Patent Description:
Carpets are a popular floor covering choice to improve comfort, aesthetics, and insulation of a room. Foot and animal traffic on the carpet deposits dirt, stains, and other debris onto and into the carpet. Carpets can include fibers, and the dirt, stains, pet dander, and other debris (hereinafter, collectively "dirt") become deeply embedded into the fibers. Other fabric-presenting products such as rugs, drapes, and upholstery on furniture become similarly dirtied.

Extraction cleaners, both of the upright and portable varieties, have been developed to clean carpets and other fabric-presenting products (hereinafter, collectively "fabric-presenting products") by removing the deeply embedded dirt. The extraction cleaners typically cause a cleaning solution to be deposited upon the fabric-presenting product. The cleaning solution extracts at least a portion of the deeply embedded dirt. The extraction cleaners then extract, typically via suction, the cleaning solution with the deeply embedded dirt from the fabric-presenting product. The fabric-presenting product is thus cleaner than before.

However, there are several problems. First, there is a problem in that the extraction cleaners sometimes extract a suboptimal percentage of the cleaning fluid from the fabric-presenting product. That is a problem because some of the dirt that the cleaning solution extracted from the fabric-presenting product remains upon or within the fabric-presenting product. Further, that is a problem because the fabric-presenting product takes a suboptimal time to dry. Second, there is a problem in that extraction of the cleaning solution from the fabric-presenting product can generate a suboptimal level of noise. That is a problem because some users may dislike what they perceive as loud noise, or circumstances may otherwise be better suited to a relatively quiet environment (e.g., a baby is napping).

<CIT> discloses a suction tool for an extraction cleaner comprising: a base forming a suction chamber and a suction outlet, and a piezoelectric element coupled to an ultrasonic horn with notches at the tip of the ultrasonic horn with a fluid flow path extending through those notches.

<CIT> D2 discloses a suction head for an extraction cleaner comprising a base forming a suction chamber and a suction outlet, and a piezoelectric element coupled to the base to generate a mist.

The present invention addresses those problems with a suction head for an extraction cleaner that includes a piezoelectric element (or a plurality of piezoelectric elements) and places the piezoelectric element in contact with a fabric-presenting product that is a target of a drying operation, such as that which might follow from a cleaning operation using the same suction head. The piezoelectric element, when activated, vibrates at a high frequency. The vibrations releases liquid from the fabric-presenting product that suction alone typically cannot capture and micronizes the liquid, which then either floats away with room currents or is captured via suction through a fluid flow path within the suction head that leads to a storage container of the extraction cleaner. A suction source of the extraction cleaner can be operated at a relatively low power to create the suction to capture the micronized liquid. The relative low power generates relatively low audible noise.

According to the present invention, a suction head for an extraction cleaner comprises:
: (a) a base forming a suction chamber and a suction outlet in fluid communication with the suction chamber; and (b) a piezoelectric element coupled to the base, the piezoelectric element comprising a first surface open to the suction chamber, a second surface facing an external environment away from the suction chamber, a thickness between the first surface and the second surface, and a through-via through the thickness open at both the first surface and the second surface.

According to an embodiment of the present invention, an extraction cleaner comprises:
(a) a main housing; (b) a suction source housed in the main housing; (c) a first fluid storage container coupled to the main housing, the first fluid storage container configured to hold a fluid; (d) a fluid distributor in fluid communication with the first fluid storage container, the fluid distributor configured to deliver the fluid from the first fluid storage container to a fabric-presenting product; (e) a second fluid storage container coupled to the main housing and in fluid communication with the suction source, the second fluid storage container configured to hold the fluid extracted from the fabric-presenting product; (f) a suction head comprising a base forming a suction chamber and a suction outlet in fluid communication with the suction chamber, the second fluid storage container, and the suction source; and a piezoelectric element coupled to the base, the piezoelectric element comprising (i) a first surface open to the suction chamber, (ii) a second surface facing an external environment away from the suction chamber, (iii) a thickness between the first surface and the second surface, and (iv) a through-via through the thickness open at both the first surface and the second surface; and (g) an activated state during which (i) the piezoelectric element and the suction source are activated and (ii) fluid flows from an external environment, through the through-via of the piezoelectric element, through the suction chamber of the base of the suction head, and into the second fluid storage container.

