Patent Description:
Surface cleaning apparatuses such as vacuum cleaners are well-known devices for removing dirt and debris (which can include dirt, dust, soil, hair, and other debris) from a variety of surfaces such as soft flooring including carpets and rugs, hard or bare flooring, including tile, hardwood, laminate, vinyl, and linoleum, or other fabric surfaces such as upholstery. Such surface cleaning apparatuses typically include a user control portion, which can include a user interface or at least one control button or switch, and a surface cleaning portion operably coupled to the user control portion. The user control portion and the surface cleaning portion can be located remotely from one another within the surface cleaning apparatus and operably coupled via at least one of a power line or a communications line.

<CIT> describes a power line communication system for controlling a function or operation of at least one component of a surface cleaning device, wherein a controller is located remotely from the at least one user control. The controller and the user control are both provided along a portion of the main body of the cleaning system.

Documents <CIT>, <CIT> and <CIT> describe in a similar manner as <CIT> mentioned above cleaning devices with a power line communication system.

Further developments are given in the dependent claims.

The invention further relates to a method of communication for a surface cleaning apparatus under use of a powerline communication system as in the invention, the method including outputting power via a DC battery-powered source through a power line, receiving a user input at a user control, generating an input to a toggle switch based on the receiving the user input, outputting a pulse width modulation signal along the power line to a controller during the outputting power and operating, via the controller, a component of the surface cleaning apparatus based on the pulse width modulation signal.

The present invention relates to a method of communication within a surface cleaning apparatus. The method of communication can be used within a variety of surface cleaning apparatuses having a power source connected to a remote processor via a power line. Non-limiting examples of such suitable surface cleaning apparatuses for cleaning debris from a surface include a portable or handheld surface cleaner, which can be in the form of a stick vacuum or wand vacuum, an upright vacuum cleaner, a canister cleaner, a cordless surface cleaner, including a stick cleaner, sweeper, or mop, an autonomous or robotic surface cleaner, an extraction cleaner, steam and hard floor cleaners, lift-off upright to portable cleaners, or commercial surface cleaners.

<FIG> is a schematic illustration of various functional systems of a surface cleaning apparatus <NUM>. The surface cleaning apparatus <NUM> can include a user control portion 2a and a surface cleaning portion 2b. The surface cleaning portion 2b is the portion of the surface cleaning apparatus <NUM> that contacts the surface to be cleaned for the removal of dirt and debris from the surface. In one example, the surface cleaning portion 2b can be a foot or base of a surface cleaning apparatus <NUM>. The user control portion 2a can be any portion of the surface cleaning apparatus <NUM> that includes at least one user control <NUM> for receiving a user input to control various features of the surface cleaning apparatus <NUM>. Non-limiting examples of such an at least one user control include a user interface, buttons, switches, and mode selectors.

The user control portion 2a and the surface cleaning portion 2b can be located remotely from one another. The term remote includes that they are spaced apart within the surface cleaning apparatus <NUM>. By way of non-limiting example, the remotely located user control portion 2a and surface cleaning portion 2b can be provided as a user control portion 2a provided on a handle or an upright portion of a surface cleaner while the surface cleaning portion 2b is the base or foot of a surface cleaner, a user control portion 2a provided at a handle with a surface cleaning portion 2b provided on a canister, or a user control portion 2a on a top surface of an autonomous or robotic surface cleaner and a surface cleaning portion 2b at a floor-contacting lower surface of the autonomous or robotic surface cleaner. The user control portion 2a can be operably coupled to a power source <NUM> for powering the various operational features of the surface cleaning apparatus <NUM>, including features provided with or located on the surface cleaning portion 2b. In one aspect, the power source <NUM> can be located adjacent to or near the user control portion 2a, and spaced apart from or remotely from the surface cleaning portion 2b. The surface cleaning portion 2b can include a controller or processor <NUM> for receiving control information and power from the power source <NUM>.

The power source <NUM> can be operably coupled to the processor <NUM> on the surface cleaning portion 2b by a power line <NUM>. In one aspect, the power line <NUM> can be a DC power line. The processor <NUM> can be any suitable processor <NUM> capable of receiving communication from the power line <NUM>, non-limiting examples of which include a microcontroller unit (MCU), a printed circuit board (PCB) or printed circuit board assembly (PCBA), or other basic processor <NUM>. The power line <NUM> can couple to the processor <NUM> by any suitable power connector, such as a two pin connector. While the power line <NUM> is illustrated as the only connection between the user control portion 2a and the surface cleaning portion 2b it will be understood that other components, fluid pathways, etc. can link the user control portion 2a and the surface cleaning portion 2b.

In a conventional surface cleaning apparatus <NUM>, when the user control portion 2a and the surface cleaning portion 2b are located remotely from one another or spaced apart from one another within the surface cleaning apparatus <NUM>, a communications line, separate from the power line <NUM>, is provided to convey control signals from the user control portion 2a to the surface cleaning portion 2b. The inclusion of a communications line results in added cost of manufacturing the surface cleaning apparatus <NUM>. In the aspects of the present disclosure, an apparatus and method are provided that allow for control signals to be provided from the user control portion 2a and the power source <NUM> to the surface cleaning portion 2b and the processor <NUM> via the power line <NUM> itself, without the need for an additional communications line.

<FIG> is a schematic illustration of the communication apparatus for the surface cleaning apparatus <NUM> and which allows for control signals to be provided from the user control portion 2a and the power source <NUM> to the surface cleaning portion 2b and the processor <NUM> via the power line <NUM> itself. A powerline communication system for a DC battery-powered surface cleaning device wherein a DC powerline that connects a "remote" power source and user control (e.g. in handle) to a processor and one or more electrically powered components in a surface cleaning portion (e.g. the foot) is also used to communicate signals between the user control and processor.

In this example, the at least one user control <NUM> is illustrated, by way of non-limiting example, as a mode selector 3a by which a user can select between cleaning modes of operation of the surface cleaning apparatus <NUM>. The mode selector 3a can selectively occupy one of a first position 3b, a second position 3c, a third position 3d, or a fourth position 3e, by way of non-limiting examples, to select the different desired mode of operation. Such positions have been schematically illustrated as boxes for illustrative purposes. By way of non-limiting example, the modes of operation to be selected from can include an auto sensing mode, a carpet mode, a hard floor mode, or an edge mode. In one example, one mode of operation can correspond to each of the first position 3b, second position 3c, third position 3d, and fourth position 3e of the mode selector 3a.

The mode selector 3a is operably coupled with a toggle switch <NUM> provided within the surface cleaning apparatus <NUM>, which can be any suitable toggle switch <NUM>, a non-limiting example of which includes a solid-state switch. The toggle switch <NUM> receives an input from the mode selector 3a via the power line <NUM>, the input from the mode selector 3a indicative of the mode selected by the user. The toggle switch <NUM> is, in turn, operably coupled with the processor <NUM> via the power line <NUM>, such that the toggle switch <NUM> can then introduce a pulse width modulation (PWM) signal to the processor <NUM> over the power line <NUM>, the PWM signal provided to the processor <NUM> via the power line <NUM> corresponding to the mode input received by the toggle switch <NUM> from the mode selector 3a. In this way, the mode selected by the user at the mode selector 3a generates an input to the toggle switch <NUM> that determines the pulse width of the PWM signal then provided from the toggle switch <NUM> to the processor <NUM> to cause an operation at the surface cleaning portion 2b that corresponds to the mode selected by the user via the mode selector 3a.

During normal operation of the surface cleaning apparatus <NUM>, when the toggle switch <NUM> is not introducing a PWM signal over the power line <NUM>, the signal transmitted over the power line <NUM> from the user control portion 2a to the processor <NUM> of the surface cleaning portion 2b is typically high or uninterrupted, and can be thought of as representing <NUM>% power transmission via the power line <NUM> and this is schematically illustrated with a line indicated as 6e. When a communication signal is transmitted from the user control to provide an input indicating a different mode of operation to the toggle switch <NUM>, the toggle switch <NUM> is prompted to introduce or toggle the PWM signal over the power line <NUM>. PWM is a method of communication by generating a pulsing signal. In this example, the toggle switch <NUM> generates the pulsing signal to be transmitted via the power line <NUM>. The pulse width of the PWM signal encodes the communication signal either by the duty cycle of the PWM signal or the frequency of the PWM signal.

During normal operation of the surface cleaning apparatus <NUM>, when the toggle switch <NUM> is not introducing a PWM signal over the power line <NUM>, the <NUM>% power transmission, illustrated schematically at 6e, via the power line <NUM> defines a regular interval or period of current supplied through the power line <NUM>. When the toggle switch <NUM> is prompted to introduce the PWM signal that is transmitted to the power line <NUM>, the power signal is pulsed, such that the 'on' time of the power supply is less than <NUM>% power transmission, or less than the regular interval or period of current. The term duty cycle refers to the proportion or percentage of 'on' time of the PWM signal to the regular interval or period of the power transmitted through the power line <NUM>. A low duty cycle corresponds to low power, because the power is off for a greater percentage of the time than it is on. A high duty cycle corresponds to high power, because the power is on for a greater percentage of the time than it is off. For example, a duty cycle of <NUM>% refers to a power signal that is on half the time and off half the time. The frequency of the PWM signal is simply the inverse of the pulse width.

In response to the mode of operation input provided from the mode selector 3a to the toggle switch <NUM>, the duty cycle generated by the PWM signal from the toggle switch <NUM> can provide an input to the processor <NUM> of the surface cleaning portion 2b, the processor <NUM> configured to affect a particular function at the surface cleaning portion 2b in response to the characteristics of the PWM signal received. The function effected by the processor <NUM> can also or alternately include control of a component <NUM> provided at the surface cleaning portion 2b that is operably coupled with the processor <NUM> to be controlled by the processor <NUM> in response to the PWM signal received at the processor <NUM>. In the illustrated example where the user control <NUM> is a mode selector 3a with multiple positions corresponding to different modes of operation, it is contemplated that, by way of non-limiting example, an <NUM>% duty cycle 6d can provide an input to the processor <NUM> to indicate that the surface cleaning portion 2b should be operated in the auto sensing mode, a <NUM>% duty cycle 6c can provide an input to the processor <NUM> to indicate that the surface cleaning portion 2b should be operated in the carpet mode, a <NUM>% duty cycle 6b can provide an input to the processor <NUM> to indicate that the surface cleaning portion 2b should be operated in the hard floor mode, and a <NUM>% duty cycle 6a can provide an input to the processor <NUM> to indicate that the surface cleaning portion 2b should be operated in the edge mode. While the 6a-6e power transmissions have been separately shown for illustrative purposes it will be understood that such transmissions are all over the same power line <NUM>.

