on an inner surface of the first wall <NUM>.

The latch member <NUM> can be complementary to or keyed with the latch receiver <NUM> to ensure proper installation of the brushroll <NUM>. The latch member <NUM> and the latch receiver <NUM> can have complementary U-shapes and can optionally taper in the insertion direction of the brushroll <NUM>, i.e. downwardly.

The latch member <NUM> can include a protruding part <NUM> that is snap fit with the latch receiver <NUM>. The protruding part <NUM> includes at least one, and optionally two, cantilever part having a hook, stud, lug, bead, or other engagement element at an end thereof. The protruding part <NUM> is deflected briefly during the joining operation and catches in a depression or undercut <NUM> in the latch receiver <NUM>. The depression or undercut <NUM> is shaped to allow separation of the brushroll <NUM> from the base housing <NUM> upon application of sufficient force.

The end cap <NUM> and base housing <NUM> can include one or more additional mating surfaces or joints which help distribute the weight of the brushroll <NUM> supported by the first wall <NUM>. The end cap <NUM> can comprise outwardly extending tabs <NUM> that rest on shoulders <NUM> adjacent to the latch receiver <NUM>.

As described above with reference to <FIG>, the brushroll detection mechanism of the floor cleaner <NUM> allows operation of at least one electrically-powered component of the floor cleaner <NUM> when the permanent magnet <NUM> is detected by the Hall Effect sensor <NUM> and prevents operation of the at least one electrically-powered component when the permanent magnet <NUM> is not detected by the Hall Effect sensor <NUM>.

The Hall Effect sensor <NUM> is provided at one end of the brush chamber <NUM> in a position to detect the permanent magnet <NUM> when the brushroll <NUM> is correctly installed in the brush chamber <NUM>. The Hall Effect sensor <NUM> can be disposed on a side of the first wall <NUM> opposite the brush chamber <NUM>, with the first wall <NUM> protecting the Hall Effect sensor <NUM> from exposure to dirt or liquid in the brush chamber <NUM>. By providing the Hall Effect sensor <NUM> outside the brush chamber <NUM>, the Hall Effect sensor <NUM> is less likely to become damaged or dirty. Other configurations and locations for mounting the Hall Effect sensor <NUM> on the base <NUM> are possible.

The permanent magnet <NUM> is coupled to the end cap <NUM> forming a portion of the non-rotatable portion of the brushroll <NUM>. A single permanent magnet <NUM> can be carried by the brushroll <NUM>. A single permanent magnet <NUM> may be preferred in order to provide precise and accurate sensing by the Hall Effect sensor <NUM>. More than one permanent magnet <NUM> may be provided on the brushroll <NUM>.

The permanent magnet <NUM> can be radially offset from the brushroll axis <NUM>. The permanent magnet <NUM> may be disposed at least partially outside the cylindrical outer surface <NUM> of the brush bar <NUM>.

The end cap <NUM> can comprise a magnet holder <NUM> for the permanent magnet <NUM>. The permanent magnet <NUM> can be press-fit or otherwise secured with the magnet holder <NUM>. For example, an adhesive may be used to secure the permanent magnet <NUM> within the magnet holder <NUM>.

The magnet holder <NUM> can comprise a recess <NUM> in the end cap <NUM>, with the permanent magnet <NUM> at least partially received within the recess <NUM>. In the cleaner shown, the permanent magnet <NUM> is disc-shaped, and the magnet holder <NUM> can comprise a circular recess for the disc-shaped magnet. Other shapes and configurations for the permanent magnet <NUM> and magnet holder <NUM> are possible.

A cover <NUM> can enclose the permanent magnet <NUM> within the recess <NUM>. The cover <NUM> can be manufactured from a non-magnetic material, such as plastic or another suitable material. The permanent magnet <NUM> may be uncovered. In this version, the cover <NUM> is preferred as this protects permanent magnet <NUM> from exposure to dirt or liquid in the brush chamber <NUM>, and from hair wrap.