Referring to <FIG>, a suction head <NUM> includes a base <NUM> and a piezoelectric element <NUM> coupled to the base <NUM>. The base <NUM> forms a suction chamber <NUM>. For example, the base <NUM> includes opposing inner surfaces <NUM>, <NUM> (see, e.g., <FIG>) separated by a distance <NUM>. The opposing inner surfaces <NUM>, <NUM> can be contiguous. The distance <NUM> can decrease as position along the opposing inner surfaces <NUM>, <NUM> moves in an upward direction <NUM>. The base <NUM> further forms a suction outlet <NUM>. For example, the base <NUM> includes opposing surfaces <NUM>, <NUM> separated by a distance <NUM>. The suction outlet <NUM> can take a tubular shape. The suction outlet <NUM> is in fluid communication with the suction chamber <NUM>, and both the suction outlet <NUM> and the suction chamber <NUM> are in fluid communication with an external environment <NUM> (e.g., external to the suction head <NUM>). As will be further described, during use of the suction head <NUM>, fluid flows from the external environment <NUM> into the suction chamber <NUM>, and then from the suction chamber <NUM> into the suction outlet <NUM>. The base <NUM> can include a throat <NUM>, where fluid flow is narrowed, demarking a separation between the suction chamber <NUM> and the suction outlet <NUM>. The base <NUM> can be formed of plastic such as via injection molding. Other materials are envisioned. The base <NUM> can be formed of multiple parts coupled together. The base <NUM> can include one or more visually transparent portions <NUM> so that the user can see fluid being extracted from the fabric-presenting product during use.

Referring additionally to <FIG>, the piezoelectric element <NUM> has a first surface <NUM> and a second surface <NUM>. At least a portion of the first surface <NUM> is open to the suction chamber <NUM>. The second surface <NUM> faces away from the suction chamber <NUM> and toward the external environment <NUM>. The piezoelectric element <NUM> further includes a thickness <NUM> between the first surface <NUM> and the second surface <NUM>. The piezoelectric element <NUM> further includes a through-via <NUM> through the thickness <NUM>. The through-via <NUM> is open at the first surface <NUM> and the second surface <NUM>.

The piezoelectric element <NUM> includes a diaphragm <NUM> and a piezoelectric material <NUM> disposed on the diaphragm <NUM>. The piezoelectric material <NUM> can be as quartz or lead zirconate titanate, although any piezoelectric material <NUM> suitable for the purposes described herein can be utilized. The piezoelectric material <NUM> can have an annular shape, as illustrated, although other shapes such as ring shaped are envisioned. The diaphragm <NUM> can be formed of stainless steel, although other materials are contemplated. In embodiments, the diaphragm <NUM> has a diameter <NUM> within a range of from <NUM> to <NUM>, such as about <NUM>. However, in other embodiments, the diameter <NUM> is below or above the stated range. The diaphragm <NUM> provides the first surface <NUM> and the second surface <NUM>, and the through-via <NUM> is through the diaphragm <NUM>. As mentioned, the piezoelectric material <NUM> is disposed on the first surface <NUM> of the diaphragm <NUM>. The piezoelectric element <NUM> further includes electrodes <NUM> to receive lead wires <NUM> in order to provide a voltage to the piezoelectric material <NUM> when activated. The voltage causes the piezoelectric material <NUM> to undergo mechanical deformation. Rapidly changing the voltage thus causes the piezoelectric material <NUM>, and thus the diaphragm <NUM>, to vibrate. In embodiments, the piezoelectric material <NUM> vibrates at a frequency within a range of from <NUM> to <NUM>, such as from <NUM> to <NUM>. However, in other embodiments, the frequency at which the piezoelectric material <NUM> vibrates is below or above the stated range.

In embodiments, the piezoelectric element <NUM> includes a plurality of through-vias <NUM>, of which the through-via <NUM> is one. In other words, the through-via <NUM> is one of the plurality of through-vias <NUM>. Each of the plurality of through-vias <NUM> are through the thickness <NUM> of the diaphragm <NUM>. Each of the plurality of through-vias <NUM> are open at both the first surface <NUM> and the second surface <NUM>. Each of the plurality of through-vias <NUM> can be formed via laser perforation methods, although other ways may be possible. In embodiments, the plurality of through-vias <NUM> number within a range of from <NUM>,<NUM> to <NUM>,<NUM>, although the number of the plurality of through-vias <NUM> could be more or less than the stated range. In embodiments, each of plurality of through-vias <NUM> of the piezoelectric element <NUM> has a diameter <NUM> (see <FIG>) that is within a range of from <NUM> to <NUM>. However, in other embodiments, the diameter <NUM> may be outside of that range.