While the example described herein refers to selecting a mode of operation for the surface cleaning apparatus <NUM>, it will be understood that the method of communicating via the power line <NUM> can be used to control any function or component <NUM> of the surface cleaning apparatus <NUM> that is provided at the surface cleaning portion 2b, non-limiting examples of which include modes of operation, an agitator, a dusting assembly, a fluid distributor, a steam generator, sensors, such as an ultrasonic floor-type sensor, and mechanically actuated features, such as a lift or a door that can raise or lower the height of the surface cleaning portion 2b relative to the surface to be cleaned, which can be selected based on a floor type detected. Any suitable function or component can be controlled such that the PWM signal input sensed by the processor <NUM> signals the processor <NUM> to effect a change or an action at the surface cleaning portion 2b.

In addition to reducing cost and complexity of the surface cleaning apparatus <NUM> by obviating the need for a separate communications line between the user control portion 2a and the surface cleaning portion 2b in addition to the power line <NUM>, another advantage of the communication method via the power line <NUM> described herein is that the power transmitted via the power line <NUM> is essentially uninterrupted to the surface cleaning portion 2b. The toggle switch <NUM> generates the PWM signal to the power line <NUM>, but the PWM signal makes up a small voltage compared to the total voltage generated by the power source <NUM>, as well as modulating the pulse width only for a percentage of the time, such that the power to the processor <NUM> is essentially uninterrupted as far as the load at the surface cleaning portion 2b. Thus, the PWM signal can be used to provide communication via the power line <NUM> without significantly hampering the ability of the power line <NUM> to provide the necessary power to the surface cleaning portion 2b from the power source <NUM>. Further yet, voltage dividers, such as a potential divider or a resistor voltage divider, can be operably coupled with the power line <NUM> or the processor <NUM> to knock down the voltage of the signal to a suitable level that can be sensed or read by the processor <NUM>.

Referring now to <FIG> and <FIG>, there is shown a schematic view of a vacuum cleaner <NUM> and a perspective view of the vacuum cleaner <NUM>, respectively, that can include the communication apparatus and method as described above, according to aspects of the present disclosure. The vacuum cleaner <NUM> is shown herein as a stick-type vacuum cleaner, with a housing including an upper unit <NUM> coupled with a base unit <NUM> adapted to be moved over a surface to be cleaned S. The vacuum cleaner <NUM> can alternatively be configured as an upright-type vacuum cleaner, a canister-type vacuum cleaner, or a hand-held vacuum cleaner. Furthermore, the vacuum cleaner <NUM> can additionally be configured to distribute a fluid and/or to extract a fluid, where the fluid may for example be liquid or steam.

The upper unit <NUM> is pivotally mounted to the base unit <NUM> for movement between an upright storage position, shown in <FIG>, and a reclined use position (not shown). The vacuum cleaner <NUM> can be provided with a detent mechanism, such as a pedal pivotally mounted to the base unit <NUM>, for selectively releasing the upper unit <NUM> from the storage position to the use position. The details of such a detent pedal are known in the art, and will not be discussed in further detail herein.

The upper unit <NUM> can include a vacuum collection system for creating a partial vacuum to suck up debris (which may include dirt, dust, soil, hair, and other debris) from the surface to be cleaned S and collecting the removed debris in a space provided on the vacuum cleaner <NUM> for later disposal.

The upper unit <NUM> includes a suction source <NUM> in fluid communication with the base unit <NUM> for generating a working airstream and a separating and collection assembly <NUM> for separating and collecting debris (which can be solid, liquid, or a combination thereof) from the working airstream for later disposal. The upper unit <NUM> further includes a handle <NUM> to facilitate movement of the vacuum cleaner <NUM> by a user. A handle coupler <NUM> can receive the proximal end of the handle <NUM>, which may be fixed with respect to the upper unit <NUM>, or may pivot to allow the handle <NUM> to rotate or fold about a horizontal axis relative to the upper unit <NUM>. As illustrated, the handle <NUM> is pivotally mounted to the upper unit <NUM> via handle coupler <NUM> for movement between an upright position, shown in <FIG>, and a folded position, shown in <FIG>. The handle <NUM> may further include the power switch <NUM> as well as other controls and indicators used during operation. The handle <NUM> may further include a handle grip <NUM> opposite the handle coupler <NUM>.

In one configuration illustrated herein, the collection assembly <NUM> can include a cyclone separator <NUM> for separating contaminants from a working airstream and a removable debris cup <NUM> for receiving and collecting the separated contaminants from the cyclone separator <NUM>. The cyclone separator <NUM> can have a single cyclonic separation stage, or multiple stages. In another configuration, the collection assembly <NUM> can include an integrally formed cyclone separator <NUM> and debris cup <NUM>, with the debris cup <NUM> being provided with a structure, such as a bottom-opening debris door, for contaminant disposal. It is understood that other types of collection assemblies <NUM> can be used, such as a centrifugal separator, a bulk separator, a filter bag, or a water-bath separator. The upper unit <NUM> can also be provided with one or more additional filters <NUM> upstream or downstream of the separating and collection assembly <NUM> or the suction source <NUM>.

The suction source <NUM>, such as a motor/fan assembly, is provided in fluid communication with the separating and collection assembly <NUM>, and can be positioned downstream or upstream of the separating and collection assembly <NUM>. The suction source <NUM> can be electrically coupled to a power source <NUM>, such as a battery or by a power cord plugged into a household electrical outlet. A suction power switch <NUM> disposed between the suction source <NUM> and the power source <NUM> can be selectively closed by the user upon pressing a vacuum power button <NUM>, thereby activating the suction source <NUM>. As shown herein, the suction source <NUM> is downstream of the separating and collection assembly <NUM> for a `clean air' system; alternatively, the suction source <NUM> can be upstream of the separation and collection assembly <NUM> for a 'dirty air' system.

In another configuration, the separation and collection assembly <NUM>, suction source <NUM>, filters <NUM>, power source <NUM> and power switch <NUM> may all be disposed within a removable hand-held unit <NUM> which is removable from the upper unit <NUM>. When disposed in the upper unit <NUM>, the hand-held unit <NUM> provides the separation and collection assembly <NUM>, suction source <NUM>, filters <NUM> and power source <NUM> for the vacuum cleaner <NUM>. When removed from the upper unit <NUM>, the hand-held unit <NUM> may operate independently from the upper unit <NUM> to create partial vacuum to suck up debris (which may include dirt, dust, soil, hair, and other debris) from the surface to be cleaned S. It is noted that features of the present disclosure may be applicable to vacuum cleaners not having a hand-held unit.

The base unit <NUM> is in fluid communication with the suction source <NUM> for engaging and cleaning the surface to be cleaned S. The base unit <NUM> includes a base housing <NUM> having a suction nozzle <NUM> at least partially disposed on the underside and front of the base housing <NUM>. The base housing <NUM> can secure an agitator <NUM> within the base unit <NUM> for agitating debris on the surface to be cleaned S so that the debris is more easily ingested into the suction nozzle <NUM>. Some examples of agitators <NUM> include, but are not limited to, a rotatable brushroll, dual rotating brushrolls, or a stationary brush. The agitator <NUM> illustrated herein is a rotatable brushroll positioned within the base unit <NUM> adjacent the suction nozzle <NUM> for rotational movement about an axis X, and can be coupled to and driven by a dedicated agitator motor provided in the base unit <NUM> via a commonly known arrangement including a drive belt. Alternatively, the agitator <NUM> can be coupled to and driven by the suction source <NUM> in the upper unit <NUM>. It is within the scope of the present disclosure for the agitator <NUM> to be mounted within the base unit <NUM> in a fixed or floating vertical position relative to the base unit <NUM>.

The vacuum cleaner <NUM> can be used to effectively clean the surface to be cleaned S by removing debris (which may include dirt, dust, soil, hair, and other debris) from the surface to be cleaned S in accordance with the following method. The sequence of steps discussed is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be divided into multiple steps, without detracting from the aspects of the present disclosure.

To perform vacuum cleaning in the canister configuration shown in <FIG>, the suction source <NUM> is coupled to the power source <NUM> and draws in debris-laden air through the base unit <NUM> and into the separating and collection assembly <NUM> where the debris is substantially separated from the working air. The air flow then passes through the suction source <NUM>, and through any optional filters <NUM> positioned upstream and/or downstream from the suction source <NUM>, prior to being exhausted from the vacuum cleaner <NUM>. During vacuum cleaning, the agitator <NUM> can agitate debris on the surface to be cleaned S so that the debris is more easily ingested into the suction nozzle <NUM>. The separating and collection assembly <NUM> can be periodically emptied of debris. Likewise, the optional filters <NUM> can periodically be cleaned or replaced.

<FIG> is the base unit <NUM> from <FIG> according to aspects of the present invention with portions of the base housing <NUM> removed. The base housing <NUM> encloses components of the base unit <NUM> to create a partially enclosed space therein. The agitator <NUM> is provided at a forward portion of the base housing <NUM>. The base housing <NUM> can also include a sole plate <NUM> fastened to the underside of the base housing <NUM> to secure the agitator <NUM> within the base housing <NUM> and define the suction nozzle <NUM>.

The suction nozzle <NUM> includes a suction nozzle opening defined by an underside suction nozzle opening <NUM> formed in the underside of the sole plate <NUM> and a front suction nozzle opening <NUM> formed in the front of the sole plate <NUM> and front the base housing <NUM>. The suction nozzle openings <NUM>, <NUM> are in fluid communication with a duct <NUM> coupled at one end to the base housing <NUM>, which fluidly communicates the suction nozzle openings <NUM>, <NUM> with the collection assembly <NUM> (<FIG>). It will be understood that the underside suction nozzle opening <NUM> and the front suction nozzle opening <NUM> may be formed from a single opening in the sole plate <NUM> and may be considered to be a single opening. Alternatively, the suction nozzle openings <NUM>, <NUM> may be considered to be separate openings wherein the suction nozzle <NUM> may be provided with at least one of the underside suction nozzle opening <NUM> or the front suction nozzle opening <NUM>.