A handle <NUM> to aid in removing the brushroll <NUM> from the brush chamber <NUM> can extending from the end cap <NUM>. The brushroll removal handle <NUM> can project so that a user can grip the handle <NUM> to lift the brushroll <NUM> out of the brush chamber <NUM>. For example, the handle <NUM> can be disposed on one side of the brushroll axis <NUM> and extends radially from an outer periphery <NUM> of the end cap <NUM>, the outer periphery <NUM> of the end cap <NUM> circumscribing the brushroll axis <NUM>.

The permanent magnet <NUM> can be disposed on the handle <NUM>. For example, the magnet holder <NUM> can be formed or otherwise joined with the handle <NUM>. The magnet holder <NUM> comprises the recess <NUM> integrally formed in an outboard surface <NUM> of the handle <NUM>. In other cleaners, the magnet holder <NUM> may be secured directly to the outboard surface <NUM> of the handle <NUM>. The outboard surface <NUM> is a surface of the handle <NUM> outside or away from the center of the brushroll <NUM>, e.g. a surface that faces the end of the brush chamber <NUM>. The outboard surface <NUM> can confront the first wall <NUM> of the brush chamber <NUM>.

An outboard surface <NUM> of the cover <NUM> may be flush with the outboard surface <NUM> of the handle <NUM>, or the cover <NUM> be slightly recessed with respect to the handle <NUM>. Such configurations may be preferred over a configuration where the cover <NUM> protrudes beyond the outboard surface <NUM> of the handle <NUM> because the handle 162can be fit tightly against with the first wall <NUM> of the brush chamber <NUM>, reducing the chance for dirt or hair to migrate in-between the handle <NUM> and the first wall <NUM>.

The handle <NUM> can optionally include indents <NUM> in the sides of the handle <NUM> to assist in gripping the handle <NUM> to lift the brushroll <NUM>. The indents <NUM> can, for example, by pinched between the thumb and forefinger of the user. The outboard surface <NUM> of the handle <NUM> in which the permanent magnet <NUM> is recessed can extend between the sides of the handle <NUM> comprising the indents <NUM>.

Referring to <FIG>, when the brushroll <NUM> is correctly installed in the brush chamber <NUM> and the nozzle cover <NUM> is coupled with the base housing <NUM>, the handle <NUM>, and therefore the permanent magnet <NUM> and magnet cover <NUM>, are covered by the nozzle cover <NUM>. This can protect these components and prevent unintended release of the brushroll <NUM> during a cleaning operation, which would inadvertently trigger the brushroll detection mechanism to turn off one or more electrically-powered components of the floor cleaner <NUM>.

The latching of the brushroll <NUM> further locks the positon of the permanent magnet <NUM> in place relative to the Hall Effect sensor <NUM>. With the end cap <NUM> blocked from shifting upwardly or downwardly, or forwardly or rearwardly, by receipt of the latch member <NUM> within the latch receiver <NUM>, the permanent magnet <NUM> likewise will not shift relative to the sensor Hall Effect sensor <NUM>, such that the permanent magnet <NUM> can be reliably detected as the brush bar <NUM> rotates and the floor cleaner <NUM> is moved about the surface to be cleaned.

Referring to <FIG>, the permanent magnet <NUM> is configured to be detected by the Hall Effect sensor <NUM> within an effective sensing zone <NUM> of the sensor <NUM>. Direct physical contact between the permanent magnet <NUM> and sensor <NUM> is not required, as the effective sensing zone <NUM> can detect the permanent magnet <NUM> within a predetermined distance away from the Hall Effect sensor <NUM>. One non-limiting example of the effective sensing zone <NUM> is indicated in phantom line in <FIG>, although it is understood that other ranges for the effective sensing zone <NUM> are possible.

<FIG> shows one example of the brushroll <NUM> installed correctly on the floor cleaner <NUM>. In this condition, the permanent magnet <NUM> is within the effective sensing zone <NUM> of the Hall Effect sensor <NUM>. During installation of the brushroll <NUM> on the floor cleaner <NUM>, as the brushroll <NUM> brought into the mounted position within the brush chamber <NUM>, the permanent magnet <NUM> moves toward and eventually interacts with the Hall Effect sensor <NUM>. Interaction of the permanent magnet <NUM> with the Hall Effect sensor <NUM> allows at least one component of the floor cleaner <NUM> (i.e., the vacuum motor <NUM>, brushroll motor <NUM>, pump <NUM>, etc., or any combination thereof) to operate.