In embodiments, the suction head <NUM> includes a plurality of piezoelectric elements <NUM> coupled to the base <NUM>. The piezoelectric element <NUM> already discussed is one of the plurality of piezoelectric elements <NUM>. Each of the plurality of piezoelectric elements <NUM> can be identical to the piezoelectric element <NUM> already discussed. For example, each of the plurality of piezoelectric elements <NUM> provides the first surface <NUM> open to the suction chamber <NUM>, the second surface <NUM> facing the external environment <NUM> and away from the suction chamber <NUM>, the thickness <NUM>, and the plurality of through-vias <NUM> through the thickness <NUM>. The number of through-vias <NUM>, the diameter <NUM> of the through-vias <NUM>, the diameter <NUM> of the diaphragm <NUM>, and the frequency at which the piezoelectric material <NUM> vibrates for each of the plurality of piezoelectric elements <NUM> can be substantially the same (e.g., the same within manufacturing tolerances). In some instances, the plurality of piezoelectric elements <NUM> numbers within a range of from <NUM> to <NUM>. However, the number of piezoelectric elements <NUM> forming the plurality of piezoelectric elements <NUM> is not particularly limited. In the illustrated embodiment, the plurality of piezoelectric elements <NUM> are arranged in rows <NUM> (see, e.g., <FIG> and <FIG>) of piezoelectric elements <NUM>, where a line <NUM> extending through centers <NUM> of the piezoelectric elements <NUM> forming any particular row <NUM> is parallel to a similar line <NUM> extending through centers <NUM> of the piezoelectric elements <NUM> forming any another row <NUM>. In short, the rows <NUM> can be parallel to each other. More or less rows <NUM> of piezoelectric elements <NUM> can be utilized than the three rows <NUM> in the illustrated embodiment.

The base <NUM> and the piezoelectric element <NUM> define a fluid flow path <NUM> (see, e.g., <FIG>). The fluid flow path <NUM> is from the external environment <NUM>, through the through-via <NUM> of the piezoelectric element <NUM>, into the suction chamber <NUM>, into the suction outlet <NUM>, and then out of the suction outlet <NUM>. In embodiments where the piezoelectric element <NUM> includes a plurality of through-vias <NUM> through the diaphragm <NUM>, the fluid flow path <NUM> is from the external environment <NUM>, through the plurality of through-vias <NUM> of the piezoelectric element <NUM>, into the suction chamber <NUM>, into the suction outlet <NUM>, and then out of the suction outlet <NUM>. In embodiments where the suction head <NUM> includes the plurality of piezoelectric elements <NUM>, the flow path is from the external environment <NUM>, through the plurality of through-vias <NUM> of each of the plurality of piezoelectric elements <NUM>, into the suction chamber <NUM>, into the suction outlet <NUM>, and then out of the suction outlet <NUM>.

Referring additionally to <FIG>, in embodiments, the suction head <NUM> further includes a bracket <NUM> coupled to the base <NUM>. The bracket <NUM> includes a first surface <NUM>, at least a portion of which faces the suction chamber <NUM>, and a second surface <NUM> that faces away from the suction chamber <NUM> toward the external environment <NUM>. The bracket <NUM> further includes a thickness <NUM> (see, e.g., <FIG>) between the first surface <NUM> and the second surface <NUM>. The bracket <NUM> further includes an aperture <NUM> through the thickness <NUM> that is open at the first surface <NUM> and the second surface <NUM>.

The aperture <NUM> accommodates the piezoelectric element <NUM>. For example, an outer region <NUM> of the first surface <NUM> of the piezoelectric element <NUM> (such as the diaphragm <NUM> provides) lies flush against the second surface <NUM> of the bracket <NUM>. The outer region <NUM> may remain unadhered to the second surface <NUM> of the bracket <NUM> to facilitate vibration of the diaphragm <NUM>. At least a portion of the piezoelectric element <NUM>, such as the piezoelectric material <NUM>, extends into the aperture <NUM> of the bracket <NUM>. The aperture <NUM> of the bracket <NUM> surrounds the piezoelectric material <NUM>. A portion <NUM> of the lead wires <NUM> of the piezoelectric element <NUM> extend adjacent to the first surface <NUM> of the bracket <NUM>. The portion <NUM> of the lead wires <NUM> extending over the first surface <NUM> of the bracket <NUM> while the outer region <NUM> of the first surface <NUM> of the piezoelectric element <NUM> lies flush against the second surface <NUM> of the bracket <NUM> together maintain the piezoelectric element <NUM> within the aperture <NUM> of the bracket <NUM> and coupled to the base <NUM>. The bracket <NUM> can be formed from plastic, such as through injection molding. However, other materials are contemplated. In variations, the diaphragms <NUM> are integral with the bracket <NUM> and in such a variation, vibration of the piezoelectric materials <NUM> causes the bracket <NUM> to vibrate and the plurality of through-vias <NUM> are through the bracket <NUM>.

In embodiments of the suction head <NUM> that include the plurality of piezoelectric elements <NUM>, the bracket <NUM> includes a plurality of apertures <NUM> (of which the aperture <NUM> is one) to accommodate the plurality of piezoelectric elements <NUM> in the same manner. The features of the aperture <NUM> of the bracket <NUM> described above apply as well to each of the plurality of apertures <NUM>. The spatial relationship between the piezoelectric element <NUM> and the aperture <NUM> of the bracket <NUM> described above applies as well to each of the plurality of piezoelectric elements <NUM> and each of the plurality of apertures <NUM>. Each of the plurality of apertures <NUM> of the bracket <NUM> accommodates a different one of the plurality of piezoelectric elements <NUM>.

