Patent Description:
The present invention relates to floor cleaning machines, and particularly to powered floor sweepers.

According to its abstract, <CIT> describes a cleaning apparatus and a dust collecting method using the same. The cleaning apparatus includes a body, a brush unit rotatably provided at the body, a dust collecting unit to store contaminants, such as dust, swept by the brush unit, and a blowing unit to suction contaminants, such as dust, scattered by the brush unit and to move the suctioned contaminants to the dust collecting unit.

According to its abstract, <CIT> describes a s weeping machine which reliably picks up small dirt particles, larger objects and leaves and has a rubbish-holding space, main roller brush rotating about horizontal axis and driven with its edge turning in direction of travel, and guide member for this bounding a gap for rubbish to pass through. The main roller brush has a similar auxiliary roller brush mounted parallel to it, as guide member, driven to rotate the opposite way. The two combine to form an upwards directed coil-shaped sweeping and conveyor zone, with their peripheral area facing the ground and each other. They can be mounted in a shared working chamber in the casing, open to the side and the ground, and adjoining the rubbish-holding space.

Described herein is a floor cleaning machine including a rotary brush rotatable about a first axis and a brushroll rotatable about a second axis. The brush and the brushroll are configured to convey debris toward a collection bin. The floor cleaning machine also includes a suction source configured to produce a first suction zone between the brush and the brushroll and a second suction zone in the collection bin. In some embodiments, the brush, the brushroll, and the suction source are powered by a rechargeable power tool battery pack.

Also described herein is a floor cleaning machine including a housing having a front end and a rear end, and a rotary brush coupled to the housing for rotation with respect to the housing. A collection bin is configured to receive debris from the rotary brush and a debris intake is in fluid communication with the collection bin. A motor rotates the rotary brush, and a power source supplies power to the motor. A suction source is in fluid communication with the collection bin to draw debris into the debris intake and to direct the debris into the collection bin. A projection is positioned adjacent the rotary brush and the debris intake engage bristles of the rotary brush to dislodge debris from the bristles, so that the suction source is configured to draw debris dislodged from the bristles of the rotary brush into the debris intake.

Also described herein is a floor cleaning machine including a housing having a front end and a rear end and a wheel coupled to the housing to facilitate moving the machine along a surface to be cleaned. A rotary brush is coupled to the housing for rotation with respect to the housing, and a collection bin is configured to receive debris from the rotary brush. The collection bin includes a front wall positioned between the front end of the housing and the rear end of the housing, the front wall defining an entry opening, a rear wall positioned adjacent the rear end of the housing, and an upper wall extending between the front wall and the rear wall. The upper wall is oriented at an oblique angle with respect to the surface being cleaned, such that a cross-sectional area of the collection bin increases in a direction from the entry opening in the front wall toward the rear wall. A debris intake is in fluid communication with the entry opening in the front wall of the collection bin. A motor rotates the rotary brush, and a power source supplies power to the motor. A suction source is configured to draw debris into the debris intake and direct the debris into the collection bin, such that debris directed into the entry opening in the front wall of the collection bin is directed along the oblique upper wall toward the rear wall.

Also described herein is a floor cleaning machine including a housing having a front end and a rear end, and a rotary brush coupled to the housing for rotation with respect to the housing. A collection bin receives debris from the rotary brush, and a debris intake is in fluid communication with the collection bin. A motor rotates the rotary brush, and a power source supplies power to the motor. A first suction source draws air and debris through the debris intake. A second suction source draws air from the collection bin to create a negative pressure in the collection bin to move the debris drawn through the debris intake by the first suction source into the collection bin in response to the negative pressure in the collection bin created by the second suction source.

<FIG> illustrates a floor cleaning machine <NUM> or floor sweeper according to an embodiment of the invention. The machine includes a housing <NUM> having a front end <NUM>, a rear end <NUM>, a handle <NUM> pivotally coupled to the housing <NUM> proximate the rear end, and first and second rotary brushes 30a, 30b coupled to the housing <NUM> proximate the front end <NUM>. A pair of ground engaging wheels <NUM> are coupled to the housing <NUM> proximate the rear end <NUM> to facilitate moving the machine <NUM> along a surface to be cleaned (see surface <NUM> in <FIG>).