<FIG> shows one example of the brushroll <NUM> installed incorrectly on the floor cleaner <NUM>. In this condition, the permanent magnet <NUM> is outside the effective sensing zone <NUM> of the Hall Effect sensor <NUM>. Lack of interaction of the permanent magnet <NUM> with the Hall Effect sensor <NUM> prevents at least one component of the floor cleaner <NUM> (i.e., the vacuum motor <NUM>, brushroll motor <NUM>, pump <NUM>, etc., or any combination thereof) from operating.

<FIG> shows one example of a brushroll 46U installed correctly on the floor cleaner <NUM>, where the brushroll 46U lacks a permanent magnet <NUM> or other detectable component. In this condition, no magnet or other detectable component is within the effective sensing zone <NUM> of the Hall Effect sensor <NUM>. Lack of interaction of any magnet or other detectable component with the Hall Effect sensor <NUM> prevents at least one component of the floor cleaner <NUM> (i.e., the vacuum motor <NUM>, brushroll motor <NUM>, pump <NUM>, etc., or any combination thereof) from operating.

Other types of brushrolls <NUM> are possible, including a bristle-only brushroll suitable for use on soft surfaces, and having bristles <NUM> as the only agitation element, or a microfiber-only brushroll suitable for use on hard surfaces and having microfiber material <NUM> as the only agitation element. Each of these brushrolls can comprise a permanent magnet <NUM> as described herein.

Optionally, the floor cleaner <NUM> can be provided with multiple, interchangeable brushrolls, which allows for the selection of a brushroll depending on the cleaning task to be performed or depending on the floor type of be cleaned. Yet another advantage of having multiple, interchangeable brushrolls is that cleaning time can be extended by allowing a soiled brushroll to be swapped out for a clean brushroll during a cleaning task.

Referring to <FIG>, the upright body <NUM> can include a tank socket or receiver <NUM> for receiving the recovery tank <NUM>. As shown herein, the tank receiver <NUM> can be defined by portions of the frame <NUM>. A recovery tank latch (not shown) can secure the recovery tank <NUM> to the upright body <NUM> within the tank receiver <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, the recovery tank <NUM> can include a recovery tank container <NUM>, which forms a collection chamber <NUM> for the recovery system, with a hollow standpipe <NUM> therein. The standpipe <NUM> forms a flow path between a tank inlet <NUM> formed at a lower end of the recovery tank container <NUM> and a tank outlet <NUM> at the upper end of the standpipe <NUM> within the interior of the recovery tank container <NUM>. When the recovery tank <NUM> is mounted to the frame <NUM> as shown in <FIG>, the tank inlet <NUM> is aligned with the conduit <NUM> to establish fluid communication between the base <NUM> and the recovery tank <NUM>.

The recovery tank <NUM> further includes a lid <NUM> sized for receipt on the recovery tank container <NUM>. The lid <NUM> at least partially encloses an open top of the recovery tank container <NUM>, and can further define an air outlet <NUM> of the recovery tank <NUM> leading to the downstream suction source <NUM> (<FIG>). A gasket <NUM> can be positioned between mating surfaces of the lid <NUM> and the recovery tank container <NUM>, and creates a seal therebetween for prevention of leaks.

The filter assembly <NUM> can be carried by the recovery tank <NUM>, and therefore is removable from the floor cleaner <NUM> upon removal of the recovery tank <NUM> and is installable on the floor cleaner upon mounting of the recovery tank <NUM> in the tank receiver <NUM>. The filter assembly <NUM> can be supported by the lid <NUM>, and the lid <NUM> can include a filter receiver <NUM> on an upwardly facing side thereof that is sized to receive the filter assembly <NUM>. The filter assembly <NUM> is removably mounted in the filter receiver <NUM>. Alternatively, the filter assembly <NUM> can be separate from the recovery tank <NUM>, and is removable and installable independently of the tank.