As in the illustrated embodiment, the suction head <NUM> can further include an outer bracket <NUM> attached to the base <NUM>. The outer bracket <NUM> holds the bracket <NUM> to the base <NUM> while maintaining the second surface <NUM> of the plurality of piezoelectric elements <NUM> exposed to the external environment <NUM>. In particular, the outer bracket <NUM> includes a shoulder <NUM> that surrounds a central aperture <NUM>. The shoulder <NUM> is angled away relative to the second surface <NUM> of the bracket <NUM>. An outer flange <NUM> of the bracket <NUM> is similarly angled. The outer bracket <NUM> includes fastener receivers <NUM> (see <FIG>) aligned with fastener receivers <NUM> of the base <NUM> to receive fasteners (not illustrated) that fasten the outer bracket <NUM> to the base <NUM>. The bracket <NUM> is sandwiched between the outer bracket <NUM> and the base <NUM>, with the shoulder <NUM> of the outer bracket <NUM> contacting and shouldering the weight of the outer flange <NUM> of the bracket <NUM>. The central aperture <NUM> of the outer bracket <NUM> allows the second surface <NUM> of the bracket <NUM> and the second surface <NUM> of the piezoelectric element <NUM> to remain exposed to the external environment <NUM>. The outer bracket <NUM> can be formed from plastic, such as through injection molding. However, other materials are contemplated.

The suction head <NUM> can further include a flexible backing <NUM>. The flexible backing <NUM> takes a sheet-like form and is disposed upon the first surface <NUM> of the bracket <NUM>. The flexible backing <NUM> includes an aperture <NUM> that is aligned with the aperture <NUM> of the bracket <NUM> to accommodate the fluid flow path <NUM> from the through-via <NUM> (or the plurality of through-vias <NUM>, as the case may be) of the piezoelectric element <NUM> to the suction chamber <NUM>. The flexible backing <NUM> further includes a tab <NUM> extending over the first surface <NUM> of the piezoelectric element <NUM> and may contact the backing material <NUM> thereof. In embodiments of the suction head <NUM> including the plurality of piezoelectric elements <NUM>, the flexible backing <NUM> includes a plurality of apertures <NUM> (of which the aperture <NUM> is one). Each of the plurality of apertures <NUM> accommodates the fluid flow path <NUM> from a different one of the plurality of piezoelectric elements <NUM> to the suction chamber <NUM> in the same manner as described above. The outer flange <NUM> of the bracket <NUM> surrounds a perimeter <NUM> of the flexible backing <NUM>. The flexible backing <NUM>, like the bracket <NUM>, is sandwiched between the outer bracket <NUM> and the base <NUM>.

The suction head <NUM> can further include, as in the illustrated embodiment, a backboard <NUM> that is disposed upon the flexible backing <NUM>, with the flexible backing <NUM> disposed between the backboard <NUM> and the bracket <NUM>. The backboard <NUM>, along with the flexible backing <NUM>, is sandwiched between the outer bracket <NUM> and the base <NUM>. The backboard <NUM> includes an aperture <NUM> to accommodate the fluid flow path <NUM> from the piezoelectric element <NUM> to the suction chamber <NUM>. The aperture <NUM> of the backboard <NUM> is thus aligned with the aperture <NUM> of the flexible backing <NUM>, the piezoelectric element <NUM>, and the aperture <NUM> of the bracket <NUM>. The aperture <NUM> has a diameter <NUM>. The diameter <NUM> (see <FIG>) of at least a portion <NUM> of the aperture <NUM> is smaller than a diameter <NUM> of the aperture <NUM> of the bracket <NUM>. For example, the diameter <NUM> can decrease in a stepwise manner away from the piezoelectric element <NUM>. The backboard <NUM>, as in the illustrated embodiment, can include an outer wall <NUM> that extends away from the bracket <NUM>. The outer wall <NUM> faces a wall of the base <NUM> at least partially defining the suction chamber <NUM>. The outer wall <NUM> surrounds a portion <NUM> of the suction chamber <NUM>. The fluid flow path <NUM> goes through the aperture <NUM> of the backboard <NUM> before entering the suction chamber <NUM>. In embodiments of the suction head <NUM> that include the plurality of piezoelectric elements <NUM>, the backboard <NUM> includes a plurality of apertures <NUM> (of which the aperture <NUM> is one). Each of the plurality of apertures <NUM> accommodates the fluid flow path <NUM> from a different one of the plurality of piezoelectric elements <NUM> to the suction chamber <NUM> in the same manner as described above.

In embodiments, such as that illustrated, the backboard <NUM> further includes projections <NUM> (see <FIG>). The projections <NUM> are positioned to extend through cooperating apertures through the flexible backing <NUM> and contact the bracket <NUM>. The projections <NUM> maintain separation between the backboard <NUM> and the bracket <NUM>, which facilitates airflow therebetween around the plurality of piezoelectric element <NUM>. The airflow in turn carries away the micronized liquid along the fluid flow path <NUM> as described.

