Patent Description:
A handheld extraction cleaner is known e.g. from <CIT> or <CIT>.

The invention relates to a handheld extraction cleaner comprising a unitary body including a carry handle; a fluid delivery system including a supply tank carried by the unitary body and at least one fluid distributor; and a recovery system including a working air path through the unitary body, a suction nozzle defining an inlet to the working air path, a suction source in fluid communication with the suction nozzle, and a recovery tank removably mounted to the unitary body. The recovery tank comprises: a tank body defining a collection chamber for dirty liquid recovered by the recovery system; an inlet opening in the tank body, the collection chamber configured to receive dirty liquid through the inlet opening; a spring-loaded flapper door that automatically seals the inlet opening when the recovery tank is removed from the unitary body; and a flapper actuator to automatically open the flapper door when the recovery tank is mounted on the unitary body. The flapper actuator comprises at least one rib to push the flapper door open and away from the inlet opening. The flapper door comprises an inner surface facing the collection chamber, an outer surface facing away from the collection chamber, and at least one projection extending from the outer surface. The at least one projection is engaged by the at least one rib when the recovery tank is mounted on the unitary body.

According to one aspect of the invention not forming part of the claimed invention, the handheld extraction cleaner includes a supply tank, a recovery tank, and a vacuum motor, all of which are carried on a unitary body having a carry handle, wherein the supply tank is provided in front of the suction motor and the recovery tank is provided below the supply tank and the suction motor, and wherein the recovery tank has a substantially flat bottom end on which the extraction cleaner can be supported in a self-standing or at rest position on a surface.

In certain embodiments, the extraction cleaner has a powered brushroll at a forward end of the body, and the vacuum motor is at a rearward end of the body. Optionally, the extraction cleaner comprises a battery below the carry handle.

In one embodiment, the extraction cleaner has a cleaning head and a neck connecting the cleaning head to a rearward body. A suction nozzle and the brushroll can be provided in the cleaning head. The vacuum motor, recovery tank, and battery can be provided in the rearward body. Optionally, the neck projects forwardly to support the cleaning head away from a surface on which the extraction cleaner is resting, spacing the suction nozzle and brushroll out of contact with the surface.

According to another aspect of the invention, a handheld extraction cleaner includes a supply tank that improves cleaning liquid usage and usable tank volume in multiple orientations. A drain-pipe is provided in the bottom of the supply tank to provide liquid to an outlet of the tank even when the extraction cleaner is tipped forward.

In one embodiment, the supply tank has a pivotally-mounted fill cap. Thus, the supply tank can be filled either on or off the extraction cleaner.

According to yet another aspect of the invention, a handheld extraction cleaner includes a recovery tank that mitigates the chance for spillage and improves usable tank volume in multiple orientations, such as in both an operational position and a storage or at rest position. The recovery tank can have an anti-spill shape which directs dirty liquid away from an inlet opening of the tank when the extraction cleaner is rested on a surface, reducing the change for spillage.

In certain embodiments, the recovery tank includes a tank body having a first portion and a second portion, wherein the first portion of the recovery tank is disposed at an angle relative to the second portion of the recovery tank, and an inlet opening in the first portion of the tank body. The second portion of the tank body can have a bottom surface configured to rest on a horizontal surface to support the handheld extraction cleaner in a horizontal orientation on the horizontal surface. To mitigate spills, the inlet opening can be disposed above the second portion of the tank body when the extraction cleaner is at rest in the horizontal orientation on the horizontal surface to direct dirty liquid away from the inlet opening.

In certain embodiments, the recovery tank has a spring-loaded flapper door that automatically seals an inlet opening of the tank when the recovery tank is removed from extraction cleaner.

According to still another aspect of the invention, a handheld extraction cleaner includes a powered brushroll. The brushroll is operably coupled with a brush drive motor by a drive assembly.

In one embodiment, the brushroll is removable from a brush chamber of the extraction cleaner. A bottom cover or sole plate secures the brushroll within the brush chamber. Removable of the sole plate allows for removal of the brushroll.

In certain embodiments, the brushroll has a handle on a non-driven end of the brushroll to facilitate removal of the brushroll from the brush chamber. Optionally, the brushroll is exchangeable with a different agitator.

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

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

The invention will now be described with respect to the drawings in which:.

The invention relates generally to extraction cleaners, and more particularly to a portable, handheld extraction cleaner which applies cleaning fluid to a surface and then extracts the applied fluid therefrom.

<FIG> is a perspective view of a handheld extraction cleaner <NUM> according to one embodiment of the invention. As illustrated herein, the extraction cleaner <NUM> is adapted to be handheld and portable, and can be easily carried or conveyed by hand. The hand-carriable extraction cleaner <NUM> can have a unitary body <NUM> provided with a carry handle <NUM> attached to the unitary body <NUM>, and is small enough to be transported by one user (i.e. one person) to the area to be cleaned.

For purposes of description related to the figures, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," "inner," "outer," and derivatives thereof shall relate to the invention as oriented in <FIG> from the perspective of a user behind the extraction cleaner <NUM>, which defines a rear end of the extraction cleaner <NUM>, and carrying the extraction cleaner <NUM> by the handle <NUM>, which defines an upper end of the extraction cleaner <NUM>. When used in referring to a direction, the term "longitudinal" refers to a direction generally extending along the length of the extraction cleaner <NUM>, between a forward end <NUM> and a rearward end <NUM> of the housing <NUM>, and the terms "transverse" or "lateral" refer to a direction generally perpendicular to the longitudinal direction. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. The use of directional terms should not be interpreted to limit the invention to any specific orientation.

The handheld extraction cleaner <NUM> comprises a unitary body <NUM> or housing that carries the various functional systems of the extraction cleaner <NUM>, including a fluid delivery system for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned and a recovery system removing the spent cleaning fluid and debris from the surface to be cleaned and storing the spent cleaning fluid and debris. The term "debris" as used herein may include dirt, dust, soil, hair, and other debris, unless otherwise noted. The term "cleaning fluid" as used herein primarily encompasses liquids, and may include steam unless otherwise noted.

Referring additionally to <FIG>, the recovery system can include a working air path through the body <NUM>, and may include a dirty air inlet and a clean air outlet. The working air path can be formed by, among other elements, a suction nozzle <NUM> defining the dirty air inlet, a suction source <NUM> in fluid communication with the suction nozzle <NUM> for generating a working air stream, a recovery tank <NUM> for separating and collecting fluid and debris from the working airstream for later disposal, and exhaust vents <NUM> in the housing defining the clean air outlet. The recovery system can further include a separator <NUM> for separating liquid and entrained debris from the working airstream. The separator <NUM> can be formed in a portion of the recovery tank <NUM>, or, as illustrated herein, can be separate from the recovery tank <NUM>. The separated fluid and debris can be collected in the recovery tank <NUM>. One suitable separator <NUM> is disclosed in <CIT>. Other examples of suitable separators are disclosed in <CIT> and <CIT>.