Each of the brushes 30a, 30b is rotatable about a brush axis <NUM> and includes a hub <NUM> (<FIG>) and a plurality of bristles <NUM> extending outward from the hub <NUM>. The bristles <NUM> extend from the hub at a downward angle such that the brushes 30a, 30b are generally bowl-shaped. The brushes 30a, 30b are configured to rotate in opposite directions to convey dirt and debris generally inward, toward a longitudinal axis <NUM> of the machine <NUM> that extends through the center of the housing <NUM> and through the front and rear ends <NUM>, <NUM>, and rearward, toward an inlet <NUM> in the front end <NUM> of the housing <NUM> (<FIG>). For example, the second rotary brush 30b on the right hand side of the machine <NUM> rotates about its brush axis <NUM> in direction <NUM>, and the first rotary brush 30a on the left hand side of the machine <NUM> rotates about its brush axis <NUM> in direction <NUM>. The brush axes <NUM> may be oriented vertically (i.e. perpendicular to the surface being cleaned <NUM>). In other embodiments, the brush axes <NUM> may be oblique with respect to the surface being cleaned <NUM>. For example, the brush axes <NUM> of <FIG> are inclined forward with respect to the surface being cleaned <NUM>. In some embodiments, the orientation of the brush axes <NUM> may be adjustable by a user of the machine <NUM>. In some embodiments, the height of each of the brushes 30a, 30b may be adjustable.

With reference to <FIG>, the machine <NUM> further includes a brushroll <NUM> rotatably supported by the housing <NUM> at a position rearward of the brushes 30a, 30b. The brushroll <NUM> defines a rotational axis <NUM> that is generally transverse to the longitudinal axis <NUM> of the housing <NUM>. The brushroll <NUM> is rotatable in direction <NUM> to sweep dust and debris upward and rearward into a collection bin <NUM> located within the housing <NUM> behind the brushroll <NUM>. The brushroll <NUM> and the rotary brushes 30a, 30b are driven by a drive assembly <NUM> that includes at least one electric motor <NUM>. In the illustrated embodiment, the brushroll <NUM> can be driven at a maximum rotational speed greater than <NUM> RPM. For example, in some embodiments, the brushroll <NUM> can be driven at a maximum rotational speed of <NUM> RPM. The high brushroll speed advantageously removes more dust and debris from the surface being cleaned than is possible at lower speeds.

The motor <NUM> of the drive assembly <NUM> may be any type of electric motor but is preferably a DC electric motor, such as a brushed DC motor or a brushless DC motor. The motor <NUM> can be coupled to the brushroll <NUM> and the rotary brushes 30a, 30b via one or more belts, pulleys, gears, and the like. In some embodiments, the drive assembly <NUM> may include multiple motors. For example, in one embodiment (not shown), the drive assembly <NUM> includes a first motor coupled to the brushroll <NUM> and a second motor coupled to the rotary brushes 30a, 30b. This allows the brushroll <NUM> and the rotary brushes 30a, 30b to be controlled independently. In another embodiment (not shown), the drive assembly <NUM> includes a first motor coupled to the brushroll <NUM>, a second motor coupled to one rotary brush 30a, and a third motor coupled to the other rotary brush 30b. This allows the brushroll <NUM> and each of the rotary brushes 30a, 30b to be controlled independently. In some embodiments, the motors may directly drive the rotary brushes 30a, 30b and/or the brushroll <NUM>.

In some embodiments, the brushroll <NUM> and the rotary brushes 30a, 30b may also be drivably coupled to the wheels <NUM>. For example, the machine <NUM> may be operable in a manual or unpowered mode in which the brushroll <NUM> and the rotary brushes 30a, 30b are driven in response to rotation of the wheels <NUM>, as a user pushes the machine <NUM> along a surface. In some embodiments, the rotary brushes 30a, 30b may be drivably coupled to other ground-engaging wheels, such as castors (not shown) extending downward from the respective hubs <NUM>.