In embodiments, such as that illustrated, the base <NUM> further defines a second suction chamber <NUM> and an inlet <NUM> into the second suction chamber <NUM> from the external environment <NUM>. The inlet <NUM> is in fluid communication with second suction chamber <NUM>, which is in fluid communication with the suction outlet <NUM>. A second fluid flow path <NUM> is defined from the external environment <NUM>, through the inlet <NUM>, then through the second suction chamber <NUM> to the suction outlet <NUM> where the second fluid flow path <NUM> joins the fluid flow path <NUM> from the suction chamber <NUM>. For example, the base <NUM> includes opposing surfaces <NUM>, <NUM> (see, e.g., <FIG>) that are separated from each other to define the second suction chamber <NUM>.

The suction head <NUM> advantageously positions the piezoelectric element <NUM> (or the plurality of piezoelectric elements <NUM>) so that the second surface <NUM> thereof can contact the fabric-presenting product. For example, the second surface <NUM> of the piezoelectric element <NUM> forms a plane <NUM>, and the second surface <NUM> of each of the plurality of piezoelectric elements <NUM> can be coplanar with the plane <NUM>. From the perspective of the suction head <NUM> being placed on a horizontal fabric-presenting product, with the second surface <NUM> of each of the plurality of piezoelectric elements <NUM> facing the fabric-presenting product, the suction chamber <NUM>, the second suction chamber <NUM>, the inlet <NUM> into the second suction chamber <NUM>, and the suction outlet <NUM> are all disposed elevationally above the plane <NUM>. In other embodiments, however, the base <NUM> can position the piezoelectric elements <NUM> so that the second surface <NUM> of each of the plurality of piezoelectric elements <NUM> are separated from the fabric-presenting product.

The suction head <NUM> can position the piezoelectric element <NUM> (or the plurality of piezoelectric elements <NUM>, as the case may be) laterally between the inlet <NUM> into the second suction chamber <NUM> and the suction outlet <NUM>. For example, from the perspective of <FIG>, the inlet <NUM> is forward <NUM> of the piezoelectric element <NUM>, which is forward <NUM> of the suction outlet <NUM>. Stated another way, a plane <NUM> that is perpendicular to both the second surface <NUM> of the piezoelectric element <NUM> and a midline <NUM> (see <FIG>) of the suction head <NUM> (that conceptually divides the suction head <NUM> into two substantially symmetrical halves) extends between the inlet <NUM> into the second suction chamber <NUM> and the suction outlet <NUM>.

The suction head <NUM> can further include an ON/OFF switch <NUM> (see, e.g., <FIG>). The ON/OFF switch <NUM> is in electrical communication with the piezoelectric element <NUM> (or the plurality of piezoelectric elements <NUM>, as the case may be). With the ON/OFF switch <NUM>, a user can selectively activate or deactivate the piezoelectric element <NUM>. The lead wires <NUM> can provide the electrical communication between the ON/OFF switch <NUM> and the piezoelectric element <NUM>. When the suction head <NUM> includes the ON/OFF switch <NUM>, the base <NUM> can further include an aperture <NUM> through which the ON/OFF switch <NUM> at least partially extends to be available for user manipulation from the external environment <NUM>.

The suction head <NUM> may be used with, or a component of, an extraction cleaner <NUM>, a portable example of which is illustrated at <FIG>. In addition to the suction head <NUM>, the extraction cleaner <NUM> includes a main housing <NUM>, a suction source <NUM>, a first fluid storage container <NUM>, a fluid distributor <NUM>, and a second fluid storage container <NUM>. The main housing <NUM> can include a handle <NUM> to facilitate the user transporting the extraction cleaner <NUM> closer to the fabric-presenting product to be cleaned. The main housing <NUM> can further include a base <NUM>, upon which the first fluid storage container <NUM> and the second fluid storage container <NUM> may be removably mounted. The main housing <NUM> can house the suction source <NUM>, which is illustrated as a motor and fan assembly, and a pump <NUM> for use with the fluid distributor <NUM>.

The first fluid storage container <NUM> is configured to hold a fluid <NUM>. For example, the first fluid storage container <NUM> can be a blow-molded plastic reservoir. The fluid <NUM> can be a cleaning fluid. For example, the fluid <NUM> that the first fluid storage container <NUM> holds can be water, detergent (e.g., surfactant(s), odor eliminators, sanitizers, surface conditioners, stabilizers, and mixtures thereof, among other options. The previous list is not exclusive. The first fluid storage container <NUM> is refillable.