The fluid delivery system can include a supply reservoir or supply tank <NUM> for storing a supply of fluid. The fluid can comprise one or more of any suitable cleaning fluids, including, but not limited to, water, compositions, concentrated detergent, diluted detergent, etc., or mixtures thereof. For example, the fluid can comprise a mixture of water and concentrated detergent. The fluid delivery system can further comprise a flow control system <NUM> for controlling the flow of fluid from the supply tank <NUM> to at least one fluid distributor <NUM>. In one embodiment, described in further detail below, the flow control system <NUM> of the fluid delivery system can comprise a pump <NUM> (see <FIG> and <FIG>), which pressurizes the system. Optionally, a heater (not shown) can be provided for heating the cleaning fluid prior to delivering the cleaning fluid to the surface to be cleaned. In yet another example, cleaning fluid can be heated using exhaust air from a motor-cooling pathway for the suction source <NUM>.

The suction source <NUM>, which may be a motor/fan assembly, is provided in fluid communication with the recovery tank <NUM>. As shown, the motor/fan assembly <NUM> includes a vacuum motor <NUM> and a fan <NUM>. A chamber <NUM> for the motor/fan assembly <NUM> can be defined by molded features in the housing <NUM>.

An agitator 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>. As shown, the agitator comprises a powered brushroll <NUM>. The brushroll <NUM> can be provided at a forward portion of the housing <NUM> and received in a brush chamber <NUM>. The brushroll <NUM> is configured for rotational movement about a substantially horizontal rotational axis, relative to the normal use position of the extraction cleaner <NUM>. While a horizontally-rotating brushroll <NUM> is shown herein, in some embodiments, dual horizontally-rotating brushrolls, one or more vertically-rotating brushrolls, or a stationary brush can be provided on the extraction cleaner <NUM>.

The brushroll <NUM> can be operably coupled to and driven by a drive assembly including a brush drive motor <NUM>. A chamber <NUM> for the drive motor <NUM> can be defined by molded features in the housing <NUM>. The coupling between the brushroll <NUM> and the drive motor <NUM> can comprise one or more belts, gears, shafts, pulleys or combinations thereof. Alternatively, the vacuum motor <NUM> can provide both vacuum suction and brushroll rotation.

The extraction cleaner <NUM> can include at least one user interface <NUM> through which a user can interact with the extraction cleaner <NUM>. The user interface <NUM> can enable operation and control of the extraction cleaner <NUM> by the user. The user interface <NUM> can be electrically coupled with electrical components, including, but not limited to, circuitry electrically connected to various components of the fluid delivery and collection systems of the extraction cleaner <NUM>. The user interface <NUM> can include one or more input controls <NUM>, <NUM>, <NUM>, which can comprise a button, trigger, toggle, key, switch, touch screen, or the like, or any combination thereof. In the embodiment shown herein, one input control <NUM> is a power input control which controls the supply of power to the vacuum motor <NUM>, another input control <NUM> is a power input control which controls the supply of power to the pump <NUM>, and another input control <NUM> is a power input control which controls the supply of power to the drive motor <NUM>. Thus, suction, fluid delivery, and brush rotation can be implemented individually, or in any combination, by operation of the input controls <NUM>, <NUM>, <NUM>. In the embodiment shown, the input controls <NUM>, <NUM>, <NUM> can comprise on/off buttons in register with a printed circuit board (PCB) <NUM>. The buttons can be provided on a forward end of the carry handle <NUM> and the PCB <NUM> can be located within the carry handle <NUM>. The input controls <NUM>, <NUM>, <NUM> can conveniently be provided on an upper side of the handle <NUM>, at a forward end thereof, for operation of the controls by a thumb of the user's hand that is gripping the carry handle <NUM>.

Electrical power can be provided by a source of mains electricity or by a battery or battery pack. In the present embodiment, the extraction cleaner <NUM> comprises a rechargeable battery pack <NUM>. An appropriate charger can be provided with the extraction cleaner <NUM>. A charging port <NUM> can be provided on the housing <NUM> and can be electrically coupled with the battery pack <NUM>. In the illustrated embodiment, the charging port <NUM> is provided on a rear end of the carry handle <NUM>. A storage and recharging cradle (not shown) can mount the extraction cleaner <NUM> when not in use, and can include a recharging connector that couples with the charging port <NUM> and an electrical cord electrically connected between the recharging connector and an AC/DC transformer that can be plugged into an electrical outlet for supplying DC recharging current to the battery pack <NUM>. In an alternative embodiment, the extraction cleaner <NUM> can have charging contacts on the housing <NUM>, and a docking station (not shown) can be provided for docking the extraction cleaner <NUM> for recharging the battery pack <NUM>.

<FIG> is a side view of the handheld extraction cleaner <NUM> from <FIG>, shown in one example of an operative or normal use position relative to a surface S to be cleaned. In the operative or normal use position, the extraction cleaner <NUM> is held with the suction nozzle <NUM> generally adjacent the surface to be cleaned. The suction nozzle <NUM> is provided at a forward end <NUM> of the housing <NUM> while the suction source <NUM>, shown in phantom line in <FIG>, is provided at a rearward end <NUM> of the housing <NUM>. The supply tank <NUM> can be provided forwardly of the suction source <NUM>, and above the suction nozzle <NUM>. The recovery tank <NUM> can be provided on the housing <NUM> below the supply tank <NUM> and suction source <NUM>, and can be longitudinally disposed between the supply tank <NUM> and the suction source <NUM>. The carry handle <NUM> is disposed above the recovery tank <NUM>, and extends behind the supply tank <NUM> in the longitudinal direction. The carry handle includes a hand grip portion and a finger receiving area, which can be a closed volume, e.g. a closed loop handgrip. The brushroll <NUM> and brush drive motor <NUM>, shown in phantom line in <FIG>, are provided at the forward end <NUM> of the housing <NUM>. The pump <NUM> and battery pack <NUM>, shown in phantom line in <FIG>, are provided above the recovery tank <NUM> and below the carry handle <NUM>. This arrangement of component parts of the extraction cleaner <NUM> offers a balanced weight in hand for the user, and a comfortable carrying and operational position.

The housing <NUM> can include a cleaning head <NUM> and a neck <NUM> connecting the cleaning head <NUM> to a rearward body <NUM> including the carry handle <NUM>. The suction nozzle <NUM> and brushroll <NUM> can be provided in the cleaning head <NUM>. The suction source <NUM>, recovery tank <NUM>, and battery pack <NUM> can be provided in the rearward body <NUM>. As can be seen in <FIG>, the carry handle <NUM> is oriented so that cleaning head <NUM> is flat against the surface S when carry handle <NUM> is generally parallel to the surface S. The recovery tank <NUM>, and particularly the bottom end <NUM> of the recovery tank <NUM>, can be angled away from the surface S in this position for maneuverability.