Referring now to <FIG>, the base unit <NUM> can further include a suction nozzle opening diverter assembly <NUM> including a diverting member <NUM>, two pivoting members <NUM>, a solenoid piston <NUM>, a diverter biasing spring <NUM> and edge illuminators <NUM> configured to selectively restrict a portion of the suction nozzle <NUM> and provide illumination when the restricting occurs. The diverter member <NUM> extends along the front of the base housing <NUM> between the front vertical edges of two vertical side walls <NUM> with a middle portion bottom edge <NUM> of the diverter member <NUM> defining the upper boundary of the front suction nozzle opening <NUM> and the upper edge of the diverter member <NUM> in communication with a front portion of the base housing <NUM> (best seen in <FIG> and <FIG>). Opposing diverter member ends <NUM> are elevated upward with respect the diverter member middle <NUM> such that the end portion bottom edges <NUM> of the diverter member ends <NUM> are elevated higher than the middle portion bottom edge <NUM> of the diverter member middle <NUM>.

The two pivoting members <NUM> extend substantially perpendicularly from the diverter member <NUM> along the sides of the base housing <NUM> towards the rear of the base housing <NUM>. The pivoting members <NUM> are provided with an aperture <NUM> that receives a horizontal pin (not shown) disposed in the base housing <NUM> for pivotally mounting the pivoting members <NUM> to the base housing <NUM> wherein the two apertures <NUM> axially align, defining a pivot axis Y. Alternatively, a pin may be provided on the pivoting members <NUM> and an aperture for receiving the axles in the base housing <NUM>. The rear end of at least one pivoting members <NUM> is further provided with a spring mount <NUM> and a diverter end portion <NUM> having an inverted diverter end wedge <NUM> disposed on the lower side of the diverter end portion <NUM> sloping upwardly towards the solenoid piston <NUM>.

The solenoid piston <NUM> is disposed in the rear of the base housing <NUM> and is configured to selectively engage at least one of the pivoting members <NUM>. The solenoid piston <NUM> is of conventional design and includes a stationary housing <NUM> having an inductive coil (not shown) mounted therein, connected to a power supply, and configured to surround a piston <NUM> having a cone-shaped termination cap <NUM>. The solenoid piston <NUM> is selectively movable between a horizontally extended position and a retracted position when the inductive coil is alternately energized and de-energized wherein the termination cap <NUM> is in communication with the diverter end wedge <NUM> of the diverter end portion <NUM> when extended and not in communication when retracted.

The edge illuminators <NUM> are mounted in the base housing <NUM> along the two vertical side walls <NUM> behind light transmitting screens <NUM> which may form a portion of the vertical side walls <NUM> such that light illuminated from the edge illuminators <NUM> pass through the light transmitting screens <NUM>. The edge illuminators <NUM> can be selected from known constructions, including light emitting diodes (LED) or incandescent lamps, for example. The edge illuminators <NUM> are of conventional construction and include at least one lens (not shown), at least one light emitting element (LED) (not shown), a printed circuit board (PCB) <NUM> and electrical leads <NUM>.

Referring now to <FIG>, electrical conductor leads <NUM> extend from the solenoid piston <NUM> and the edge illuminators <NUM> electrical leads <NUM>, routing through the base unit <NUM> through the upper unit <NUM> and handle <NUM>, and are connected to an electrical switch <NUM> housed in the handle <NUM>. The electrical switch <NUM> is, in turn, connected to a power source <NUM> to selectively energize the solenoid piston <NUM> and edge illuminators <NUM>. In this manner it will be understood that the It will be understood that the electrical leads and electrical conductor leads form a power line. The electrical switch <NUM> may be operatively coupled to a conventional push button <NUM> disposed in the front portion of the handle <NUM> as illustrated or a "rocker" or toggle switch <NUM> (<FIG>) as is commonly known in the art can be included on a portion of the power line such that it becomes selectively engaged when a user engages the push button <NUM>.

An optional visual indicator, such as an indicator light <NUM>, may be mounted to upper portion of the handle <NUM> for indicating when the solenoid piston <NUM> and edge illuminators <NUM> have been activated. The indicator light <NUM> can be selected from known constructions, including light emitting diodes (LED) or incandescent lamps, for example. The indicator light <NUM> is of conventional construction and includes a lens (not shown), a light emitting element (LED) (not shown), and electrical leads (not shown) connected in series with the electrical switch <NUM>, solenoid piston <NUM> and edge illuminators <NUM>.

It will be understood that the operation of the vacuum cleaner <NUM> can be controlled via one or more controllers <NUM> (<FIG>) operatively coupled with one or more components of the vacuum cleaner <NUM>. For example, a controller can be operably coupled with the agitator <NUM> and suction source <NUM> to adjust the rotation of the agitator <NUM> or operation of the suction source <NUM>. The controller (<FIG>) can include a printed circuit board (PCB) operably coupled with a user interface or user control. Alternatively, the controller can be a portion of the component itself such a motor controller.

<FIG> shows a cross section of the diverter assembly <NUM> and solenoid piston <NUM> of <FIG> taken along line V-V and more clearly illustrates the interaction between the termination cap <NUM> and the diverter end wedge <NUM>. The cone shape of the termination cap <NUM> forms a piston wedge <NUM> sloping towards the diverter end portion <NUM>. The piston wedge <NUM> is in register with, but does not fully engage the diverter end wedge <NUM> when the piston <NUM> of the solenoid piston <NUM> is in the retracted position as illustrated. When the piston <NUM> is extended, the piston wedge <NUM> engages the diverter end wedge <NUM>.

The piston wedge <NUM> converts the horizontal force of the piston <NUM> into a force perpendicular to the piston wedge <NUM> having horizontal and vertical components and imparts it to the diverter end wedge <NUM>. As the piston <NUM> extends, the diverter end wedge <NUM> and piston wedge <NUM> slip relative to each other such that the diverter end portion <NUM> pivots upward about the pivot axis Y. When the piston <NUM> is again retracted, the piston wedge <NUM> and the diverter end wedge <NUM> disengage and the diverter end portion <NUM> pivots downwards due to the tension force of the diverter biasing spring <NUM> shown in <FIG>. The movement of the piston <NUM> and diverter end portion <NUM> are schematically illustrated by arrows <NUM>. It will be understood that the forces imparted on the diverter end wedge <NUM> by the solenoid piston <NUM> when the piston <NUM> is extended may be optimized to overcome all resistive forces such as friction, weight and spring tension in order provide for upward movement of the diverter end portion <NUM>. It will also be understood that the diverter biasing spring <NUM> may have a spring rate that is optimized to overcome all resistive forces such as friction and weight in order to provide for downward movement of the diverter end portion <NUM> when the piston <NUM> is retracted.

Referring again to <FIG>, the diverter member <NUM> is configured to selectively pivot about the pivot axis Y so as to move upwards and downwards to selectively restrict a portion of the suction nozzle <NUM>, thereby increasing the suction force through the unrestricted portion, given that the same volume of air is being drawn through a smaller opening. The upward movement of the diverter end portion <NUM> caused by the piston <NUM> extending and the downward movement of the diverter end portion <NUM> caused by the diverter biasing spring <NUM> when the piston <NUM> is retracted causes the diverter assembly <NUM> to pivot about the pivot axis Y such that the diverter member <NUM> pivots downward and upward respectively as schematically illustrated by arrows <NUM>.

Referring to <FIG>, according to aspects of the present disclosure where like elements from the previous disclosure are identified with the same reference numerals and include a prime (') symbol, the solenoid piston <NUM> and indicator light <NUM> of the first aspect are replaced with a foot actuated pedal assembly <NUM>. The pedal assembly <NUM> includes a mode indicator <NUM>, a pivoting pedal <NUM>, a pedal biasing spring <NUM>, a sliding wedge <NUM> and sliding wedge biasing spring <NUM>. The pedal assembly <NUM> is disposed in the rear of the base housing <NUM>' and is configured to selectively engage at least one of the pivoting members <NUM>'. The base housing <NUM>' may also include a pedal recess <NUM> formed in the rear vertical side of the base housing <NUM>' such that a portion of the pedal <NUM> may pass through the pedal recess <NUM> as well as an indicator recess <NUM> formed in the rear of the upper horizontal side of the base housing <NUM>' such that the indicator recess <NUM> may be selectively covered by a portion of the mode indicator <NUM>.

The pivoting pedal <NUM> includes an actuating surface <NUM> connected to a cylindrical axle <NUM> by an arm member <NUM>. The actuating surface <NUM> is configured to be depressed by a user's foot. The cylindrical axle <NUM> is pivotally mounted to the base housing <NUM>' with the centerline of the cylindrical axle <NUM> substantially parallel to the pivot axis Y'. The arm member <NUM> extends between the actuating surface <NUM> and the cylindrical axle <NUM> such that the actuating surface <NUM> is disposed above and behind the cylindrical axle <NUM>, and includes a vertical protrusion <NUM> extending upwards from the top surface of the arm member <NUM> adjacent to the actuating surface <NUM>. The arm member <NUM> also includes an arm wedge <NUM> (shown in <FIG>) provided on the underside of the arm member <NUM> which slopes toward the diverter end portion <NUM>' of the pivoting member <NUM>'.

The pivoting pedal <NUM> is configured to selectively rotate about the cylindrical axle <NUM> axis between an up position wherein the upper portion of the arm member <NUM> is in contact with the upper boundary of the pedal recess <NUM> and a down position wherein the lower surface of the arm member <NUM> is in contact with the lower boundary of the pedal recess <NUM>. The pedal biasing spring <NUM> is attached to the cylindrical axle <NUM> and the base housing <NUM>' and provides torsion to the cylindrical axle <NUM> so as to bias the pivoting pedal <NUM> to the up position. The pedal assembly <NUM> may further include a detent mechanism for selectively securing the pivoting pedal <NUM> in the down position. The details of such a detent mechanism are known in the art, and will not be discussed in further detail herein.