The fluid distributor <NUM>, as illustrated, can be disposed at the suction head <NUM>. The fluid distributor <NUM> is in fluid communication with the first fluid storage container <NUM>. For example, the extraction cleaner <NUM> can further include a flexible hose <NUM>. The suction head <NUM> is selectively attachable and detachable from the flexible hose <NUM>. The flexible hose <NUM> includes an internal fluid conduit <NUM> that is in fluid communication with the first fluid storage container <NUM>. When the suction head <NUM> is attached to the flexible hose <NUM>, the fluid distributor <NUM> is placed in fluid communication with the internal fluid conduit <NUM> of the flexible hose <NUM> and thus the first fluid storage container <NUM>. The pump <NUM> is in fluid communication with both the fluid distributor <NUM> and the first fluid storage container <NUM>. The pump <NUM> causes the fluid <NUM> from the first fluid storage container <NUM> to be expelled from the fluid distributor <NUM> onto the fabric-presenting product. The flexible hose <NUM> can include an actuator <NUM> in electrical communication with the pump <NUM> that, when manipulated, activates the pump <NUM> to expel the fluid <NUM>. The main housing <NUM> may further include a heater (not illustrated) to heat the fluid <NUM> from the first fluid storage container <NUM> before the fluid <NUM> is expelled.

The second fluid storage container <NUM> is configured to hold fluid <NUM> as well. For example, the second fluid storage container <NUM> can be a blow-molded plastic reservoir. The fluid <NUM> that the second fluid storage container <NUM> holds can be fluid <NUM> extracted from the fabric-presenting product. The second fluid storage container <NUM> is in fluid communication with the suction source <NUM>. The suction source <NUM> can be placed downstream from the second fluid storage container <NUM>.

The second fluid storage container <NUM> can include an air/liquid separator assembly <NUM>. A purpose of the air/liquid separator assembly <NUM> is to separate the fluid <NUM> into its constituent air and liquid components. The air/liquid separator assembly <NUM> comprises a stack <NUM> for the fluid <NUM> through the second fluid storage container <NUM> and a float assembly <NUM> for selectively closing the extraction path through the second fluid storage container <NUM>. The stack <NUM> includes an inlet conduit <NUM> that receives the fluid <NUM> from the suction head <NUM> and opens into the interior of the second fluid storage container <NUM>, and an outlet conduit <NUM> that passes substantially clean air, and substantially no liquid, to the suction source <NUM>. The separated liquid remains in the second fluid storage container <NUM>.

The suction outlet <NUM> of the suction head <NUM> is in fluid communication with the suction source <NUM> and the second fluid storage container <NUM>. For example, the flexible hose <NUM> includes a conduit <NUM> that is in fluid communication with the suction source <NUM> and the second fluid storage container <NUM>. When the suction head <NUM> is attached to the flexible hose <NUM>, the suction outlet <NUM> of the suction head <NUM> is in fluid communication with the conduit <NUM> of the flexible hose <NUM>. The fluid flow path <NUM> as described above for the suction head <NUM> thus continues through the conduit <NUM> of the flexible hose <NUM> to the second fluid storage container <NUM>.

The flexible hose <NUM> can place the ON/OFF switch <NUM> and thus the piezoelectric element <NUM> in electrical communication with a power source. The power source can be mains power accessed via a cord <NUM> of the extraction cleaner <NUM>. Alternatively, the power source can be a battery <NUM> housed in the main housing <NUM> of the extraction cleaner <NUM>. The suction head <NUM> and the flexible hose <NUM> can include mating electrical connectors <NUM>, <NUM> (see <FIG>), respectively, which are placed in electrical communication when the suction head <NUM> is attached to the flexible hose <NUM>. As another alternative, the suction head <NUM> can further include a battery <NUM>, which can be replaceable and/or rechargeable, that is in electrical communication with both the ON/OFF switch <NUM> and the piezoelectric element <NUM>. The inclusion of the battery <NUM> can render the electrical connectors <NUM>, <NUM> unnecessary.

Referring to <FIG>, in use, the user moves the extraction cleaner <NUM> near a fabric-presenting product <NUM> that the user desires to be deeply cleaned. The user takes hold of the suction head <NUM> or the flexible hose <NUM> near the suction head <NUM>. The user manipulates the actuator <NUM> to cause the pump <NUM> to distribute the fluid <NUM> from the first fluid storage container <NUM> through the fluid distributor <NUM> onto the fabric-presenting product <NUM>. The user can then scrub the fabric-presenting product <NUM>, such as with bristles (not illustrated) disposed on the suction head <NUM> or elsewhere. Alternatively, or in addition, the user can manipulate the ON/OFF switch <NUM> to activate the piezoelectric element <NUM> (or the plurality of piezoelectric elements <NUM>, as the case may be). The resulting high frequency vibrations agitate the fabric-presenting product <NUM> and the fluid <NUM> deposited thereupon. The agitation can release dirt within the fabric-presenting product <NUM>.