Referring to <FIG>, one embodiment of the filter assembly <NUM> including the detectable component, e.g. permanent magnet, is shown. The filter assembly <NUM> can include a filter <NUM> and a filter housing <NUM> including a frame <NUM> having an open area through which air may pass, the filter <NUM> supported within the frame <NUM>. A seal <NUM> on the filter housing <NUM> blocks the escape of air from the working air path or recovery pathway <NUM>. The filter <NUM> has an intake side <NUM> and an exhaust side <NUM>, and the seal <NUM> can extend around the exhaust side <NUM> of the filter <NUM>. The filter assembly <NUM> can have a handle <NUM> or other gripping feature that is made to be grasped or held by the hand for easy removal of the filter assembly <NUM>. The permanent magnet <NUM> is disposed on the handle <NUM>.

The intake side <NUM> of the filter <NUM> is an upstream side that faces the air outlet <NUM> of the recovery tank <NUM>. The exhaust side <NUM> of the filter <NUM> is a downstream side that generally opposes the upstream side relative to the direction of airflow through the recovery pathway <NUM>. Air therefore flows into the filter <NUM> through the intake side <NUM> and out of the filter <NUM> through the exhaust side <NUM>.

The filter <NUM> can comprise any suitable type or combination of types of filter media suitable for filtering particles entrained within an airstream. Non-limiting examples of filter media include paper, cellulosic material, non-woven material, spunbond material, pleated filter media, open cell foam, polyester type matrix (e.g., polyethylene terephthalate), and combinations thereof. The filter media can also be a reusable or washable type of media such as a non-woven or foam type filter media, for example. It will be understood that the particle filtration size of the filter will vary depending on the floor cleaner <NUM> in which the filter assembly <NUM> is intended for use. For the embodiment of the multi-surface wet/dry floor cleaner <NUM> shown, the filter <NUM> is a pleated filter, and can be made of a material that remains porous when wet, e.g., air can still flow through the filter <NUM> when wet (unlike conventional paper filters).

The filter <NUM> can be secured within the filter housing <NUM> using any suitable securement method. For example, adhesive may be applied between the filter <NUM> and the frame <NUM>. The filter hosing <NUM> and frame <NUM> can be made from a more rigid material than the filter <NUM> to provide stiffness to the filter assembly <NUM>.

The frame <NUM> of the filter housing <NUM> includes at least one peripheral side wall <NUM> defining the open area through which air may pass and in which the filter <NUM> is situated. In the embodiment shown, the frame <NUM> is rectilinear and comprises four walls <NUM>. While the frame <NUM> is shown as rectilinear, the frame <NUM> may have different geometric shapes to suit the cross-sectional area in which the filter assembly <NUM> may be mounted. It will be understood that the dimensions of the filter assembly <NUM> will vary depending on the floor cleaner <NUM> in which the filter assembly <NUM> is intended for use.

The seal <NUM> can include a perimeter seal portion <NUM> surrounding the exhaust side <NUM> of the filter <NUM>. The permanent magnet <NUM> can be disposed outward of the perimeter seal portion <NUM>, such that the permanent magnet <NUM> is disposed outside the recovery pathway <NUM> of the floor cleaner <NUM>.

In certain embodiments, the seal <NUM> can extend at least partially over the handle <NUM> and can overlie the permanent magnet <NUM>. In this case, the seal <NUM> can include a handle seal portion <NUM> extending from the perimeter seal portion <NUM> at least partially over the handle <NUM>.

The seal <NUM> can be overmolded or otherwise secured on the filter housing <NUM>. For example, the seal <NUM> can be formed separately and attached to the filter housing <NUM> using an adhesive. For an overmolded seal <NUM>, the seal <NUM> may be made from any material that can be suitable bonded to the material of the filter housing <NUM>. In one non-limiting example, the seal <NUM> can be made from a thermoplastic elastomer and the filter housing <NUM> can be polypropylene.

Referring to <FIG>, a ceiling of the tank receiver <NUM> can be configured to fit tightly against the seal <NUM>, and optionally also with the lid <NUM> the recovery tank <NUM>, to provide a sealed pathway from the filter assembly <NUM> to the suction source <NUM> (<FIG>), and the tank receiver <NUM> can include a grille <NUM> through which air can pass to the chamber <NUM>. The seal <NUM> may be compressed when the recovery tank <NUM> is installed on the tank receiver <NUM>.