The handheld extraction cleaner <NUM> can be rested in a stable manner on a surface, without leakage from either tank <NUM>, <NUM>. <FIG> is a side view of the handheld extraction cleaner <NUM> showing the handheld extraction cleaner <NUM> in a self-standing or at rest position on a surface S. As shown, the extraction cleaner <NUM> can rest on the surface S in a horizontal position, with the handheld extraction cleaner <NUM> supported on a substantially flat bottom end <NUM> of the recovery tank <NUM>. The flat bottom end <NUM> of the recovery tank <NUM> can lie on the surface S, while the neck <NUM> of the housing <NUM> projects forwardly to support the cleaning head <NUM> away from the surface S. This can be helpful, because a user can set the extraction cleaner <NUM> down in a stable position, upon a shelf or a countertop, for example, without having the suction nozzle <NUM> or brushroll <NUM> in contact with the surface S, and any residual fluid or dirt on the brushroll <NUM> will not transfer to the surface S. Heavy components (relative to the weight of other components of the cleaner <NUM>) such as the suction source <NUM> and battery pack <NUM> are disposed in the rearward body <NUM>, which increases stability in the horizontal position.

Returning to <FIG>, the suction nozzle <NUM> can include a front wall <NUM> and a rear wall <NUM> defining a narrow suction pathway <NUM> therebetween, with an opening forming a suction nozzle inlet <NUM> at a lower end thereof. The suction pathway <NUM> is in fluid communication with the separator <NUM> leading to the recovery tank <NUM>.

The front wall <NUM> can optionally be formed by a nozzle cover <NUM> that is removable from the housing <NUM> for cleaning clogs and the like in the suction pathway <NUM>. The rear wall <NUM> can optionally define a portion of the brush chamber <NUM>, and can be disposed forwardly of the brushroll <NUM>. Alternatively, the front and rear walls <NUM>, <NUM> can be fixedly attached together in a non-separable configuration. For example, the front and rear walls <NUM>, <NUM> can be welded together.

The fluid distributor <NUM> can include at least one distributor outlet <NUM> for delivering fluid to the surface to be cleaned. The outlet <NUM> can be positioned to deliver fluid directly to the surface to be cleaned, outwardly in front of the suction nozzle <NUM> so that user can clearly see where fluid is being applied. Alternately, the outlet <NUM> can deliver fluid onto the brushroll <NUM> within the brush chamber <NUM>, rearwardly of the suction nozzle <NUM>. Alternatively, the outlet <NUM> can deliver fluid behind the suction nozzle <NUM> and brush chamber <NUM>. The outlet <NUM> can comprise any structure, such as a nozzle or spray tip. Multiple outlets can also be provided in other embodiments of the extraction cleaner <NUM>. As illustrated in <FIG>, the distributor <NUM> can comprise one spray tip provided on the front of the suction nozzle <NUM> which distributes cleaning fluid to the surface to be cleaned in front of the suction nozzle <NUM> from the distributor outlet <NUM>.

<FIG> is a partially-exploded view of the handheld extraction cleaner <NUM> from <FIG>, illustrating the removal of the recovery tank <NUM>, supply tank <NUM>, and nozzle cover <NUM> from the housing <NUM>. The recovery tank <NUM> can be removably mounted in a recovery tank receiver <NUM> formed on a lower side of the housing <NUM>. The supply tank <NUM> can be removably mounted in a supply tank receiver <NUM> formed on an upper side of the housing <NUM>. The supply tank receiver <NUM> has a tank receiver inlet <NUM> which couples with the supply tank <NUM> to place the supply tank <NUM> in fluid communication with the pump <NUM> (<FIG>). Latches or other suitable structures can be provided on the housing <NUM> to secure the tanks <NUM>, <NUM> within their respective receivers <NUM>, <NUM>. Other mounting arrangements for the tanks <NUM>, <NUM> are possible, including mounting arrangements where one or both of the tanks <NUM>, <NUM> are fixedly attached to the housing <NUM> in a non-separable configuration.

An opening <NUM> from the suction pathway <NUM> to the separator <NUM> can be formed in the rear wall <NUM> of the suction nozzle <NUM> defining the suction pathway <NUM>. The nozzle cover <NUM> can be removably mounted over a forward end <NUM> of the housing <NUM> to enclose the opening <NUM> to the separator <NUM>. Optionally, in addition to the front and rear walls <NUM>, <NUM> the suction pathway <NUM> can further by at least one peripheral wall <NUM> extending between the front and rear walls <NUM>, <NUM> and around one or more of the sides and top of the suction pathway <NUM>. As shown herein, the peripheral wall <NUM> can comprise a rib extending from the rear wall <NUM> and mating with the nozzle cover <NUM> when the nozzle cover <NUM> is mounted on the forward end <NUM> of the housing <NUM>.

At least a portion of the fluid distributor <NUM> can extend through an opening <NUM> in the nozzle cover <NUM> to position the distributor outlet <NUM> on the exterior of the nozzle cover <NUM>. The opening <NUM> receives and holds the fluid distributor <NUM> when the cover <NUM> is mounted on the housing <NUM>. When the user removes the nozzle cover <NUM> from the housing <NUM>, the fluid distributor <NUM> remains on the housing <NUM>.

The extraction cleaner <NUM> can include a retainer <NUM> to removably secure the nozzle cover <NUM> on the housing <NUM>. In the illustrated embodiment, the retainer <NUM> includes a flexible latch <NUM> on the nozzle cover <NUM> and a latch receiver <NUM> on the housing <NUM>. To mount the nozzle cover <NUM> to the housing <NUM>, the nozzle cover <NUM> can be hooked onto the forward end <NUM> of the housing <NUM> at a lower end thereof via a hook (not shown) and pivoted until the latch <NUM> snap-fits into the latch receiver <NUM>. The supply tank <NUM> can rest on top of the nozzle cover <NUM> when mounted in the supply tank receiver <NUM>, further securing the nozzle cover <NUM> in place. To remove the nozzle cover <NUM>, a user can lift up on a lip <NUM> of the latch <NUM> to free the latch <NUM> from the latch receiver <NUM> and pull the cover <NUM> off the housing <NUM>. With the embodiment of the extraction cleaner <NUM> shown herein, the supply tank <NUM> must be removed prior to removal of the nozzle cover <NUM>. In other embodiments, the nozzle cover <NUM> may be removable without first removing the supply tank <NUM>.

<FIG> is a schematic view of the fluid delivery system of the handheld extraction cleaner <NUM>. As discussed above, the fluid delivery system illustrated herein includes the supply tank <NUM>, the pump <NUM>, the fluid distributor <NUM>, and optionally additional conduits, ducts, tubing, hoses, connectors, etc. fluidly coupling the components of the fluid delivery system together and providing a supply path from the tank <NUM> to the fluid distributor <NUM>. For example, a first conduit <NUM> can connect an outlet <NUM> of the receiver <NUM> with an inlet <NUM> of the pump <NUM> and a second conduit <NUM> can connect an outlet <NUM> of the pump <NUM> with an inlet <NUM> of the fluid distributor <NUM>, which is in fluid communication with the outlet <NUM>. The conduits <NUM>, <NUM> are indicated in phantom line in <FIG>, but it is understood that any of the conduits can comprise flexible tubing or molded rigid conduits.