After (or before) the fabric-presenting product <NUM> is suitably scrubbed, the user can activate the suction source <NUM> of the extraction cleaner <NUM>, such as by pressing a switch <NUM> on the housing. When both the suction source <NUM> and the piezoelectric element <NUM> are activated, the extraction cleaner <NUM> is in an activated state <NUM>. While in the activated state <NUM>, the fluid <NUM> (now including dirt taken from the fabric-presenting product <NUM>), is caused to flow because of the suction along the fluid flow path <NUM> from the fabric-presenting product <NUM>, through the through-via <NUM> (or plurality of through-vias <NUM>) of the piezoelectric element <NUM> (or the plurality of piezoelectric elements <NUM>), through the suction chamber <NUM> of the base <NUM> of the suction head <NUM>, through the conduit <NUM> of the flexible hose <NUM>, and into the second fluid storage container <NUM>. The high frequency vibration from the piezoelectric element <NUM> (i) withdraws fluid <NUM> from the fabric-presenting product <NUM> and (ii) converts liquid of the fluid <NUM> into fine mist particles with diameters ranging from <NUM> to <NUM>.

In embodiments of the suction head <NUM> that includes the second suction chamber <NUM>, when the extraction cleaner <NUM> is in the activated state <NUM>, the fluid <NUM> additionally flows from the fabric-presenting product <NUM> through the inlet <NUM> of the base <NUM> and into the second suction chamber <NUM>. The user may have to slightly tilt the suction head <NUM> so that the inlet <NUM> contacts the fabric-presenting product <NUM>. The fluid <NUM> from the suction chamber <NUM> and the second suction chamber <NUM> join and flow combined through the suction outlet <NUM>, through the conduit <NUM> of the hose, and into the second fluid storage container <NUM>.

The transformation of the liquid from the fluid <NUM> into fine mist particles is thought to quicken extraction of the fluid <NUM> from the fabric-presenting product <NUM>. That leads to the fabric-presenting product <NUM> drying faster than if the piezoelectric element <NUM> had not been activated and suction alone was relied upon. The suction head <NUM> provides a sort of "drying multiplier" effect where the suction source <NUM> drawing in fluid <NUM> from the inlet <NUM> into the second suction chamber <NUM> extracts potentially a relatively large percentage of the fluid <NUM> from the fabric-presenting product <NUM> while the piezoelectric element <NUM> supplements the extraction by pulling and micronizing additional fluid from the fabric-presenting product <NUM> that suction alone was unable to extract. Surface tension may cause some of the fluid <NUM> within the fabric-presenting product <NUM> to resist extraction via suction alone. The vibrations from the piezoelectric element <NUM> can overcome the surface tension and liberate the fluid <NUM> from the fabric-presenting product <NUM> and allow the same to be extracted therefrom.

In another possible use scenario, the user can utilize the suction source <NUM> without activating the piezoelectric element <NUM> to extract much of the fluid <NUM> from the fabric-presenting product <NUM>. The user can then activate the piezoelectric element <NUM> while maintaining activation of the suction source <NUM> to extract additional fluid <NUM>. The user can judge whether the suction source <NUM> alone has ceased extracting fluid <NUM> from the fabric-presenting product <NUM> visually through the portions of the base <NUM> of the suction head <NUM> that are transparent. Alternatively, the suction head <NUM> can include a moisture sensor <NUM> in communication with a controller <NUM> (either located at the suction head <NUM> or the main housing <NUM> of the extraction cleaner <NUM>). Once the controller <NUM> determines, as a function of signals received from the moisture sensor <NUM>, that a predetermined minimum level has been achieved, the controller <NUM> can then activate the piezoelectric element <NUM>.

The suction source <NUM> can be operable, for the activated state <NUM>, at at least two power levels. When operated at one of the power levels, the suction source <NUM> generates less suction at the suction head <NUM> and generates less audible noise than when operated at the other of the at least two power levels. For example, the power levels can be a "high" power and a "low" power, where "high" and "low" mean only relative to each other.

Further, the user can cause only the piezoelectric element <NUM> (or plurality of piezoelectric elements <NUM>) to be activated without simultaneously activating the suction source <NUM>. The high frequency vibrations transform the liquid of the fluid <NUM> upon and within the fabric-presenting product <NUM> into mist, which floats due to air currents within the external environment <NUM> away from the fabric-presenting product <NUM>. This mode of operation can be useful where the user desires very low levels of audible noise. The user may leave the suction head <NUM> with the piezoelectric element <NUM> upon the fabric-presenting product <NUM> in an activated state <NUM> and let the piezoelectric element <NUM> cause the fabric-presenting product <NUM> unattended. This mode of operation can be useful when the fluid <NUM> upon the fabric-presenting product <NUM> is relatively clean water and when capture of soiled cleaning fluid is unnecessary.