The mode indicator <NUM> includes an L-shaped indicating portion <NUM> connected to a body portion <NUM>. The horizontal surface of the indicating portion <NUM> is configured to selectively cover the indicator recess <NUM> and the vertical surface of the indicating portion extends downward and connects to the rear of the body portion <NUM>. The body portion <NUM> includes a guide slot <NUM> extending horizontally, perpendicular to the pivot axis Y'. As seen in <FIG>, the guide slot <NUM> is configured to receive a stationary screw <NUM> wherein the screw head <NUM> abuts the underside of the body portion <NUM> and the screw shaft <NUM> extends through the guide slot <NUM> and attaches to the base housing <NUM>' (not shown) to slidably secure the mode indicator <NUM> to the base housing <NUM>'. The body portion <NUM> may further include a hollow cylindrical spring holder <NUM> (<FIG>) configured to receive one end of an indicator biasing spring (not shown) wherein the other end of the spring is attached to the base housing <NUM>'. The indicator biasing spring exerts a horizontal force on the mode indicator <NUM> such that the rear of the body portion <NUM> is biased against the forward portion of the vertical protrusion <NUM> (<FIG>).

As the pivoting pedal <NUM> is pivoted to the down position, the vertical protrusion <NUM> pivots down and away from the mode indicator <NUM> allowing the mode indicator <NUM> to move towards the rear of the base housing <NUM>' under the spring force of the indicator biasing spring (not shown) until the stationary screw <NUM> abuts the forward portion of the guide slot <NUM> such that the horizontal surface of the indicator portion <NUM> covers the indicator recess <NUM> formed in the base housing <NUM>'. When the pivoting pedal <NUM> is returned to the up position, the vertical protrusion <NUM> engages the mode indicator <NUM> and moves it forward such that the horizontal surface of the indicating portion <NUM> does not cover the indicator recess <NUM>.

The sliding wedge <NUM> forms an elongated structure extending parallel to the pivot axis Y' wherein one side of the sliding wedge <NUM> forms a sliding pedal wedge <NUM> and spring mount <NUM>, and the opposing side forms a sliding diverter wedge <NUM>. The sliding pedal wedge <NUM> slopes downwardly and away from the diverter end portion <NUM>' and is disposed beneath the arm wedge <NUM> (<FIG>) of the pivoting pedal <NUM>. The sliding diverter wedge <NUM> slopes downwardly and towards the diverter end portion <NUM>' and is adjacent to the diverter end wedge <NUM>' of the diverter end portion <NUM>'. The spring mount <NUM> is formed at the bottom of the sliding pedal wedge <NUM> and is configured to attach to one end of the sliding wedge biasing spring <NUM>. The opposite end of the spring <NUM> is attached to the base housing <NUM>'.

The sliding wedge <NUM> is configured to linearly slide along the bottom of the base housing <NUM>' towards and away from the diverter end portion <NUM>' along an axis parallel to the pivot axis Y'. The base housing <NUM>' may include a track or guide to ensure a linear sliding path. The sliding wedge biasing spring <NUM> is configured to bias the sliding wedge <NUM> away from the diverter end portion <NUM>'.

The switch <NUM>' may be disposed in the base housing <NUM>' wherein the switch is, in turn, connected to power source <NUM>' to selectively energize edge illuminators <NUM>'. The switch <NUM>' may be configured such that actuating the pivoting pedal <NUM> to the down position energizes the edge illuminators <NUM>'. Alternatively, a sensor may be provided in the base housing <NUM>' to sense when the pivoting pedal <NUM> has been actuated and activate the switch <NUM>', thereby energizing the edge illuminators <NUM>'.

<FIG> shows a cross section of the diverter assembly <NUM>' and pedal assembly <NUM> of <FIG> taken along line VIII-VIII of <FIG> and more clearly illustrates the interaction between the pivoting pedal <NUM>, the sliding wedge <NUM> and the diverter end wedge <NUM>' of the diverter end portion <NUM>'. The arm wedge <NUM> on the pedal <NUM> is disposed above and in register, but not fully engaged with the sliding pedal wedge <NUM> when the pivoting pedal <NUM> is in the up position as illustrated. When the pivoting pedal <NUM> is depressed to the down position, the arm wedge <NUM> converts the downward force of the pivoting pedal <NUM> into a force perpendicular to the arm wedge <NUM> having horizontal and vertical components and imparts it to the sliding pedal wedge <NUM>. As the pivoting pedal <NUM> travels downward, the arm wedge <NUM> and the sliding pedal wedge <NUM> slip relative to each other such that the sliding wedge <NUM> moves horizontally and the sliding diverter wedge <NUM> engages the diverter end wedge <NUM>' of the diverter end portion <NUM>'. The sliding diverter wedge <NUM> converts the horizontal force of the sliding wedge <NUM> into a force perpendicular to the piston wedge <NUM> having horizontal and vertical components and imparts it to the diverter end wedge <NUM>'. As the sliding wedge <NUM> continues sliding, the diverter end wedge <NUM>' and sliding diverter wedge <NUM> slip relative to each other such that the diverter end portion <NUM>' pivots upward about the pivot axis Y'. When the pivoting pedal <NUM> is again returned to the up position, the sliding wedge <NUM> slides away from the diverter end portion <NUM>' under the tension force of the sliding wedge biasing spring <NUM> such that the sliding diverter wedge <NUM> and diverter end wedge <NUM>' disengage and the diverter end portion <NUM>' pivots downwards due to the tension force of the diverter biasing spring <NUM>' shown in <FIG>. The movement of the pivoting pedal <NUM>, sliding wedge <NUM> and diverter end portion <NUM>' are schematically illustrated by arrows <NUM>. It will be understood that the biasing springs may have spring rates that are optimized to overcome all resistive forces such as friction, weight and spring tension in order to provide for upward and downward movement of the diverter end portion <NUM>' when pivoting pedal <NUM> is in the down or up position respectively.

The operation of the diverter assembly <NUM> will now be described with respect to the first aspect of the base unit <NUM> shown in <FIG>. However, it is noted that the diverter assembly <NUM>' of the second aspect of the base unit <NUM>' shown in <FIG> operates in a similar manner, and so the following description of <FIG> also applies for the second aspect.

<FIG> shows a perspective view of the base unit <NUM> with the diverter member <NUM> in an up position. The base housing <NUM> may further include a diverter recess <NUM> (best seen in <FIG>) configured to receive the diverter member <NUM> such that the base housing front portion <NUM> is flush with the front surface of the diverter member <NUM> as shown. During operation, the diverter member <NUM> in the up position allows debris laden air to be drawn into the base unit <NUM> through the front suction nozzle opening <NUM> along the entire length of the diverter member <NUM> as indicated by arrows <NUM>.

<FIG> shows a perspective view of the base unit <NUM> with the diverter member <NUM> in a down position. When in the diverter member <NUM> is in the down position the edge illuminators <NUM> (<FIG>) are energized such that light illuminated from the edge illuminators <NUM> passes through the light transmitting screens <NUM> as indicated by arrows <NUM>. During operation when the diverter member <NUM> is in the down position, the diverter member middle <NUM> restricts a portion of the front suction nozzle opening <NUM> such that debris laden air may only be drawn into the base unit <NUM> through the unrestricted portions of the front suction nozzle opening <NUM> disposed under the diverter member ends <NUM> as illustrated by arrows <NUM>. The restricted portion of the front suction nozzle opening <NUM> increases the suction in the unrestricted portions such that suction is focused, resulting in a higher velocity airstream created in the area under the diverter member ends <NUM> than when the diverter member <NUM> is in the up position as shown in <FIG>.

<FIG> shows the front suction nozzle opening <NUM> having an open height <NUM> defined by the height between the surface to be cleaned S and the diverter member <NUM> middle portion bottom edge <NUM>. When in the down position as shown in <FIG> it can be seen the middle portion bottom edge <NUM> abuts the surface to be cleaned S such that a closed height <NUM> of the front suction nozzle opening <NUM>, defined by the height between the surface to be cleaned S and the diverter member <NUM> end portion bottom edge <NUM>, is smaller than that of the open height <NUM> shown in <FIG>.

It is noted that, regardless of the position of the diverter assembly <NUM>, i.e. regardless of whether the front suction nozzle opening <NUM> is unrestricted or partially restricted by the diverter member <NUM>, the underside suction nozzle opening <NUM> formed in the underside of the sole plate <NUM> may remain open to allows debris laden air to be drawn into the base unit <NUM> through the underside suction nozzle opening <NUM>. The bristles of the agitator <NUM> can project through the underside suction nozzle opening <NUM> to agitator debris on the surface to be cleaned.

Referring now to <FIG> and <FIG>, another aspect of the present disclosure relates to the pivoting handle <NUM> of the vacuum cleaner <NUM>. The handle <NUM> is selectively pivotable between an upright position as shown in <FIG> and a folded position as shown in <FIG>. A trigger <NUM> disposed on the rear of the handle <NUM> is operably coupled to the handle coupler <NUM> so as to selectively allow the handle <NUM> to be pivoted about the handle coupler <NUM>. The trigger is configured to be linearly movable to and from an unlocked pivoting position by a user pulling the trigger <NUM> upwards. When the trigger <NUM> is in the locked position, the handle <NUM> is locked in the upright position as shown in <FIG>. When the trigger <NUM> is in the unlocked pivoting position, the handle <NUM> may pivot to a folded position as shown in <FIG>. It is noted that a vacuum cleaner having the pivoting handle <NUM> described herein may be combined with either base unit <NUM>, <NUM>', or may be provided with a different vacuum cleaner base.

<FIG> shows an exploded view of the handle <NUM>. The handle <NUM> includes a front casing <NUM>, a rear casing <NUM>, an interlocking assembly <NUM> forming a portion of the handle coupler <NUM>, buttons <NUM>, <NUM>, their associated switches <NUM>, <NUM>, <NUM>, and the trigger <NUM>. The interlocking assembly <NUM> includes a trigger shaft <NUM> connected to an interlocking mechanism <NUM> and is disposed within the front casing <NUM> and rear casing <NUM>. A portion of the trigger <NUM> passes through the rear casing <NUM> and couples to the upper end of the trigger shaft <NUM>. A portion of the interlocking mechanism <NUM> couples to the upper unit <NUM> to form the handle coupler <NUM>.

<FIG> shows an exploded view of the interlocking mechanism <NUM> and the lower portion of the trigger shaft <NUM>. The lower portion of the trigger shaft <NUM> includes a shaft wedge <NUM> having bisecting inclined walls <NUM>, <NUM> sloping away from each other and extending perpendicular to a vertical portion of the trigger shaft <NUM>. The interlocking mechanism <NUM> includes a first and second pivoting handle mount <NUM>, <NUM>, two interlock members <NUM>, two retention springs <NUM> and two upper unit stationary mounts <NUM>.