The pump power input control <NUM> can be provided to power the pump <NUM> and dispense fluid to the distributor <NUM>. In one example, the pump <NUM> can be a centrifugal pump. In another example, the pump <NUM> can be a diaphragm or membrane pump. In still another example, the pump <NUM> can be a manually actuated spray pump. In yet another configuration of the fluid delivery system, the pump <NUM> can be eliminated and the flow control system <NUM> can comprise a gravity-feed system having a valve fluidly coupled with an outlet of the supply tank <NUM>, whereby when valve is open, fluid will flow under the force of gravity to the distributor <NUM>. However, the use of a pump offers the advantage of orienting the supply tank <NUM> and fluid distributor <NUM> relative to other components on the body <NUM> to provide a more balanced weight in hand as well as providing more consistent fluid flow rate compared to a gravity fed system.

<FIG> is a close-up sectional view showing the supply tank <NUM>. The supply tank <NUM> comprises a hollow tank body <NUM> defining a supply chamber <NUM> for holding a supply of cleaning liquid, with a tank outlet <NUM>. The tank outlet <NUM> can comprise a quick connect fitting <NUM> configured to mate with the tank receiver inlet <NUM>, whereby the tank outlet <NUM> can be quickly connected and unconnected to the receiver inlet <NUM> using a single hand. The quick connect fitting <NUM> can have a check valve <NUM> that is closed with the quick connect fitting <NUM> is disconnected from the receiver inlet <NUM>. Via the check valve <NUM>, the cleaning fluid is contained within the supply tank <NUM> automatically when the supply tank <NUM> is disconnected from the housing <NUM>, preventing leaks.

<FIG> shows an exemplary liquid level, indicated by phantom line L, in the tank <NUM> in the operative or normal use position of the extraction cleaner <NUM> (see <FIG>). <FIG> shows the liquid level L when the extraction cleaner <NUM> is tipped forward. In the tipped position, the liquid moves into a space <NUM> disposed generally opposite from the tank outlet <NUM>. To prevent the liquid from getting trapped, the supply tank <NUM> includes a drain pipe <NUM> so that the pump <NUM> can suck liquid from the supply tank <NUM> even when the extraction cleaner <NUM> is tipped forward. Below a certain level of liquid and at certain degrees of tip, liquid in the tank <NUM> would not be able to reach the tank outlet <NUM> without the drain pipe <NUM>.

The quick connect fitting <NUM> is on one side of the tank body <NUM> and thus, without the drain pipe <NUM>, a significant portion of liquid gets trapped in the space <NUM> disposed generally opposite from the quick connect fitting <NUM> when the tank <NUM> is tipped as shown in <FIG>. In the embodiment shown herein, where the quick connect fitting <NUM> is on the back or rear corner of the tank body <NUM>, the space <NUM> generally covers a front corner of the tank body <NUM> opposite the quick connect fitting <NUM>. As shown herein, the tank body <NUM> includes at least a front wall <NUM>, rear wall <NUM>, bottom wall <NUM> and side walls <NUM>, and the space <NUM> can be the space or volume of the supply chamber <NUM> defined by a lower portion of the front wall <NUM>, forward portion of the bottom wall <NUM> and lower forward portions of the side walls <NUM>. The quick connect fitting <NUM> can project outwardly from the rear wall <NUM>.

The drain pipe <NUM> is disposed at the bottom of the supply chamber <NUM>, and comprises a pipe inlet <NUM> in fluid communication with the supply tank <NUM> and a pipe outlet <NUM> in fluid communication with, or optionally forming, the tank outlet <NUM>. In the embodiment shown herein, liquid is supplied through the pipe outlet <NUM> to the check valve <NUM>. The drain pipe <NUM> can be defined by a horizontal baffle <NUM> separating the supply chamber <NUM> from a drain pathway <NUM>. Optionally, the drain pipe <NUM> can be a molded feature integrally formed with the tank body <NUM> as shown, or a separated pipe inserted into the tank body <NUM>.

Referring to <FIG>, the supply tank <NUM> has a fill opening <NUM> through which cleaning liquid can be poured into the supply chamber <NUM> and a fill cap <NUM> selectively closing the fill opening <NUM>. The fill cap <NUM> is pivotally coupled to the tank body <NUM> and can be opened to expose the fill opening <NUM>. The pivotable coupling ensures the fill cap <NUM> will not completely separate from the tank body <NUM> during filling. The fill opening <NUM> can be provided at a side of the tank body <NUM> that is accessible to a user when the supply tank <NUM> is mounted on the housing <NUM>, i.e. on a portion of the supply tank <NUM> that is exterior rather than interior to the extraction cleaner <NUM> when the supply tank <NUM> is mounted on the housing <NUM>.

The fill cap <NUM> can include a cover <NUM> and a plug <NUM> on a lower side of the cover <NUM> which fits into the fill opening <NUM> when the fill cap <NUM> is closed. The plug <NUM> is aligned with the fill opening <NUM> and sized to seal the fill opening <NUM> when the fill cap <NUM> is closed for a fluid-tight closure, such that the supply tank <NUM> does not leak when the fill cap <NUM> is closed. The plug <NUM> can be at least partially received in the fill opening <NUM> to stop up the fill opening <NUM> and can comprise a seal made of an elastomeric or other resilient material. Other sealing arrangements are possible, including seals which are not received within the fill opening <NUM> itself, but which provide a fluid-tight and leak proof engagement between the fill opening <NUM> and the fill cap <NUM>.

A first check valve <NUM> is provided on the fill cap <NUM> to allow ambient air into the supply tank <NUM> to displace dispensed liquid. The check valve <NUM> can be, for example, an umbrella valve, having a resilient circular sealing flap <NUM> for selectively sealing at least one vent hole <NUM>, which can be formed in the plug <NUM> of the fill cap <NUM>. The sealing flap <NUM> can lie adjacent to an inner surface of the plug <NUM> when closed. As liquid is pumped out of the supply tank <NUM>, negative pressure inside the supply tank <NUM> pulls the sealing flap <NUM> open, drawing ambient air into the supply chamber <NUM> via the vent hole(s) <NUM> to equalize pressure. Once pressure equalizes, the check valve <NUM> closes.

A second check valve <NUM> is provided on the tank body <NUM> for relieving positive pressure or off-gassing caused by some cleaning liquids. With some formulations of cleaning liquids, excess gas is generated inside the supply tank <NUM> due to reactions between various additives or off-gassing from peroxide formulations, for example. The check valve <NUM> can be, for example, an umbrella valve, having a resilient circular sealing flap <NUM> for selectively sealing at least one vent hole <NUM>, which can be formed in a top wall <NUM> of the tank body <NUM>, which is covered by the fill cap <NUM> when the fill cap <NUM> is closed. The sealing flap <NUM> can lie adjacent to the top wall <NUM> when closed. As excess gas forms in the supply tank <NUM>, positive pressure inside the supply tank <NUM> pushes the sealing flap <NUM> open, thereby venting the excess gas through the vent hole(s) <NUM> and under the fill cap <NUM> into the surrounding atmosphere. Once pressure equalizes, the check valve <NUM> closes.