The handle <NUM> can aid in removing the filter assembly <NUM> from the filter receiver <NUM>, and can extend from one of the walls <NUM> of the frame <NUM>. The handle <NUM> can project so that a user can grip the handle <NUM> to lift the filter assembly <NUM> out of the filter receiver <NUM>.

Returning to <FIG>, a pull tab <NUM> can project from one of the walls <NUM> of the frame <NUM>, preferably from a different wall <NUM> than the handle <NUM>. The pull tab <NUM> can assist the user in lifting the filter assembly <NUM> out of the filter receiver <NUM>. In other embodiments, the pull tab <NUM> may be eliminated, and the filter assembly <NUM> may be liftable out of the filter receiver <NUM> via the handle <NUM> alone.

The filter assembly <NUM> comprises at least one additional filter media upstream of the filter <NUM>. In the depicted embodiment, a mesh screen <NUM> is disposed on the intake side <NUM> of the filter <NUM> and is coupled with the filter housing <NUM>. The mesh screen <NUM> has a larger pore size than the filter <NUM>. When referring to the filter <NUM> or mesh screen <NUM>, the pore size is the size of the largest particles that can successfully pass through that element. The pore size may be an effective pore size or an average of pore sizes across the media. It is contemplated that by providing multiple filtration media, e.g. the mesh screen <NUM> and the filter <NUM>, of decreasing pore size to sequentially filter larger and then smaller particulate, the finer filter <NUM> is prevented from becoming obstructed with larger debris.

The filter assembly <NUM> includes a door <NUM> pivotally coupled with the filter housing <NUM>, the door <NUM> having an open grid and the mesh screen <NUM> covering the open grid. The door <NUM> can swing open, e.g. away from the intake side <NUM> of the filter <NUM>, to clean the mesh screen <NUM> and filter <NUM>.

The filter assembly <NUM> can have a poka-yoke installation to prevent a user from inadvertent error in installing the filter assembly <NUM> on the recovery tank <NUM>. In one embodiment, the poka-yoke installation includes at least one projecting feature <NUM> on the filter assembly <NUM> and/or on the filter receiver <NUM> that prevents a user from installing the filter assembly <NUM> incorrectly by interfering with the insertion of the filter assembly <NUM> into the filter receiver <NUM>.

As described above with reference to <FIG>, the filter detection mechanism of the floor cleaner <NUM> allows operation of at least one electrically-powered component of the floor cleaner <NUM> when the permanent magnet <NUM> is detected by the Hall Effect sensor <NUM> and prevents operation of the at least one electrically-powered component when the permanent magnet <NUM> is not detected by the Hall Effect sensor <NUM>.

The Hall Effect sensor <NUM> is provided at one side of the tank receiver <NUM> in a position to detect the permanent magnet <NUM> when the filter assembly <NUM> is correctly installed in the floor cleaner <NUM>, with the filter <NUM> located in the recovery pathway <NUM>. The Hall Effect sensor <NUM> can be disposed behind a wall <NUM> delimiting the tank receiver <NUM>, the recovery tank <NUM> removably mounted on an opposite side of the wall <NUM>. The wall <NUM> therefore protects the Hall Effect sensor <NUM> from exposure to the working air flow. By providing the Hall Effect sensor <NUM> outside the recovery pathway <NUM>, the Hall Effect sensor <NUM> is less likely to become damaged or dirty. In other embodiments, the Hall Effect sensor <NUM> may be provided elsewhere on the floor cleaner <NUM>, for example, adjacent to a filter receiver for the filter assembly <NUM> in a position to detect the permanent magnet <NUM> when the filter assembly <NUM> is correctly installed in the floor cleaner <NUM>.

In the embodiment shown, the permanent magnet <NUM> is coupled to the handle <NUM>. A single permanent magnet <NUM> can be carried by the filter assembly <NUM>. A single permanent magnet <NUM> may be preferred in order to provide precise and accurate sensing by the Hall Effect sensor <NUM>. In other embodiments, more than one permanent magnet <NUM> may be provided on the filter assembly <NUM>.

The handle <NUM> can be located outside the air flow pathway or recovery pathway <NUM>, with the seal <NUM> blocking off the handle <NUM> from exposure to the working air flow. As the permanent magnet <NUM> is disposed on the handle <NUM>, the permanent magnet <NUM> is thus located outside the recovery pathway <NUM> and is protected from exposure to the working air flow. By providing the permanent magnet <NUM> outside the recovery pathway <NUM>, the permanent magnet <NUM> is less likely to become damaged or dirty.