Referring to <FIG>, the illustrated machine <NUM> includes a suction source <NUM> that generates a suction airflow at a first suction zone <NUM> and a second suction zone <NUM> (<FIG>). The first suction zone <NUM> is located proximate a leading edge of the brushroll <NUM> and generally between the brushroll <NUM> and the rotary brushes 30a, 30b. The second suction zone <NUM> is located in the collection bin <NUM> to produce negative pressure within the collection bin <NUM>. The suction source <NUM> is fluidly coupled to the first suction zone <NUM> via a first flow path <NUM>, and the suction source <NUM> is fluidly coupled to the second suction zone <NUM> via a second flow path <NUM>. The first flow path <NUM> and the second flow path <NUM> each extend through a filter <NUM> (e.g., a pleated filter), located between the suction zones <NUM>, <NUM> and the suction source <NUM>. In the illustrated embodiment, the filter <NUM> is located above the collection bin <NUM>; however, the filter can be located elsewhere. In some embodiments, the suction source <NUM> can generate a maximum combined airflow rate along the first flow path <NUM> and the second flow path <NUM> between about <NUM> CFM and about <NUM> CFM.

Referring to <FIG>, in the illustrated embodiment, the suction source <NUM> includes a first vacuum motor <NUM> configured to generate airflow along the first flow path <NUM> and a second vacuum motor <NUM> configured to generate airflow along the second flow path <NUM>. The vacuum motors may <NUM>, <NUM> be controlled to independently vary the airflow rate along the first flow path <NUM> and the second flow path <NUM>. In other embodiments, the suction source <NUM> may include a single vacuum motor configured to generate airflow along both the first flow path <NUM> and the second flow path <NUM>. In such embodiments, one or more valves or dampers may be provided in one or both the first flow path <NUM> and the second flow path <NUM> to independently vary the airflow rate along the first flow path <NUM> and the second flow path <NUM>. In some embodiments, the suction source <NUM> may not include a vacuum motor but instead may include one or more fans driven by the drive assembly <NUM>.

With reference to <FIG>, the first flow path <NUM> includes first and second debris intake nozzles <NUM> that are positioned in the first suction zone <NUM>. The intake nozzles <NUM> are positioned forward of the brushroll <NUM> and are spaced from one another in a direction parallel to the rotational axis <NUM> of the brushroll <NUM>. The intake nozzles <NUM> are preferably located just above the bristles <NUM> of the rotary brushes 30a, 30b so as to intake dust shed by the rotary brushes 30a, 30b.

As shown in <FIG> and <FIG>, projections <NUM> are provided in the travel path of the bristles <NUM> to engage and agitate the bristles <NUM> as they pass near the intake nozzles <NUM> in the first suction zone <NUM>. In other embodiments, the first flow path <NUM> may include only a single intake nozzle <NUM> that may extend along the width of the housing <NUM>, or more than two intake nozzles <NUM> may be used.

Referring to <FIG>, the collection bin <NUM> in the illustrated embodiment includes an upper wall <NUM>, a rear wall <NUM>, a front wall <NUM> generally opposite the rear wall <NUM>, and an entry opening <NUM> in front wall. The upper wall <NUM> is angled upward at an oblique angle <NUM> such that a cross-sectional area of the collection bin <NUM> increases in a direction from the front wall <NUM> toward the rear wall <NUM>. The angled upper wall <NUM> provides clearance for debris that is propelled by the brushroll <NUM> to pass into the collection bin <NUM> along an arcuate or generally parabolic trajectory <NUM>. This advantageously reduces the likelihood that debris entering the collection bin <NUM> will jam together near the entry opening <NUM>. In the illustrated embodiment, a comb <NUM> extends from the entry opening <NUM> into engagement with the rear side (i.e. the trailing side) of the brushroll <NUM>. The comb <NUM> thus spans any gap between the front wall <NUM> of the collection bin <NUM> and the brushroll <NUM> to inhibit debris from accumulating between the brushroll <NUM> and the front wall <NUM>. The comb <NUM> also engages the brushroll <NUM> as it rotates and may thus dislodge debris from the brushroll <NUM>. The comb <NUM> is made of metal in some embodiments for strength and durability.