The first and second pivoting handle mounts <NUM>, <NUM> form generally cylindrical bodies having interior and exterior features and include circular locking projections <NUM>, <NUM>, wherein the locking projections <NUM> on the first pivoting handle mount <NUM> are configured to be coaxially received by the locking projections <NUM> on the second pivoting handle mount <NUM>. The first and second pivoting handle mount <NUM>, <NUM> further include a rectangular sleeve <NUM> configured to receive the two interlock members <NUM>. The first pivoting handle mount <NUM> further includes handle mounting flanges <NUM> that attach to the rear casing <NUM> (<FIG>).

The two interlocking members <NUM> each include a wedge protrusion <NUM>, a male locking connector <NUM> opposing the wedge protrusion <NUM>, a rectangular middle portion <NUM> and a void <NUM> configured to receive the retention spring <NUM>.

The two upper unit stationary mounts <NUM> form generally cylindrical bodies having interior and exterior features and include a spring retainer <NUM> configured to retain the two retention springs <NUM>, upper unit mounting flanges <NUM>, configured to attach to the upper unit <NUM> (<FIG>) and a rectangular female locking connector <NUM> disposed on the interior of the two upper unit stationary mounts <NUM> configured to selectively receive the male locking connectors <NUM>.

<FIG> shows a cross sectional view of <FIG> taken along line XVI-XVI with the trigger <NUM> (<FIG>) in the locked position. The different components of the interlocking mechanism assemble together along a handle pivot axis Z as indicated by assembly arrows <NUM> shown in <FIG>. The two upper unit stationary mounts <NUM> and first and second pivoting handle mounts <NUM>, <NUM> assemble together such that a portion of the exterior of two upper unit stationary mounts <NUM> are received by a portion of the interior of the first and second pivoting handle mounts <NUM>, <NUM>. The retention springs <NUM> are retained between the two upper unit stationary mounts <NUM> and the two interlocking members <NUM>. The two interlocking members <NUM> are retained between the two upper unit stationary mounts <NUM> and the first and second pivoting handle mounts <NUM>, <NUM> such that the male locking connectors <NUM> are received by the female locking connectors <NUM> and the wedge protrusions <NUM> are in communication with the bisecting inclined walls <NUM>, <NUM> of the shaft wedge <NUM>. The interlocking members <NUM> are coupled to the first and second pivoting handle mount <NUM>, <NUM> by the rectangular middle portion <NUM> received in the rectangular sleeves <NUM> and the male locking connectors <NUM> engage the female locking connectors <NUM> to prevent rotation of the interlocking members <NUM>, therefore the first and second pivoting handle mounts <NUM>, <NUM> are prevented from pivoting as well.

<FIG> shows a cross sectional view of <FIG> taken along line XVI-XVI with the trigger <NUM> (<FIG>) in the unlocked pivoting position. When the trigger <NUM> (<FIG>) is in the unlocked pivoting position, the trigger shaft <NUM> and shaft wedge <NUM> move upwards. The bisecting inclined walls <NUM>, <NUM> exert a force perpendicular to the bisecting inclined walls <NUM>, <NUM>, having horizontal and vertical components, and impart the movement to the wedge protrusions <NUM> of the interlocking members <NUM>. As the trigger shaft <NUM> and shaft wedge <NUM> move upwards, the bisecting inclined walls <NUM>, <NUM> and wedge protrusions <NUM> slip relative to each other such that the interlocking members <NUM> move outward towards the spring retainers <NUM> until the male locking connectors <NUM> disengage the rectangular female locking connectors <NUM>. Once disengaged, the interlocking members <NUM> are free to rotate relative to the two upper unit stationary mounts <NUM> while still being coupled to the first and second pivoting handle mount <NUM>, <NUM> connected to the handle <NUM>. Therefore, the trigger shaft <NUM>, first and second pivoting handle mount <NUM>, <NUM> and interlocking members <NUM> all rotate together with the handle <NUM>, while the two upper unit stationary mounts <NUM> connected to the upper unit <NUM> do not pivot.

When the handle is returned to the upright position as shown in <FIG> and the trigger <NUM> is in the locked position, the retention springs <NUM> move the interlocking members <NUM> towards the shaft wedge <NUM> such that the male locking connectors <NUM> engage the rectangular female locking connectors <NUM> and rotation of the handle <NUM> is prevented. It will be understood the retention springs <NUM> may have a spring rate that is optimized to along for disengaging movement the interlocking members <NUM> by a user linearly moving the trigger <NUM> and to overcome all resistive forces such as friction and weight in order to provide for engaging movement of the interlocking members <NUM>. It is contemplated that the trigger shaft <NUM> can optionally be configured to actuate one or more additional interlocking members <NUM> to provide increased strength of the interlocking mechanism <NUM> and increased torsional stiffness at the handle coupler <NUM> joining the handle <NUM> to the upper unit <NUM>. The at least one additional locking member (not shown) can function in a substantially similar way as the previously disclosed locking member <NUM>, but can include an alternate structure, such as a cylindrical pin, for example.

The vacuum cleaner <NUM> disclosed herein provides improved cleaning performance and ease of use. One advantage that may be realized in the practice of some aspects of the described vacuum cleaner <NUM> is that the vacuum cleaner <NUM> can be configured to selectively provide increased suction to the edges of the suction nozzle <NUM> so as to increase cleaning potential along edges and walls. Furthermore, the edges or walls to be cleaned may be automatically illuminated to increased user visibility by the user. Another advantage is that the vacuum cleaner <NUM> can be configured such that the handle <NUM> may be easily folded by a simple pull of the trigger <NUM> by a user.

By incorporating the communication method as described with respect to <FIG> in the vacuum cleaner <NUM> as described in <FIG>, a variety of functions and features of the vacuum cleaner <NUM> can be controlled by the power source <NUM> via the power line, or electrical conductor leads <NUM>. Rather than requiring a separate communications line coupling the electronic controls of the upper unit <NUM> with the base unit <NUM>, a toggle switch <NUM> (<FIG>) can be operably coupled with the power line or electrical conductor leads <NUM> to introduce a PWM signal via the power line or electrical conductor leads <NUM> in response to inputs from the electronic controls of the upper unit <NUM>, which can be considered the user control portion, and to effect operation of a function or component at the base unit <NUM>, which can be considered the surface cleaning portion. Non-limiting examples of such exemplary functions, components, and features that can be controlled include the diverter assembly <NUM>, <NUM>', including the solenoid piston <NUM> and the inductive coil, edge illuminators <NUM> for operating in an edge mode, the pivoting pedal <NUM>, and the switch <NUM>. It will be understood that communicating via the power line or electrical conductor leads <NUM> can be used to control any function or component of the vacuum cleaner <NUM>. Any suitable function or component can be controlled such that the PWM signal input sensed by the PCB <NUM> or other controller <NUM> signals the PCB <NUM> or other controller <NUM> to effect a change or an action.

<FIG> is a schematic view of various functional systems of a surface cleaning apparatus <NUM> in the form of an exemplary vacuum cleaner <NUM>. The functional systems of the exemplary vacuum cleaner <NUM> can be arranged into any desired configuration including as a portable cleaner adapted to be hand carried by a user for cleaning relatively small areas. The vacuum cleaner <NUM> can be adapted to include a hose or other conduit, which can form a portion of the working air conduit between a nozzle and the suction source.

The vacuum cleaner <NUM> can include a recovery system <NUM> for removing debris from the surface to be cleaned and storing the debris. The recovery system <NUM> can include a suction inlet or suction nozzle <NUM>, a suction source <NUM> in fluid communication with the suction nozzle <NUM> for generating a working air stream, and a recovery container <NUM> for separating and collecting debris from the working airstream for later disposal.

The suction nozzle <NUM> can be provided on a base or cleaning head adapted to move over the surface to be cleaned. An agitator <NUM> can be provided adjacent to the suction nozzle <NUM> for agitating the surface to be cleaned so that the debris is more easily ingested into the suction nozzle <NUM>. Some examples of agitators <NUM> include, but are not limited to, a horizontally-rotating brushroll, dual horizontally-rotating brushrolls, one or more vertically-rotating brushrolls, or a stationary brush.

The suction source <NUM> can be any suitable suction source and is provided in fluid communication with the recovery container <NUM>. The suction source <NUM> can be electrically coupled to a power source <NUM>, such as a battery or by a power cord plugged into a household electrical outlet. A suction power switch <NUM> between the suction source <NUM> and the power source <NUM> can be selectively closed by the user, thereby activating the suction source <NUM>.

A separator <NUM> can be formed in a portion of the recovery container <NUM> for separating entrained debris from the working airstream.

The vacuum cleaner <NUM> shown in <FIG> can be used to effectively remove debris from the surface to be cleaned in accordance with the following method. The sequence of steps discussed is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be divided into multiple steps.

In operation, the vacuum cleaner <NUM> is prepared for use by coupling the vacuum cleaner <NUM> to the power source <NUM>. During operation of the recovery system <NUM>, the vacuum cleaner <NUM> draws in debris-laden working air through the suction nozzle <NUM> and into the downstream recovery container <NUM> where the fluid debris is substantially separated from the working air. The airstream then passes through the suction source <NUM> prior to being exhausted from the vacuum cleaner <NUM>. The recovery container <NUM> can be periodically emptied of collected fluid and debris.

<FIG> is a perspective view illustrating that the vacuum cleaner <NUM> can include a housing <NUM> with an upright assembly <NUM> and a base assembly <NUM>. The upright assembly <NUM> can be pivotally connected to the base assembly <NUM> for directing the base assembly <NUM> across the surface to be cleaned. It is contemplated that the vacuum cleaner <NUM> can include any or all of the various systems and components described in <FIG>, including a recovery system <NUM> for separating and storing dirt or debris from the surface to be cleaned. The various systems and components schematically described for <FIG> can be supported by either or both the base assembly <NUM> and the upright assembly <NUM> of the vacuum cleaner <NUM>.

<FIG> illustrates a partially-exploded view of the vacuum cleaner <NUM> of <FIG>. The upright assembly <NUM> includes a hand-held portion <NUM> supporting components of the recovery system <NUM>, including, but not limited to, the suction source <NUM> and the recovery container <NUM>. By way of non-limiting example, the suction source <NUM> can includes a motor/fan assembly <NUM> (<FIG>).