<FIG> is a perspective view showing the fill cap <NUM> in an open or fill position. The fill cap <NUM> can be opened by lifting a lip <NUM> of the fill cap <NUM> that can be spaced from the top wall <NUM>. When the fill cap <NUM> is open, liquid from a liquid source, such as a faucet, hose, vessel, etc. can pour into the supply chamber <NUM>. Because the supply tank <NUM> can be refilled whether it is removed from or still connected with the housing <NUM>, the supply tank <NUM> is readily refilled. In the illustrated embodiment, the supply tank <NUM> is removable from the housing <NUM>, and can be refilled when the supply tank <NUM> is removed from the housing <NUM> or when the supply tank <NUM> is still mounted on the housing <NUM>. In another embodiment, the supply tank <NUM> may not be removable from the housing <NUM> by the user, and is refilled by carrying the entire extraction cleaner <NUM> to a faucet or the like.

<FIG> is a sectional view showing the recovery system of the handheld extraction cleaner <NUM>. As discussed above, the recovery system illustrated herein includes the suction nozzle <NUM>, the separator <NUM>, the recovery tank <NUM>, the suction source <NUM>, the exhaust vents <NUM> (<FIG>), and optionally additional conduits, ducts, tubing, hoses, connectors, etc. fluidly coupling the components of the recovery system together and providing a recovery path from the nozzle inlet <NUM> to the exhaust vents <NUM>. For example, working air separated from liquid and debris by the separator <NUM> can travel through a diffuser conduit <NUM> before reaching an inlet <NUM> of the suction source <NUM>. The diffuser conduit <NUM> has a gradually-increasing cross-sectional area to decrease the speed of the working air and increase its pressure. The diffuser conduit <NUM> can pass underneath the carry handle <NUM>. Optionally, a tortuous conduit <NUM> can connect an air outlet <NUM> of the separator <NUM> with an inlet <NUM> of the diffuser conduit <NUM> to improve air/liquid separation and reduce noise.

Referring to <FIG>, the recovery tank <NUM> comprises a hollow tank body <NUM> defining a collection chamber <NUM> for holding a recovered liquid and debris, with an inlet opening <NUM> that is in fluid communication with the separator <NUM> (<FIG>). A removable tank cap <NUM> can be provided in an outlet opening <NUM> formed in the tank body <NUM> for emptying any liquid or debris in the recovery tank <NUM> that may be collected in the collection chamber <NUM>.

The recovery tank <NUM> can include a flapper door <NUM> that seals the inlet opening <NUM> when the recovery tank <NUM> is removed from the housing <NUM>. The flapper door <NUM> normally closes the inlet opening <NUM>, as shown in <FIG>, and can pivot between the closed position shown in <FIG> and an open position shown in <FIG>. A torsion spring <NUM> or other suitable biasing means can bias the flapper door <NUM> toward the closed position. When removed from the housing <NUM>, the spring-loaded flapper door <NUM> automatically seals the inlet opening <NUM>. Optionally, a seal <NUM> can be provided on the flapper door <NUM> for sealing the interface between the flapper door <NUM> and the recovery tank inlet opening <NUM> when the flapper door <NUM> is closed.

Referring to <FIG>, the separator <NUM> includes a debris outlet <NUM> for transferring debris and liquid separated from the working airstream into the recovery tank <NUM>. A flapper actuator <NUM> can be provided adjacent the debris outlet <NUM> in order to automatically open the flapper door <NUM> when the recovery tank <NUM> is mounted on the housing <NUM>. In one embodiment of the invention, the actuator <NUM> can comprise at least one rib <NUM> which pushes the flapper door <NUM> open, or away from the tank inlet opening <NUM>, for example to the open position shown in <FIG>. The rib <NUM> can extend longitudinally across the debris outlet <NUM> and project downwardly. The flapper door <NUM> can include at least one projection <NUM> which is engaged by the actuator <NUM>. In the embodiment shown, the flapper door <NUM> includes a pair of projections <NUM> and the actuator <NUM> includes a pair of ribs <NUM>, although only one is shown in <FIG>. Other configurations for the flapper <NUM> and flapper actuator <NUM> are possible.

The projections <NUM> and ribs <NUM> can have complementary rounded profiles, which help to prevent scratching. The projections <NUM> also allow the ribs <NUM> to be shorter and less likely to be damaged while the recovery tank <NUM> is disassembled from the housing <NUM>.

When the recovery tank <NUM> is mounted on the housing <NUM>, the ribs <NUM> push open the flapper door <NUM>. Debris and liquid separated from the working airstream by the separator <NUM> can enter the recovery tank <NUM> via the aligned separator debris outlet <NUM> and recovery tank inlet opening <NUM>. Optionally, a seal <NUM> can be provided around the separator debris outlet <NUM> for preventing debris, liquid and air leaks between the separator debris outlet <NUM> and the recovery tank inlet opening <NUM>. The working airflow from the separator <NUM> passes through the air outlet <NUM> to the tortuous conduit <NUM> and diffuser conduit <NUM> connecting the separator <NUM> with the suction source <NUM>.

In some embodiments, the recovery tank <NUM> has an anti-spill shape which directs dirty liquid away from the inlet opening <NUM> when the extraction cleaner <NUM> is at rest, such as in the self-standing horizontal position shown in <FIG>, reducing the change for spillage. <FIG> shows an exemplary dirty liquid level, indicated by phantom line D, in the tank <NUM> in the operative or normal use position of the extraction cleaner <NUM>. <FIG> shows the liquid level D when the extraction cleaner <NUM> is at rest in the self-standing horizontal position. In the rest position, the liquid moves away from the tank inlet opening <NUM>.

The recovery tank <NUM> shown is approximately V-shaped in side elevation, and includes a first portion or leg <NUM> and a second portion or leg <NUM> that extends non-parallel to the first leg <NUM>. The inlet opening <NUM> can be provided at an upper end of the first leg <NUM> and the outlet opening <NUM> can be provided at an upper end of the second leg <NUM> (see <FIG>). In operation, dirty liquid is received through the inlet opening <NUM> at the first leg <NUM> of the recovery tank <NUM> and flows to the lowest point in the collection chamber <NUM> as shown in <FIG>, generally indicated at <NUM>. When the extraction cleaner <NUM> is rested in the horizontal position, as shown in <FIG>, the lowest point <NUM> in the collection chamber <NUM> shifts due to the changing angle of the recovery tank <NUM> and the liquid flows toward the second leg <NUM>, away from the inlet opening <NUM> in the first leg <NUM>. While a V-shaped tank is shown, other anti-spill shapes for the recovery tank <NUM> are possible, such as an L-shaped recovery tank.

The first and second portions <NUM>, <NUM> collectively define the collection chamber <NUM>. The volume of the collection chamber <NUM> defined by the second leg <NUM> can be greater than the volume of the collection chamber <NUM> defined by the first leg <NUM>, so that a greater amount of dirty liquid can be accommodated in the second leg <NUM> when the extraction cleaner <NUM> is at rest in the horizontal position. In the illustrated embodiment, the second leg <NUM> can be elongated relative to the first leg <NUM> to provide the second leg <NUM> with a greater volume than the first leg <NUM>.