The handle <NUM> can comprise a magnet holder <NUM> for the permanent magnet <NUM>. The permanent magnet <NUM> can be press-fit or otherwise secured with the magnet holder <NUM>. For example, an adhesive may be used to secure the permanent magnet <NUM> within the magnet holder <NUM>.

The magnet holder <NUM> can comprise a recess <NUM> having an opening in a side of the handle <NUM>, with the permanent magnet <NUM> at least partially received within the recess <NUM>. The opening of the recess <NUM> can be disposed toward the exhaust side <NUM> of the filter <NUM>.

In the embodiment shown, the permanent magnet <NUM> is rectangular, and the magnet holder <NUM> can comprise a rectangular recess <NUM> for the rectangular permanent magnet <NUM>. Other shapes and configurations for the permanent magnet <NUM> and magnet holder <NUM> are possible.

A cover <NUM> can enclose the permanent magnet <NUM> within the recess <NUM>. The cover <NUM> can be manufactured from a non-magnetic material, such as plastic or another suitable material. In other embodiments, the permanent magnet <NUM> may be uncovered. In this embodiment, the cover <NUM> is preferred as this permits the seal <NUM> to be overmolded onto the cover <NUM>, and the cover <NUM> to be hidden by the handle seal portion <NUM> of the seal <NUM>.

Referring to <FIG>, the permanent magnet <NUM> is configured to be detected by the Hall Effect sensor <NUM> within an effective sensing zone <NUM> of the Hall Effect sensor <NUM>. Direct physical contact between the permanent magnet <NUM> and Hall Effect sensor <NUM> is not required, as the effective sensing zone <NUM> can detect the permanent magnet <NUM> within a predetermined distance away from the Hall Effect sensor <NUM>. One non-limiting example of the effective sensing zone <NUM> is indicated in phantom line in <FIG>, although it is understood that other ranges for the effective sensing zone <NUM> are possible.

<FIG> shows one example of the filter assembly <NUM> installed correctly on the floor cleaner <NUM>. In this condition, the permanent magnet <NUM> is within the effective sensing zone <NUM> of the Hall Effect sensor <NUM>. During installation of the recovery tank <NUM> on the floor cleaner <NUM>, as the recovery tank <NUM> brought into the mounted position within the tank receiver <NUM>, the permanent magnet <NUM> on the filter assembly <NUM> moves toward and eventually interacts with the Hall Effect sensor <NUM>. Interaction of the permanent magnet <NUM> with the Hall Effect sensor <NUM> allows at least one component of the floor cleaner <NUM> (i.e., the vacuum motor <NUM>, brushroll motor <NUM>, pump <NUM>, etc., or any combination thereof) to operate.

<FIG> shows one example of the filter assembly <NUM> installed incorrectly on the floor cleaner <NUM>. In this condition, the permanent magnet <NUM> is outside the effective sensing zone <NUM> of the Hall Effect sensor <NUM>. Lack of interaction of the permanent magnet <NUM> with the Hall Effect sensor <NUM> prevents at least one component of the floor cleaner <NUM> (i.e., the vacuum motor <NUM>, brushroll motor <NUM>, pump <NUM>, etc., or any combination thereof) from operating.

Claim 1:
A filter assembly (<NUM>) for a floor cleaner for cleaning a floor surface, comprising:
a filter (<NUM>) having an intake side (<NUM>) and an exhaust side (<NUM>);
a filter housing (<NUM>) comprising a frame (<NUM>) having an open area through which air may pass, the filter supported within the frame;
a handle (<NUM>) projecting from the filter housing;
characterised by
a mesh screen (<NUM>) on the intake side of the filter, the mesh screen having a pore size configured to filter a larger particle size than the filter;
a door ( <NUM>) pivotally coupled with the filter housing, the door having an open grid and the mesh screen covering the open grid;
a seal (<NUM>) on the filter housing, the seal extending around the exhaust side of the filter; and
a permanent magnet (<NUM>) disposed on the handle.