The hand-held portion <NUM> can be coupled to a wand <NUM> having at least one wand connector <NUM>. In the illustrated example, both a first end <NUM> of the wand <NUM> and a second end <NUM> of the wand <NUM> include a wand connector <NUM>. The wand connector <NUM> at the second end <NUM> of the wand <NUM> can be coupled to the base assembly <NUM> via a wand receiver <NUM>. The wand connector <NUM> at the first end <NUM> of the wand <NUM> can couple to a second wand receiver <NUM> within the hand-held portion <NUM>. It is contemplated that the wand connectors <NUM> can be the same type of connector or can vary. Any suitable type of connector mechanism can be utilized, such as a quick connect mechanism or a tubing coupler in non-limiting examples.

A pivotal connection between the upright assembly <NUM> and the base assembly <NUM> can be provided by at least one pivoting mechanism. In the illustrated example, the pivoting mechanism can include a multi-axis swivel joint assembly <NUM> configured to pivot the upright assembly <NUM> from front-to-back and side-to-side with respect to the base assembly <NUM>. A lower portion <NUM> of the swivel joint assembly <NUM> is located between the wand <NUM> and the base assembly <NUM>. The lower portion <NUM> of the swivel joint assembly <NUM> provides for pivotal forward and backward rotation between the wand <NUM> and the base assembly <NUM>. An upper portion <NUM> of the swivel joint assembly <NUM> is also located between the wand <NUM> and the base assembly <NUM> and provides for lateral or side-to-side rotation between the wand <NUM> and base assembly <NUM>. More specifically, the lower portion <NUM> of the swivel joint assembly <NUM> is coupled between the base assembly <NUM> and the upper portion <NUM> of the swivel joint assembly <NUM>. The upper portion <NUM> of the swivel joint assembly <NUM> is coupled to the wand receiver <NUM> at the second end <NUM> of the wand <NUM>. Wheels <NUM> can be coupled to the lower portion <NUM> of the swivel joint assembly <NUM> or directly to the base assembly <NUM>, and are adapted to move the base assembly <NUM> across the surface to be cleaned.

The hand-held portion <NUM> can also include the recovery container <NUM>, illustrated herein as a dirt separation and collection module <NUM> fluidly coupled to the suction source <NUM> via an air outlet port <NUM>. The dirt separation and collection module <NUM> can be removable from the hand-held portion <NUM> by a release latch <NUM> as shown so that it can be emptied of debris.

An upper end of the hand-held portion <NUM> can further include a hand grip <NUM> for maneuvering the vacuum cleaner <NUM> over a surface to be cleaned and for using the vacuum cleaner <NUM> in hand-held mode. At least one control mechanism is provided on the hand grip <NUM> and coupled to the power source <NUM> (<FIG>) for selective operation of components of the vacuum cleaner <NUM>. In the contemplated example, the at least one control mechanism is an electronic control that can form the suction power switch <NUM>.

The agitator <NUM> of the illustrated example includes a brushroll <NUM> (<FIG>) configured to rotate about a horizontal axis and operatively coupled to a drive shaft of a drive motor via a transmission, which can include one or more belts, gears, shafts, pulleys, or combinations thereof. An example of which will be explained in more detail below. An agitator housing <NUM> is provided around the suction nozzle <NUM> and defines an agitator chamber <NUM> (<FIG>) for the brushroll <NUM> (<FIG>).

Referring now to <FIG>, a recovery airflow conduit <NUM> can be formed between the agitator housing <NUM> and the dirt separation and collection module <NUM>. For example, a hose conduit <NUM> in the base assembly <NUM> can be fluidly coupled to a wand central conduit <NUM> within the wand <NUM>. The hose conduit <NUM> can be flexible to facilitate pivoting movement of the swivel joint assembly <NUM> about multiple axes. The wand central conduit <NUM> is fluidly connected to a dirt inlet <NUM> on the dirt separation and collection module <NUM> via the air outlet port <NUM>.

In the illustrated example, the power source <NUM> is in the form of a battery pack <NUM> containing one or more batteries, such as lithium-ion (Li-Ion) batteries. Optionally, the vacuum cleaner <NUM> can include a power cord (not shown) to connect to a wall outlet. In still another example, the battery pack <NUM> can include a rechargeable battery pack, such as by connecting to an external source of power to recharge batteries contained therein.

During operation of the vacuum cleaner <NUM>, the power source <NUM> can supply power for the suction source <NUM>, such as by way of non-limiting example a motor/fan assembly <NUM> (<FIG>) to provide suction through the recovery airflow conduit <NUM>. Debris-laden working air within the agitator housing <NUM> can be directed through the flexible hose conduit <NUM> and wand central conduit <NUM> before flowing into the dirt separation and collection module <NUM> by way of the dirt inlet <NUM> as shown. In addition, the swivel joint assembly <NUM> can provide for forward/backward and side-to-side pivoting motion of the upright assembly <NUM> with respect to the base assembly <NUM> when moving the base assembly <NUM> across the surface to be cleaned. Additional details of the motor/fan assembly <NUM> (<FIG>) are described in <CIT>.

<FIG> illustrates an exemplary hand grip <NUM> that can be utilized in the vacuum cleaner <NUM>. The hand grip <NUM> can include a user interface <NUM> with at least one status indicator for a component of the vacuum cleaner <NUM>. The status indicator is illustrated in the form of a suction level indicator <NUM> and a battery level indicator <NUM>. While not shown, other status indicators can be provided on the user interface <NUM>. In non-limiting examples, an LED or text display (not shown) can also indicate that a filter is clogged, that the recovery container <NUM> needs emptying, or that a brushroll <NUM> needs cleaning or inspecting.

The suction level indicator <NUM> is illustrated as being positioned at lateral edges of the user interface <NUM> and can illuminate to show a current level of suction power. More specifically, three progressively-illuminated LEDs <NUM> can be positioned at each lateral edge to indicate a level of suction between "high," "medium," and "low" suction powers for the suction level indicator <NUM>. For example, repeated pressing of a suction mode selector button <NUM> can cycle through the "high," "medium," and "low" suction power levels, and each LED <NUM> of the suction level indicator <NUM> can illuminate in sequence accordingly. In the illustrated example, the "medium" suction power level is shown wherein two of the three LEDs <NUM> are illuminated on the suction level indicator <NUM> of the user interface <NUM>. It will be understood that, in the illustrated example, the suction mode selector button <NUM> is configured to operate the suction source <NUM> (<FIG>) with low, medium, and high suction power, which in turn operates the suction source <NUM> including the motor/fan assembly <NUM> (<FIG>) at predetermined low, medium and high rotational speeds. Further still, a power button <NUM> can be positioned adjacent the suction mode selector button <NUM> or elsewhere on the user interface <NUM> to selectively power the suction source <NUM>.

It will be understood that the modes or options presented to a user may not be labeled as "high," "medium," and "low" instead the modes can correlate to "modes" such as carpet, hard floor, and edge. While the mode selector has been illustrated as a button it could be any suitable user control including a switch or other mechanism. Regardless of the specific mechanism utilized it will be understood that the mode selector button <NUM> can also be configured to operably couple with a toggle switch <NUM> (<FIG>) which in a non-limiting example includes a solid-state switch. The toggle switch <NUM> can receives an input from the mode selector button <NUM> via the power line <NUM> and any suitable conductors, the input from the mode selector button <NUM> indicative of the mode selected by the user.

The battery level indicator <NUM> is in the form of a series of lights, such as light-emitting diodes (LEDs) <NUM> that progressively illuminate to show a level of charge of the battery pack <NUM>. In an alternate example, the battery level indicator <NUM> can be in the form of a pre-drawn icon displayed on a screen to indicate a level of charge of the battery pack <NUM>.

<FIG> illustrates an exploded view of the hand grip <NUM> of <FIG>, which more clearly illustrates that the LEDs <NUM> and <NUM> can be provided within a substructure of the hand grip <NUM>. An upper grip <NUM> with an aperture <NUM> configured to receive and surround the power button <NUM> and suction mode selector button <NUM>. A lower grip <NUM> coupled to the upper grip <NUM> can include a reflective concave portion <NUM>, such as a white-colored or reflective or mirrored surface. The lower grip <NUM> can also include a plurality of divider walls <NUM> to isolate light emitted by the LEDs <NUM> and <NUM>. The LEDs <NUM> (<FIG>) and <NUM> (<FIG>) for the suction level indicator <NUM> and the battery level indicator <NUM>, respectively, can be positioned on a printed circuit board (PCB) <NUM>. In addition, an isolator <NUM> can be coupled to the PCB <NUM> and include a first seat 416a for the power button <NUM> and a second seat 416b for the suction mode selector button <NUM>. The isolator <NUM> can include openings 418a, 418b along each lateral edge to permit light for the suction level indicator <NUM> to be emitted. The isolator <NUM> can further include additional openings <NUM> through which the LEDs <NUM> can shine for the battery level indicator <NUM>.

<FIG> illustrates the assembled hand grip <NUM>. As assembled within the hand grip <NUM>, the PCB <NUM> defines a lower surface 414a and an upper surface 414b. The LEDs <NUM> for the suction level indicator <NUM> are positioned on the lower surface 414a of the PCB <NUM> and emit light downward, toward the lower grip <NUM> as illustrated by first arrows <NUM>. The reflective concave portion <NUM> of the lower grip <NUM> reflects the emitted light upward, toward the upper grip <NUM>. Over-molded portions <NUM> of the lower grip <NUM> can block or redirect emitted light from the LEDs <NUM> to shine upwardly toward the isolator <NUM>. The openings 418a, 418b along each lateral edge of the isolator <NUM> permit the emitted light to shine through at the edges of the upper grip <NUM>, as indicated via arrow <NUM>, thereby forming the suction level indicator <NUM> at each lateral edge of the hand grip <NUM>. It is further contemplated that the upper grip <NUM> can include molded or shaped portions to further direct or diffuse the emitted light, such as a translucent portion forming a viewing window for each LCD in the suction level indicator <NUM>.

Turning to <FIG>, the assembled hand-held portion <NUM> of the upright assembly <NUM> is shown including a portion of the wand <NUM>, the battery pack <NUM>, the hand grip <NUM>, the motor/fan assembly <NUM>, and the dirt separation and collection module <NUM>.

As illustrated, a wand axis <NUM> can be defined through the center of the wand <NUM> (<FIG>) and wand connector <NUM>. In <FIG> the wand <NUM> is held upright, and thus the wand axis <NUM> is vertical. In this example, references to "a vertical axis" will be understood to also refer to the wand axis <NUM>. It will be understood, that during use the wand <NUM> may be oriented in any suitable manner including angled with respect to the vertical axis.