The suction head <NUM> and extraction cleaner <NUM> of the present disclosure addresses the aforementioned problems, in at least several ways. First, regarding the problem of extraction cleaners extracting a suboptimal percentage of the fluid <NUM> from the fabric-presenting product <NUM>, the extraction cleaner <NUM> incorporating the suction head <NUM> of the present disclosure with the piezoelectric element <NUM> extracts a greater volume of the fluid <NUM> compared to if the piezoelectric element <NUM> was not included. Thus, less dirt remains on the fabric-presenting product <NUM> with the non-extracted fluid <NUM>, and the fabric-presenting product <NUM> dries faster, compared to if the piezoelectric element <NUM> was not included. The faster drying provides an added benefit of increasing energy efficiency of the extraction cleaner <NUM> to achieve a certain level of dryness. Second, regarding the problem of extraction cleaners generating a suboptimal level of noise, the extraction cleaner <NUM> of the present disclosure includes a suction source <NUM> that can be operated at more than one power level including a relatively low power level. Although the suction source <NUM> is operated at a relatively low power level, the incorporation of the piezoelectric element <NUM> draws cleaning fluid from the fabric-presenting product <NUM> and transforms it to mist that is moved to and collected within the second fluid storage container <NUM>. Without the piezoelectric element <NUM>, the suction source <NUM> operating at the relatively low power level would be unable to extract as much of the fluid <NUM>.

Although the suction head <NUM> has been described herein thus far in terms of an attachable/detachable component of the extraction cleaner <NUM>, the suction head <NUM> can be an integral component of the extraction cleaner <NUM>, such as permanently attached to the flexible hose <NUM>. Further, although the disclosure described the extraction cleaner <NUM> in terms of a portable extraction cleaner, the extraction cleaner <NUM> could just as well be an upright extraction cleaner or a handheld extraction cleaner. In the instance of the handheld extraction cleaner <NUM>, the body of the suction head <NUM> may be provided by the main housing <NUM> as an integrated unit.

The suction head <NUM> can take different shapes and forms than have described herein, and the piezoelectric elements <NUM> can nevertheless be positioned to contact the fabric-presenting product <NUM> to facilitate extraction of the fluid <NUM> therefrom. For example, in reference to <FIG>, a suction head 10A includes a plurality of piezoelectric elements <NUM> aligned in a row <NUM> held therein by a base 12A. The suction head <NUM> further includes an inlet 114A into a suction chamber 16A and a second inlet <NUM> into the suction chamber 16A. The plurality of piezoelectric elements <NUM> are disposed between the inlet <NUM> and the second inlet <NUM>, and the row <NUM> is parallel to both the inlet <NUM> and the second inlet <NUM>. The suction head <NUM> further includes agitators <NUM> in the form of bristles.

Example <NUM>- For Example <NUM>, <NUM> grams of water was added to fabric-presenting product, in particular a carpet. A suction head not of the present disclosure (e.g., not including a piezoelectric element) was attached to a suction source. The suction head with the suction source activated was then passed over the carpet in a single extraction stroke. A down force of <NUM> pounds was applied to the suction head during the single extraction stroke. After the single extraction stroke, <NUM> grams of water remained on the carpet, meaning that the single extraction stroke had extracted <NUM>% of the water initially added to the fabric-presenting product.

The suction head not of the present disclosure was then replaced with a suction head of the present disclosure including a plurality of piezoelectric elements. Both the plurality of piezoelectric elements and the suction source were activated. The suction head was then passed over the carpet in four extraction strokes. The same down force of <NUM> pounds was applied during the extraction strokes. After the four extraction strokes, <NUM> grams of water remained in the carpet, meaning that the suction head extracted an additional <NUM>% of the water initially added to the carpet.

Example <NUM> - For Example <NUM>, <NUM> grams of water was added to a fabric-presenting product, in particular, a cushion similar to that used on a typical couch. The weight of water remaining as a function of time was measured. From the measured weight, the volume of water lost due to evaporation was calculated to provide a baseline. After <NUM> minutes, <NUM> of water had evaporated.

Next, about <NUM> grams of water was added to another cushion. A suction head of the present disclosure with a single piezoelectric element was then applied to the couch with a down force of <NUM> grams. A suction source was not activated to determine the extraction capability of the single piezoelectric element alone. The weight of water remaining as a function of time was measured. From the measured weight, the volume of water extracted was calculated. The volume of water extracted was then plotted as a function of time in the graph reproduced at <FIG>. The line 2A represents the data for the single piezoelectric element. After <NUM> minutes, for example, the single piezoelectric element extracted <NUM> of water from the cushion, which is a marked increase over the <NUM> baseline of evaporative loss.

Claim 1:
A suction head (<NUM>) for an extraction cleaner (<NUM>) comprising:
a base (<NUM>) forming a suction chamber (<NUM>) and a suction outlet (<NUM>) in fluid communication with the suction chamber (<NUM>); and
a piezoelectric element (<NUM>) coupled to the base (<NUM>), the piezoelectric element (<NUM>) comprising a first surface (<NUM>) open to the suction chamber (<NUM>), a second surface (<NUM>) facing an external environment (<NUM>) away from the suction chamber (<NUM>), a thickness (<NUM>) between the first surface (<NUM>) and the second surface (<NUM>), and a through-via (<NUM>) through the thickness (<NUM>) open at both the first surface (<NUM>) and the second surface (<NUM>).