The recovery tank <NUM> has a V-shaped bottom <NUM>, in side elevation, defined where the flat bottom end <NUM> on which the extraction cleaner <NUM> rests on the horizontal position and a sloped front end <NUM> which meets the bottom end <NUM>. The V-shaped bottom <NUM> defines the lowest point <NUM> in the collection chamber <NUM> in the use position, which provides the recovery tank <NUM> with a larger usable tank volume than a tank with an entirely flat bottom.

The recovery tank <NUM> can be removably received in the recovery tank receiver <NUM> formed on the bottom of the housing <NUM>. A spring-loaded tank release latch <NUM> can be provided on the bottom of the housing <NUM> to secure the recovery tank <NUM> within the receiver <NUM>. Other mounting arrangements for the recovery tank <NUM> are possible.

Referring to <FIG>, in one embodiment, the recovery tank <NUM> can be suspended on an underside of the housing <NUM>, between front and rear hangers <NUM>, <NUM> of the tank receiver <NUM>. One of the hangers can be carried by the spring-loaded tank release latch <NUM> to release the tank <NUM> from the hanger. In the illustrated embodiment, the release latch <NUM> can be pivotally mounted on the housing <NUM> and includes a latching end forming the front hanger <NUM> and which engages a front end <NUM> of the recovery tank <NUM>. The rear hanger <NUM> seats a rear end <NUM> of the tank <NUM> to support the rearward end of the tank <NUM> on the housing <NUM>, with the rear hanger <NUM> blocking dislocation of the tank <NUM> from the housing <NUM> and providing a pivot point for rotation of the tank <NUM> upwardly into latched engagement with the housing <NUM>.

The release latch <NUM> can include a post <NUM> pivotally coupled to the housing <NUM> at an upper end thereof. The front hanger <NUM> can project from a lower end of the post <NUM>, such that pivoting of the post <NUM> moves the front hanger <NUM>. A user-engagable end <NUM> is also provided at the lower end of the post <NUM> and can positioned within the area of the neck <NUM> for easy access.

The release latch <NUM> is biased toward the latching position shown in <FIG> by a return spring <NUM>. A spring seat <NUM> projects from the post <NUM> in a direction opposite that of the front hanger <NUM>. The force from the return spring <NUM> on the spring seat <NUM> biases the lower end of the post <NUM> rearwardly to bring the front hanger <NUM> into engagement with the front end <NUM> of the recovery tank <NUM>.

To mount the recovery tank <NUM> to the housing <NUM>, the rear end <NUM> of the tank <NUM> is placed in the rear hanger <NUM> and the front portion of the tank <NUM> is pivoted upwardly about the rear hanger <NUM> and latched into place, with the front hanger <NUM> fitting under the front end <NUM> of the tank <NUM>. To remove the tank <NUM>, a user can pull forwardly on the user-engagable end <NUM> of the latch <NUM> to free the front end <NUM> from the front hanger <NUM> and pull the tank <NUM> off the housing <NUM>. Other tank latches are possible. For example, in other embodiments, the recovery tank <NUM> can be fastened to the housing <NUM> via an interference detent.

Referring to <FIG>, the brushroll <NUM> can be removably mounted in the cleaning head <NUM>. In some embodiments, the cleaning head <NUM> includes a brush housing <NUM> defining the brush chamber <NUM> and brush motor chamber <NUM>. A bottom cover or sole plate <NUM> is mounted beneath the brush housing <NUM> and secures the brushroll <NUM> within the brush chamber <NUM>. The sole plate <NUM> includes an opening <NUM> through which a portion of the brushroll <NUM> can project to engage the surface to be cleaned. Removable of the sole plate <NUM> allows for removal of the brushroll <NUM>, as described in further detail below.

The brush housing <NUM> can optionally include various molded features, such as a first brushroll cradle <NUM> for supporting one end of the brushroll <NUM> within the brush chamber <NUM>, a second brushroll cradle <NUM> (<FIG>) for supporting the other end of the brushroll <NUM> within the brush chamber <NUM>, and a partition <NUM> separating the brush chamber <NUM> from the motor chamber <NUM>.

In the embodiment shown herein, the brush housing <NUM> includes an upper cover <NUM> and a lower cover <NUM> which are coupled together to collectively define various features of the cleaning head <NUM>, such as the brush chamber <NUM>, brush motor chamber <NUM>, cradles <NUM>, <NUM>, and partition <NUM>. A gasket <NUM> can be provide at the interface between the upper and lower covers <NUM>, <NUM>. Other configurations for the brush housing <NUM> are possible, including brush housings <NUM> having more than two covers coupled together, or less than two covers coupled together, i.e. a unitary housing.

The sole plate <NUM> can lie substantially beneath the lower cover <NUM>. Portions of the sole plate <NUM> may extend above the lower cover <NUM>. Optionally, the sole plate <NUM> includes various molded features, such as a cradle <NUM> for supporting an end of the brushroll <NUM> within the brush chamber <NUM> and a partition <NUM> separating the brush chamber <NUM> from a handle cavity <NUM> within the brush housing <NUM>, described in further detail below. The handle cavity <NUM> can optionally be formed as a molded feature on the lower cover <NUM> as shown in <FIG>.

In <FIG>, one embodiment of a drive assembly for the brushroll <NUM> is shown. As disclosed previously, the brushroll <NUM> can be operably coupled to and driven by a drive assembly including the brush drive motor <NUM>. The brushroll <NUM> includes a driven end <NUM> and a non-driven end <NUM>. The brushroll <NUM> is mounted at the driven end <NUM> to a first brush holder <NUM> and at the non-driven end <NUM> to a second brush holder <NUM>. The first brush holder <NUM> transmits torque to the brushroll <NUM>. The second brush holder <NUM> can be releasably mounted, as described below, so that the brushroll <NUM> can be easily detached from the first brush holder <NUM> and removed from the brush chamber <NUM>.

The first brush holder <NUM> can be held in the first cradle <NUM> of the brush housing <NUM>, and optionally retained between the upper and lower covers <NUM>, <NUM> of the brush housing <NUM>. The second brush holder <NUM> can be releasably held between the second cradle <NUM> of the brush housing <NUM> and the cradle <NUM> of the removable sole plate <NUM>.

The first brush holder <NUM> is driven by the brush motor <NUM>. A drive gear <NUM> is fixed with a shaft (not shown) of the brush drive motor <NUM> and is adapted for cooperative rotation therewith. A driven gear <NUM> is attached to the first brush holder <NUM> by a stub shaft <NUM>. The stub shaft <NUM> is attached to both the driven gear <NUM> and the first brush holder <NUM>, and is rotatably mounted to the brush housing <NUM> by a bearing <NUM>.