A collector axis <NUM> can be defined through the center of the dirt separation and collection module <NUM>, and a motor axis <NUM> can be defined through the center of the motor/fan assembly <NUM>. It is contemplated that the wand axis <NUM>, the collector axis <NUM>, and the motor axis <NUM> can all be parallel to one another as shown. Put another way, when the wand <NUM> is held upright such that the wand axis <NUM> is vertical, the collector axis <NUM> and the motor axis <NUM> are also vertical.

A grip axis <NUM> can be defined through the center of the hand grip <NUM> as shown. The grip axis <NUM> forms a grip angle <NUM> with respect to a vertical direction, such as <NUM> degrees in a non-limiting example. Further, a battery axis <NUM> can be defined through the center of the battery pack <NUM> and intersect the grip axis <NUM>. The battery axis <NUM> can also define a battery angle <NUM> with respect to a vertical direction, such as <NUM> degrees in a non-limiting example. Optionally, the grip axis <NUM> can be orthogonal to the battery axis <NUM>.

<FIG> illustrates additional details of the dirt separation and collection module <NUM>. The dirt separation and collection module <NUM> can include a dirt cup in the form of recovery container <NUM> with an inlet port in the form of the dirt inlet <NUM>, and a separator assembly <NUM> coupled to the recovery container <NUM>. Working air can enter through the dirt inlet <NUM> and swirls around a first stage separator assembly chamber <NUM> for centrifugally separating debris from the working air flow. The separator assembly <NUM> includes a first stage separator <NUM>, such as a grill, that, in combination with the swirling working air, removes relatively large debris out of the working air which collects at a lower portion of the recovery container <NUM> defining a first stage collection area <NUM>.

The working air moves through an inlet to a second stage separator <NUM> in the separator assembly <NUM>, such as a grill or a mesh configured to filter smaller debris, and enters a second stage separation chamber <NUM>, which is shown as a cyclonic separator herein. Smaller debris removed from the working air collects in a second stage collector <NUM> near the bottom of the recovery container <NUM>. The first stage collector <NUM> can surround the second stage collector <NUM> as shown.

An exhaust outlet <NUM> and filter housing <NUM> are fluidly coupled to an upper portion of the second stage separation chamber <NUM>. With additional reference to <FIG>, working air exits the second stage separation chamber <NUM> through the exhaust outlet <NUM> and at least one filter in the filter housing <NUM> and which is shown herein as a pre-motor filter <NUM> of the motor/fan assembly <NUM>. The filtered working air flows into the motor/fan assembly <NUM> whereupon it can be exhausted into the surrounding atmosphere through an exhaust filter, i.e. a post-motor filter <NUM>, and an air outlet of the working air pathway through the vacuum cleaner <NUM>, which is shown herein as formed by an exhaust grill <NUM>.

The outer surface of the first stage separator <NUM> can accumulate debris, such as hair, lint, or the like that may become stuck thereon and may not fall into the first stage collection area <NUM>. <FIG> shows the separator assembly <NUM> being removed and <FIG> shows the separator assembly <NUM> fully removed from the recovery container <NUM> to empty collected dirt and debris from the first and second stage collection areas <NUM> and <NUM>.

The separator assembly <NUM> can further include a ring <NUM> slidably coupled to the recovery container <NUM>. The ring <NUM> can be coupled to a wiper <NUM>, such as an annular wiper, configured to contact the first stage separator <NUM>. The separator assembly <NUM> can be lifted upwards with respect to the ring <NUM> and recovery container <NUM>. During this lifting, the ring <NUM> temporarily remains coupled to the recovery containers <NUM>, either by friction fit or a mechanical coupling such as bayonet hook, for example, and the wiper <NUM> slides or scrapes along the first stage separator <NUM> to remove accumulated debris from the outer surface of the first stage separator <NUM> or grill, which falls down to the first stage collection area <NUM>.

When the separator assembly <NUM> has been raised to a predetermined level, it can lift away from the recovery container <NUM> along with the ring <NUM> and wiper <NUM>. The recovery container <NUM> can then be inverted to remove dirt and debris from the first and second stage collection areas <NUM> and <NUM>. After emptying, the separator assembly <NUM> can be repositioned within the recovery container <NUM> and the ring <NUM> can once again be coupled to the recovery container <NUM> for additional use of the vacuum cleaner <NUM>.

<FIG> shows additional details of an exemplary wand assembly, which can include a wand body <NUM> enclosing the wand central conduit <NUM>. In one example, the wand body <NUM> can be formed from an extrusion of aluminum, and is illustrated as having an exterior rounded triangular geometric profile defining an outer periphery <NUM> (<FIG>). Wand connectors <NUM> can couple to the wand body <NUM> at each end <NUM> and <NUM>. A first wand connector <NUM> can couple the wand body <NUM> to the base assembly <NUM> and a second wand connector <NUM> can couple the wand body <NUM> to the hand-held portion <NUM> (<FIG>).

A decorative insert <NUM> can be coupled to at least a portion of the wand body <NUM>. In the illustrated example, the decorative insert <NUM> can be in the form of a flat plate and configured to couple to a recessed portion defining a face <NUM> of the triangular shaped wand body <NUM>. Optionally, the decorative insert <NUM> can included rounded edges to form smooth surface transitions between an outer surface of the decorative insert and a second face of the wand body. It is contemplated that the decorative insert <NUM> can be formed of plastic, including transparent or translucent plastic. Optionally, the decorative insert <NUM> can include logos or other markings or indicators for operations of the vacuum cleaner <NUM>, or locating features so as to couple a correct end of the wand body <NUM> to one of the base assembly <NUM> or hand-held portion <NUM> of the upright assembly <NUM>, for example.

<FIG> illustrates a sectional view of the wand <NUM>. It is contemplated that the wand body <NUM> can include an outer wall defining the outer periphery <NUM> with at least one inner partition <NUM> defining the wand central conduit <NUM>. The outer wall defining the outer periphery <NUM> is further illustrated as including a hook <NUM> defining a corresponding recess <NUM> on either side of the face <NUM>. Protrusions <NUM> on either side of the decorative insert <NUM> can be received within the recesses <NUM>. It is contemplated that the protrusions <NUM>, or the entire decorative insert <NUM>, can have material flexibility such that the protrusions <NUM> can be "snap-fit" into the recesses <NUM> of the wand body <NUM>. In another non-limiting example, the protrusions <NUM> can be made of a material having higher elasticity than that of a remainder of the decorative insert <NUM>, such as a plastic decorative insert having rubber hooked portions configured to snap-fit or snugly insert into the recesses <NUM> of the wand body <NUM>.

<FIG> illustrates another example of a wand assembly that can be utilized in the vacuum cleaner <NUM>. In the illustrated example, the wand body 462a can have a generally V-shaped geometric profile with an open face <NUM> on one side, such as by forming a V-shaped extrusion of aluminum. A tubular member <NUM> can be coupled within the wand body 462a. The tubular member <NUM> can have an inner surface defining the wand central conduit 378a, and an outer surface shaped to form a smooth surface transition between the tubular member <NUM> and the wand body 462a.

<FIG> illustrates a sectional view with the tubular member 465a assembled within the wand body 462a. The wand body 462a can have an outer wall 468a with at least one projection 476a. The tubular member 465a can have a corresponding at least one recess 472c formed by spaced walls 472a and 472b. The at least one recess 472c is configured to surround the at least one projection 476a to securely fix the tubular member 465a in place. In one example, the at least one projection 476a can be formed from an elastic material to provide "snap-fit" coupling between the tubular member 465a and wand body 462a. In another example, the wand body 462a can have sufficient elasticity such that the tubular member 465a can be press-fit into the wand body 462a, and the at least one projection 476a can "snap" into place within the corresponding at least one recess 472c.

The tubular member 465a can be formed from a transparent material such as extruded thermoplastic or polycarbonate material. In such a case, the assembled wand would include a transparent face defined by the exposed face of the tubular member 465a when assembled within the wand body 462a. In this configuration, a transparent tubular member would provide visibility within the wand central conduit 378a, such that dirt and debris moving through the conduit would be visible to a user during operation of the vacuum cleaner <NUM>. Additionally, potential obstructions or clogs within the tubular member could also be viewed in a facile manner through the transparent tubular member. A transparent section <NUM> has been illustrated in the tubular member 465a by way of non-limiting example.

<FIG> illustrates one example of a base assembly <NUM>. The base assembly <NUM> can extend between a first side <NUM> and a second side <NUM> and a cover <NUM> can at least partially define the agitator chamber <NUM> therebetween. An aperture <NUM> is located in a portion of the second side <NUM> and allows for insertion and removal of the brushroll <NUM>. A front bar <NUM> extends between the first side <NUM> and the second side <NUM> along a lower portion of the base assembly. The front bar <NUM> is configured to be located behind the cover <NUM> when the cover <NUM> is mounted. A headlight array <NUM> is illustrated as being located on the front bar <NUM> and extending along the width of the base assembly between the first side <NUM> and the second side <NUM>. The headlight array <NUM> can be any suitable illumination assembly including an LED headlight array. Even though the headlight array <NUM> is positioned under the cover <NUM> it can be considered to be positioned along an outer portion of the base assembly <NUM>. In one example, the cover <NUM> can include a transparent portion such that when installed, the transparent portion covers and protects the headlight array <NUM> and permits emitted light to shine through to the surface to be cleaned. In another example, the cover <NUM> can leave the headlight array <NUM> uncovered so as not to block emitted light from the headlight array <NUM>.

A brushroll <NUM> can be positioned within the agitator chamber <NUM> by sliding a first end through the aperture <NUM> located at the second side <NUM> of the base assembly <NUM>. When fully inserted, a second end 370b of the brushroll <NUM> can be flush with the aperture <NUM>. In addition, the hose conduit <NUM> can fluidly couple the agitator chamber <NUM> to the wand central conduit <NUM> (<FIG>).

The base assembly <NUM> can include a brush drive assembly <NUM> positioned opposite the aperture <NUM> and configured to drive rotational motion of the agitator <NUM> (e.g. brushroll <NUM>) within the agitator chamber <NUM>. The brush drive assembly <NUM> can have components including, but not limited to, a brush motor <NUM>, a belt <NUM> within a belt housing <NUM>, and a brush drive gear <NUM>.