With reference to <FIG>, the illustrated collection bin <NUM> includes a U-shaped first handle <NUM> pivotally coupled to the front of the collection bin <NUM> and a second handle <NUM> formed in the rear of the collection bin <NUM>. To remove the collection bin <NUM> from the housing <NUM>, a user pivots the first handle <NUM> up (<FIG>), then lifts up on the first and second handles <NUM>, <NUM> simultaneously to free the collection bin <NUM> from the housing <NUM> (<FIG>). With the collection bin <NUM> free from the housing <NUM>, the user can allow the weight of the collection bin <NUM> to pivot the collection bin <NUM> downward about the first handle <NUM> into a carrying position (<FIG>). In the carrying position, the entry opening <NUM> of the collection bin <NUM> is oriented upward toward the first handle <NUM> so that debris is maintained in the collection bin <NUM> under the influence of gravity. The user can then empty the collection bin <NUM> as illustrated in <FIG>. After emptying the collection bin <NUM>, the user can re-attach the collection bin <NUM> to the housing <NUM> by reversing the previous steps. In some embodiments, the collection bin <NUM> includes one or more transparent regions to permit a user to determine when the collection bin <NUM> should be emptied.

With reference to <FIG>, in the illustrated embodiment, the handle <NUM> includes a first portion <NUM> pivotally coupled to the housing <NUM> and a second portion <NUM> that can telescope into and out of the first portion <NUM> to vary an overall length of the handle <NUM>. The handle <NUM> is movable between a deployed position (<FIG>), in which the second portion <NUM> is fully extended from the first portion <NUM>, and the handle <NUM> extends upward and rearward from the housing <NUM>, and a storage position (<FIG>) in which the second portion <NUM> is fully inserted into the first portion <NUM> and the handle <NUM> is pivoted downward so as to overlie (i.e. extend along the top surface of) the housing <NUM>. In some embodiments, the handle <NUM> can be locked in the storage position, allowing the machine <NUM> to be transported upright on the wheels <NUM> (<FIG>). In some embodiments, controls (including, for example, one or more switches, buttons, dials, and the like) may be provided on the second portion <NUM> of the handle <NUM> for controlling operation of the machine <NUM>. For example, the user may manipulate the controls to turn the suction source <NUM> on and off, vary the airflow rate along the first flow path <NUM> and the second flow path <NUM>, turn the brushroll <NUM> and the brushes 30a, 30b on and off, and vary the speed of the brushroll <NUM> and the brushes 30a, 30b (<FIG>).

Referring to <FIG>, the illustrated machine <NUM> further includes a battery <NUM> configured to provide power to the drive assembly <NUM> and the suction source <NUM>. In some embodiments, the machine <NUM> is configured to draw a maximum power from the battery <NUM> during operation of less than <NUM> Watts. The battery <NUM> is removably coupled to a battery receptacle <NUM>, which, in the illustrated embodiment is located on top of the housing <NUM> and centered along the axis <NUM>. Alternatively, the battery <NUM> and receptacle <NUM> can be located elsewhere. The illustrated battery <NUM> is a power tool battery pack with a plurality of rechargeable battery cells (e.g., lithium-based battery cells; not shown) providing the battery <NUM> with a nominal output voltage of about 18V. In other embodiments, the battery <NUM> can have a different nominal voltage, such as, for example, 12V, 36V, or 40V. In another embodiment illustrated in <FIG>, the machine <NUM> includes two batteries <NUM> disposed in adjacent battery receptacles <NUM>. In such an embodiment, the batteries <NUM> may be connected in series or in parallel. In other embodiments, the machine <NUM> may include more than two batteries <NUM>. Alternatively, the machine <NUM> may be configured to receive power from a wall outlet or other remote power source. With reference to <FIG>, in some embodiments, at least a portion of the air flowing along the first flow path <NUM> and/or the second flow path <NUM> may be directed to cool the battery <NUM> (or batteries <NUM>). For example, the suction source <NUM> may be configured to discharge air over the battery <NUM>.