A drive belt interconnects the drive gear <NUM> to the driven gear <NUM>. The drive belt <NUM> is maintained under tension between the gears <NUM>, <NUM> so that during operation when the brush drive motor <NUM> is active, rotation of the drive gear <NUM> induces rotation of the drive belt <NUM> and, thereby, the driven gear <NUM> to drive the rotation of the first brush holder <NUM>. The cleaning head <NUM> can include a belt frame <NUM> defining a compartment sized to receive the drive belt <NUM>. The belt frame <NUM> can be disposed at the driven end <NUM> of the brushroll <NUM>. The belt frame <NUM> can be attached within the brush housing <NUM> or can be formed as part of the brush housing <NUM>.

The first brush holder <NUM> comprises a plurality of holes <NUM> into which corresponding protrusions <NUM> on the driven end <NUM> of the brushroll <NUM> fit to transmit torque from the first brush holder <NUM> to the brushroll <NUM>. Alternatively, a splined or keyed connection can be used to transmit torque from the first brush holder <NUM> to the brushroll <NUM>.

At the non-driven end <NUM>, the brushroll <NUM> is attached to the second brush holder <NUM> by a bushing <NUM>. The bushing <NUM> surrounds a stub shaft <NUM> mounted in the non-driven end <NUM> of the brushroll <NUM>. A retaining ring <NUM> can be mounted on the terminal end of the stub shaft <NUM> to secure the second brush holder <NUM> on the stub shaft <NUM>. The non-driven end <NUM> of the brushroll <NUM> can optionally include a flange <NUM> that fits over a peripheral edge of the second brush holder <NUM> to help isolate the bushing <NUM> and shaft <NUM> from dirt.

Referring to <FIG>, one embodiment of the brushroll <NUM> is shown. As discussed previously the second brush holder <NUM> can be attached at the non-driven end <NUM> of brushroll <NUM> and removably mounted within the brush chamber <NUM>. To facilitate removal of the brushroll <NUM>, a handle <NUM> can be provided at the non-driven end <NUM> of brushroll <NUM>. The handle <NUM> can be coupled with, such as by being integrally formed with or otherwise joined to, the second brush holder <NUM>.

In one embodiment, the brushroll <NUM> comprises a dowel <NUM> and a plurality of bristles <NUM> extending from the dowel <NUM>. The pattern, shape and type of bristles <NUM> can vary from the pattern, shape, and type shown herein. The bristles <NUM> may be arranged in a plurality of tufts or in a unitary strip. The dowel <NUM> can be constructed of a polymeric material such as acrylonitrile butadiene styrene (ABS), polypropylene or styrene, or any other suitable material such as plastic, wood, or metal. The bristles <NUM> can be constructed of nylon, or any other suitable synthetic or natural fiber. As well, other types of agitation elements are equally usable, such as paddles, flails, wires, elongated teeth or nubs, microfiber material, or a scrubbing material, such as a non-woven or open cell foam scrubbing material.

The handle <NUM> can comprise a lever arm <NUM> attached to the brush holder <NUM>. The brush holder <NUM> can be axially mounted on the brushroll <NUM>, with the brush holder <NUM> having an aperture <NUM> for receiving the stub shaft <NUM>. The lever arm <NUM> can project substantially tangentially from the brush holder <NUM>, thereby projecting tangentially relative to the axis of the brushroll <NUM>. This offsets the lever arm <NUM> from the axis of the brushroll <NUM>, placing the lever arm <NUM> closer to the bottom of the brush housing <NUM> (see <FIG>). Alternatively, the lever arm <NUM> can project substantially radially from the brush holder <NUM>.

Referring additionally to <FIG>, the bushing <NUM> fixed on the stub shaft <NUM> can be press fit into a recess <NUM> in the brush holder <NUM> surrounding the aperture <NUM>. With the brush holder <NUM> attached to the stub shaft <NUM>, the dowel <NUM> can spin relative to the brush holder <NUM> during operation, i.e. when the brush motor <NUM> is active.

Optionally, the brush holder <NUM> can be keyed with the brushroll <NUM> to locate maintain alignment between the handle <NUM> and the brushroll <NUM> without slipping. In the illustrated embodiment, the bushing <NUM> is keyed with the recess <NUM>, such as by having flat surfaces <NUM> which are aligned with flat sides <NUM> of the recess <NUM>. The keyed coupling ensures that pivoting of the handle <NUM> can rotate the brush holder <NUM> relative to the dowel <NUM>, while maintaining axial alignment between the brush holder <NUM> and the dowel <NUM>.

Referring to <FIG>, the sole plate <NUM> can be removable from the brush housing <NUM> for accessing the brushroll <NUM>, and also for cleaning debris and the like in the brush chamber <NUM>. In one embodiment, the sole plate <NUM> is removable without the use of tools. For example, the extraction cleaner <NUM> can include a snap-lock retainer to removably secure the sole plate <NUM> on the brush housing <NUM> without the user of tools. In the illustrated embodiment, the snap-lock retainer includes a latch <NUM> on the sole plate <NUM> and a latch receiver <NUM> on the brush housing <NUM>. The latch <NUM> can be provided on a rearward end of the sole plate <NUM>, with the latch receiver <NUM> on a rearward side of the brush housing <NUM>.

Optionally the latch <NUM> can include a flexible finger <NUM> having a hook end <NUM>, and the latch receiver <NUM> can include a flange <NUM> forming a shoulder <NUM>. When the sole plate <NUM> is retained on the brush housing <NUM>, the finger <NUM> snaps around the flange <NUM>, with the hook end <NUM> seated on the shoulder <NUM> to lock the sole plate <NUM> on the brush housing <NUM>.

A lip <NUM> on the sole plate <NUM> seats on an ledge <NUM> of the brush housing <NUM> to support the forward end of the sole plate <NUM> on the brush housing <NUM>, with the ledge <NUM> blocking dislocation of the sole plate <NUM> from the brush housing <NUM> and providing a pivot point for rotation of the sole plate <NUM> upwardly into latched engagement with the brush housing <NUM>. The lip <NUM> can project laterally from the opening in the sole plate <NUM>, and the ledge <NUM> can project in opposition to the lip <NUM>.

To mount the sole plate <NUM> to the housing <NUM>, the lip <NUM> is slid onto the ledge <NUM> of the brush housing <NUM> and the rear portion of the sole plate <NUM> is pivoted upwardly about the ledge <NUM> and snapped into place, with the latch <NUM> snap-fitting into the latch receiver <NUM>. To remove the sole plate <NUM>, a user can pull downwardly on an edge <NUM> of the latch <NUM>, which projects outwardly away from the brush housing <NUM>, to free the latch <NUM> from the latch receiver <NUM> and pull the sole plate <NUM> off the brush housing <NUM>. The latch <NUM> can positioned within the area of the neck <NUM> for easy access. Other sole plate latches are possible. For example, in other embodiments, the sole plate <NUM> can be fastened to the brush housing <NUM> via mechanical fasteners, integrally formed snaps, clips, or a combination thereof.