Additional details of the brushroll <NUM> are shown in <FIG>. The first end of the brushroll <NUM> can include an end plate <NUM> having projections <NUM>, such as teeth, configured to engage a portion of the brush drive assembly <NUM> (<FIG>). The brushroll <NUM> further includes a central shaft <NUM> coupled to brush bearings <NUM> (<FIG>) at each end. In the illustrated example, the brushroll <NUM> includes a bristled brushroll <NUM> with offset, swept tufts <NUM> extending along an outer surface of the brushroll <NUM>. The bristle tufts <NUM> can be positioned offset from a center line <NUM> of a tufting platform <NUM>, and the tufts <NUM> can also be non-orthogonal to the tufting platform <NUM>. In this manner, the bristled brushroll <NUM> can be configured to prevent hair from wrapping around the brushroll <NUM> during operation. Additional details of a similar brushroll are described in <CIT>,.

The assembled base assembly <NUM> is shown in <FIG>, where the projections <NUM> of the end plate are coupled with the brush drive gear <NUM>. In this manner the brush drive gear <NUM> is also coupled to the shaft <NUM> by way of a drive gear bearing. With additional reference to <FIG>, as the brush motor <NUM> drives rotation of the belt <NUM> and brush drive gear <NUM>, the brushroll <NUM> can be rotated at a variety of speeds depending on the selected suction mode (<FIG>). A brush removal endcap <NUM> at the second end of the brushroll <NUM> provides for unlocking or removal of the brushroll <NUM> from the agitator chamber <NUM>, such as for cleaning of the bristle tufts <NUM>.

It is contemplated that a variety of agitators <NUM> and brushrolls <NUM> can be utilized within the agitator chamber <NUM>. <FIG> illustrates a microfiber brushroll <NUM> that can be utilized. The microfiber brushroll <NUM> is similar to the bristled brushroll <NUM>; one difference is the outer surface includes a microfiber layer instead of bristles. Whereas bristles can be utilized to lift hair and debris from carpet fibers, the microfiber layer can lift dirt and debris from hard surfaces such as wood or tile. Each of the brushrolls can include a brush removal endcap <NUM> including fasteners <NUM>. In the illustrated example, the fasteners <NUM> include bayonet fasteners wherein a given brushroll is inserted through the aperture <NUM> and rotated, for example by <NUM> degrees, to lock the brushroll into place within the agitator chamber <NUM> (<FIG>) via corresponding fastener receivers <NUM>. It will be understood that other brushroll types not explicitly described can be utilized in the vacuum cleaner <NUM>.

<FIG> illustrates the base assembly <NUM> sitting on a surface to be cleaned, the surface to be cleaned defining a first plane <NUM>. As illustrated in cross-sectional view a center line of the headlight array <NUM> can be defined as a second plane <NUM>. The second plane <NUM> is spaced above the first plane defined by the surface to be cleaned by a height <NUM>. It has been determined that providing the headlight array <NUM> close to the first plane <NUM> and relatively low on the base assembly <NUM> provides unexpected benefits. The height can be any suitable small height that provides such benefits including, by way of non-limiting examples, spaced above the surface to be cleaned at not more than <NUM>, at less than <NUM>, and at <NUM>. Further still, by way of non-limiting example, the illuminance measurements as a delta from ambient values at <NUM> meters from the headlight array <NUM> can be <NUM> Lux and at <NUM> can be greater than <NUM> Lux. In another example, the headlight array <NUM> can be aligned with the lower front edge of the front bar <NUM>.

More specifically, during operation of the vacuum cleaner <NUM> when the headlight array <NUM> provides illumination it has been determined that the placement of the headlight array <NUM> in this very low position across the front of the base assembly <NUM> illuminates the surface to be cleaned very well, including that dust and/or debris are illuminated exceptionally well. It has been determined that performance is noticeably better as compared to when LEDs are mounted higher up and pointing downwardly at the surface to be cleaned. Because of the low position of the headlight array <NUM> and because the headlight array <NUM> faces forward and projects illumination at substantially a horizontal projection along the second plane <NUM> shadows are cast by debris on the surface to be cleaned and these shadows are very obvious to a user of the vacuum cleaner <NUM>. It will be understood that the beam provided by the headlight array <NUM> can be projected with a zero-degree angle that provides a beam that is parallel to the surface to be cleaned as defined by the first plane <NUM>.

By incorporating the communication method as described with respect to <FIG> in the vacuum cleaner <NUM> as described in <FIG>, a variety of functions and features of the vacuum cleaner <NUM> can be controlled a power line <NUM> or one or more conductor leads. By way of non-limiting example, a power communication system can be utilized rather than requiring a separate communications line to couple the electronic control of the upright assembly with the base assembly. More specifically, the power communication system of the vacuum cleaner <NUM> can include the power line <NUM> and at least one user control in the form of the suction mode selector button <NUM>, and a toggle switch <NUM> (<FIG>), which is operably coupled with the power line <NUM> to introduce a PWM signal via the power line <NUM> in response to inputs from the suction mode selector button <NUM> to effect operation of a function or component at the base assembly <NUM>. A separate processor or controller such as the controller <NUM> can be included in the base assembly <NUM> and be configured to receive the PWM signal via the power line <NUM>. Alternatively, or additionally, a controller can be included in the component itself located in the base assembly <NUM> such as a motor controller for the brush motor <NUM>. Further still, the controller <NUM> can be separate from a "main controller" (not shown) that can control portions of the upright assembly such as the motor/fan assembly.

The controller <NUM> can be configured to receive the PWM signal provided by the power communication system via the power line <NUM> or various conductor leads. More specifically, during operation the suction mode selector button <NUM> can be utilized to select one of the mode. As explained above the mode can refer to an operational mode such as the type of flooring or to a suction level by way of non-limiting examples.

The toggle switch <NUM> can receive an input from the mode selector button <NUM> via the power line <NUM> and any suitable conductors, the input from the mode selector button <NUM> is indicative of the mode selected by the user. The toggle switch <NUM> can then introduce a PWM signal to the controller <NUM> over the power line <NUM>, the PWM signal provided to the controller <NUM> via the power line <NUM> corresponding to the mode input received by the mode selector button <NUM> or other user controls. In this way, the mode selected by the user at the mode selector button <NUM> generates an input to the toggle switch <NUM> that determines the pulse width of the PWM signal then provided from the toggle switch <NUM> to the controller <NUM> to cause an operation at the base assembly <NUM> that corresponds to the mode selected by the user.

It is contemplated that during operation of the vacuum cleaner <NUM> that no mode may be selected and that the toggle switch <NUM> is not introducing a PWM signal over the power line <NUM> and the signal transmitted over the power line <NUM> to the controller <NUM> is typically high or uninterrupted, and can be thought of as representing <NUM>% power transmission. When a communication signal is transmitted from the user control, including but not limited to the suction mode selector button <NUM>, this can provide an input indicating a different mode of operation to the toggle switch <NUM> and the toggle switch <NUM> is prompted to introduce or toggle the PWM signal over the power line <NUM>.

It is contemplated that the vacuum cleaner <NUM> may only be operational in a mode or when a suction mode is selected. By way of further non-limiting example it is contemplated that a first mode can include an auto sensing mode and that when this mode is selected an <NUM>% duty cycle can provide an input to the controller <NUM> to indicate that one or more components of the base assembly <NUM> should be operated in the auto sensing mode, a <NUM>% duty cycle can provide an input to the controller <NUM> to indicate that one or more components of the base assembly <NUM> should be operated in the carpet mode, a <NUM>% duty cycle can provide an input to the controller <NUM> to indicate that one or more components of the base assembly <NUM> should be operated in the hard floor mode. The controller <NUM> as part of the powerline communication system is configured to affect a particular function or control of one or more components in response to the characteristics of the PWM signal received. The powerline communication system can be utilized to control any number of features and functions. Further, non-limiting examples of such functions, components, and features that can be controlled individually or in combination include an agitator <NUM> or brush motor <NUM>, a headlight array <NUM>, or other components or functions provided at the base assembly <NUM>.

It will be understood that the above disclosure provides for a number of benefits including co-opting the power line or electrical conductor leads by using powerline communications. The powerline communication system and surface cleaners utilize a PWM signal, which is introduced over line or leads and a signal is encoded by either the duty cycle of the PWM signal or the frequency of the PWM signal, which will be understood to be the inverse of the pulse width modulation. The signal is intermittent, in that during operation, the power line or electrical lead is primarily high and when a communication signal is transmitted, a solid state switch toggles the PWM signal over the line and then the line returns to high such that the DC power is essentially uninterrupted as far as the load at the foot is concerned.

To the extent not already described, the different features and structures of the various aspects of the present disclosure may be used in combination with each other as desired. Thus, the various features of the different aspects may be mixed and matched as desired to form new aspects, whether or not the new aspects are expressly described.

Further aspects of the invention are provided by the subject matter of the following clauses:.

Claim 1:
A powerline communication system (<NUM>) for controlling a function or operation of at least one component (<NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) of a surface cleaning device (<NUM>, <NUM>), the powerline communication system comprising:
a power source (<NUM>, <NUM>, <NUM>, <NUM>', <NUM>);
at least one user control (<NUM>, <NUM>, <NUM>) adapted to receive an input from a user;
a controller (<NUM>, <NUM>, <NUM>, <NUM>) in a base (2b, <NUM>, <NUM>) of the surface cleaning device and located remotely from the at least one user control (<NUM>, <NUM>, <NUM>) provided in a handle (2a, <NUM>, <NUM>), the controller (<NUM>, <NUM>, <NUM>, <NUM>) configured to control operation of the at least one component (<NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>); and
a power line (<NUM>, <NUM>, <NUM>) electrically coupling the power source (<NUM>, <NUM>, <NUM>, <NUM>', <NUM>), the controller (<NUM>, <NUM>, <NUM>, <NUM>), and the at least one component (<NUM>, <NUM>, <NUM>', <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) and wherein the power line (<NUM>, <NUM>, <NUM>) is further adapted to provide a communication signal between the at least one user control (<NUM>, <NUM>, <NUM>) and the controller (<NUM>, <NUM>, <NUM>, <NUM>), characterized in that the communication signal is intermittently transmitted and electrical power at the base (2b, <NUM>, <NUM>) is substantially uninterrupted.