With reference to <FIG>, in operation, a user grasps the handle <NUM> and pushes the machine <NUM> along a surface to be cleaned. The battery <NUM> powers the drive assembly <NUM>, which drives the rotary brushes 30a, 30b and the brushroll <NUM>. The rotary brushes 30a, 30b sweep dust and debris toward the inlet <NUM> (<FIG>). After entering the housing <NUM>, the dust and debris is swept up and rearward into the collection bin <NUM> by the brushroll <NUM> (<FIG>). The angled upper surface <NUM> of the collection bin <NUM> allows the dust and debris to enter the collection bin <NUM> along an arcuate path <NUM> to avoid debris build up at the entry opening <NUM>. Dust and debris that may cling to the bristles <NUM> of the brushes 30a, 30b is agitated off of the bristles <NUM> by the projections <NUM> (<FIG> and <FIG>) and can then be entrained in the first air flow path <NUM> via the inlet nozzles <NUM> or swept up by the brushroll <NUM>. Dust and debris that may cling to the brushroll <NUM> is agitated off of the brushroll <NUM> by the comb <NUM>. The negative pressure in the collection bin <NUM> due to the second suction zone <NUM> helps draw dust and debris into the collection bin <NUM>. The user may manipulate the controls to turn the suction source <NUM> on and off, independently vary the airflow rate along the first flow path <NUM> and the second flow path <NUM>, turn the brushroll <NUM> and the brushes 30a, 30b on and off, and vary the speed of the brushroll <NUM> and the brushes 30a, 30b to optimize cleaning performance.

In some embodiments, the machine <NUM> may also be used in a manual or unpowered mode (e.g., if the battery <NUM> is depleted or removed from the machine <NUM>). In the manual mode, the brushroll <NUM> and the rotary brushes 30a, 30b are driven in response to rotation of the wheels <NUM> or other ground-engaging features as the user pushes the machine <NUM> along the surface to be cleaned. In the manual mode, the drive assembly <NUM> may be disconnected from the brushroll <NUM> and the brushes 30a, 30b.

<FIG> illustrate a floor cleaning machine <NUM> according to another embodiment. The floor cleaning machine <NUM> is similar to the floor cleaning machine <NUM> described above with reference to <FIG> but includes two brushrolls 1066a, 1066b, each rotating in opposite directions. In addition, the collection bin <NUM> is disposed between the wheels <NUM> and has a cylindrical shape defining a longitudinal axis <NUM> that is coaxial with the rotational axis of the wheels <NUM>.

Claim 1:
A floor cleaning machine (<NUM>) comprising:
a housing (<NUM>) having a front end and a rear end;
a rotary brush (30a, 30b) coupled to the housing for rotation with respect to the housing, the rotary brush rotatable about an axis (<NUM>) that extends at an oblique angle with respect to a surface to be cleaned;
a collection bin (<NUM>) configured to receive debris from the rotary brush;
a brushroll (<NUM>) coupled to the housing between the front end (<NUM>) and the rear end (<NUM>) for rotation with respect to the housing, the brushroll rotating about a brushroll axis, the brushroll axis being substantially parallel to the surface to be cleaned;
a debris intake in fluid communication with the collection bin, the debris intake including at least one nozzle (<NUM>) located forward of the brushroll and above bristles (<NUM>) of the rotary brush;
a motor (<NUM>) that rotates the rotary brush;
a power source (<NUM>) that supplies power to the motor;
a suction source (<NUM>) in fluid communication with the collection bin, the suction source configured to draw debris into the debris intake and to direct the debris into the collection bin;
a projection (<NUM>) positioned adjacent the rotary brush and the debris intake, the projection engages bristles of the rotary brush to dislodge debris from the bristles such that the suction source is configured to draw debris dislodged from the bristles of the rotary brush into the debris intake.