When the brushroll <NUM> is installed in brush chamber <NUM>, the second brush holder <NUM> fits in the cradle <NUM> formed in the brush housing <NUM>, with the lever arm <NUM> projecting into the cavity <NUM>. The brushroll <NUM> is secured in the brush chamber <NUM> by the attachment of the sole plate <NUM>, with the sole plate cradle <NUM> pressing the brush holder <NUM> against the cradle <NUM> of the brush housing <NUM>.

The handle <NUM> provides a convenient place to grip the brushroll <NUM> during removal. Often, users must directly grip a dirty and/or wet brushroll to remove it from a surface cleaning apparatus. The handle <NUM> can lie within the cavity <NUM>, and be enclosed by the partition <NUM> on the sole plate <NUM> to protect the handle <NUM> from dirt and liquid in the brush chamber <NUM>. The handle <NUM> is also covered by the sole plate <NUM> when the sole plate <NUM> is attached to the brush housing <NUM>. Thus, the handle <NUM> remains relatively clean and dry.

A method of removing the brushroll <NUM> can include the steps shown in <FIG>. The specific sequence of steps discussed is for illustrative purposes only and does not limit the method unless otherwise noted, 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 invention. In <FIG>, the sole plate <NUM> is attached to the brush housing <NUM>. Upon removal of the sole plate <NUM>, as shown in <FIG>, the handle <NUM> is exposed. When the lever arm <NUM> is lifted up, the stub shaft <NUM> (<FIG>) will rotate with the brush holder <NUM>, the while the dowel <NUM> remains stationary, and the user can lift up on the lever arm <NUM> to pull the brushroll <NUM> out of the brush chamber <NUM> as shown in <FIG>.

As shown in <FIG>, when retracted into the brush housing <NUM>, the handle <NUM> can be spaced from a surface of the cavity <NUM> by a fixed distance or gap <NUM> so that a user can reach under the lever arm <NUM> to pivot the lever arm <NUM> out of the cavity <NUM> in the brush housing <NUM> as shown in <FIG>. A standoff <NUM> can be provided in the handle cavity <NUM> to maintain the gap <NUM> between the handle <NUM> and the brush housing <NUM>.

Optionally, the brushroll <NUM> can be exchanged for another agitator. In some embodiments, multiple agitators can be provided with the handheld extraction cleaner <NUM>, and can be interchangeably mounted to the body <NUM>. Some examples of other agitators are shown in <FIG>. Each of the agitators can have a handle <NUM> coupled to a non-driven end of the agitator. Alternatively, one handle <NUM> can be interchanged among the different agitators.

Referring to <FIG>, in one embodiment, an agitator for the extraction cleaner <NUM> is a hybrid brushroll <NUM> that includes multiple agitation materials to optimize cleaning performance on different types of surfaces to be cleaned, including hard and soft surfaces, and for different cleaning modes, including wet and dry vacuum cleaning. In one embodiment, the brushroll <NUM> comprises a plurality of bristles <NUM> and microfiber material <NUM> arranged between the bristles <NUM>. The microfiber material <NUM> can be constructed of polyester, polyamides, or a conjugation of materials including polypropylene or any other suitable material known in the art from which to construct microfiber. Embodiments of a suitable hybrid brushroll are disclosed in <CIT>.

Referring to <FIG> in a further embodiment, an agitator for the extraction cleaner <NUM> is a brushroll <NUM> having a plurality of flexible paddles or wipers <NUM> arranged at an angle to the longitudinal axis of the brushroll <NUM>. In one embodiment, the brushroll <NUM> comprises a dowel <NUM>, with the paddles or wipers <NUM> extending radially from the dowel <NUM>. The paddles or wipers <NUM> can be constructed of an elastomer, such as ethylene propylene diene monomer (EPDM) rubber, thermoplastic elastomer (TPE), or thermoplastic polyurethane (TPU).

Referring to <FIG> in yet another embodiment, an agitator for the extraction cleaner <NUM> is a brushroll <NUM> having a dowel <NUM>, a plurality of bristles <NUM> extending from the dowel <NUM>, and a plurality of paddles or wipers <NUM> extending from the dowel <NUM> and arranged between the bristles <NUM>.

Referring to <FIG> in still another embodiment, an agitator for the extraction cleaner <NUM> is a brushroll <NUM> in the form of a twist-wire brush having a continuous helix of bristles <NUM> bound together by a twist-wire spindle <NUM>. Optionally, the twist-wire spindle <NUM> can be constructed of stainless steel and the bristles <NUM> can be nylon, or any other suitable synthetic or natural fiber.

The handheld extraction cleaner <NUM> can be used to effectively remove debris (which may include dirt, dust, soil, hair, and other debris) and fluid from the surface to be cleaned in accordance with the above-described methods. The sequence of steps discussed herein for any method of using the extraction cleaner <NUM> 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 invention.

To the extent not already described, the different features and structures of the various embodiments of the invention, may be used in combination with each other as desired, or may be used separately. That one handheld extraction cleaner <NUM> is illustrated herein as having all of these features does not mean that all of these features must be used in combination, but rather done so here for brevity of description. Furthermore, while the extraction cleaner <NUM> shown herein is handheld, some features of the invention can be useful on a conventional upright or stick cleaner. Still further, the extraction cleaner <NUM> can additionally have steam delivery capability. Thus, the various features of the different embodiments may be mixed and matched in various extraction cleaner configurations as desired to form new embodiments, whether or not the new embodiments are expressly described.

Claim 1:
A handheld extraction cleaner (<NUM>), comprising:
a unitary body (<NUM>) including a carry handle (<NUM>);
a fluid delivery system including a supply tank (<NUM>) carried by the unitary body (<NUM>) and at least one fluid distributor (<NUM>);
a recovery system including a working air path through the unitary body (<NUM>), a suction nozzle (<NUM>) defining an inlet to the working air path, a suction source (<NUM>) in fluid communication with the suction nozzle (<NUM>), and a recovery tank (<NUM>) removably mounted to the unitary body (<NUM>), the recovery tank (<NUM>) comprising:
a tank body (<NUM>) defining a collection chamber (<NUM>) for dirty liquid recovered by the recovery system;
an inlet opening (<NUM>) in the tank body (<NUM>), the collection chamber (<NUM>) configured to receive dirty liquid through the inlet opening (<NUM>);
a flapper door (<NUM>) that automatically seals the inlet opening (<NUM>) when the recovery tank (<NUM>) is removed from the unitary body (<NUM>); characterized in that the flapper door (<NUM>) is spring-loaded, wherein
a flapper actuator (<NUM>) automatically opens upen the flapper door (<NUM>) when the recovery tank (<NUM>) is mounted on the unitary body (<NUM>);
wherein the flapper actuator (<NUM>) comprises at least one rib (<NUM>) to push the flapper door (<NUM>) open and away from the inlet opening (<NUM>);
wherein the flapper door (<NUM>) comprises an inner surface facing the collection chamber (<NUM>), an outer surface facing away from the collection chamber (<NUM>), and at least one projection (<NUM>) extending from the outer surface; and
wherein the at least one projection (<NUM>) is engaged by the at least one rib (<NUM>) when the recovery tank (<NUM>) is mounted on the unitary body (<NUM>).