Patent Description:
Handheld extraction cleaners, such as those used to clean up after pets, may be used to clean carpets or other soft surfaces, including vehicle interiors, upholstery, and rugs, in addition to other surfaces. A cleaning fluid or solution may be kept or stored onboard the handheld extraction cleaner and may be applied to assist in cleaning the target area. The handheld extraction cleaner can include a suction source that extracts dispensed cleaning fluid and/or debris from the surface and into a recovery tank carried by the cleaner. <CIT> shows one example of such a cleaner.

The invention provides a handheld extraction cleaner as claimed in claim <NUM>. The extraction cleaner includes a suction nozzle defining an inlet path. A suction fan is configured to provide suction to an opposite end of the inlet path, such that the inlet path brings liquid and air into the handheld extraction cleaner.

A vacuum motor is operatively driving the suction fan. The suction fan has a fan entrance, and a recovery tank has a tank inlet spaced from the fan entrance. A separator element configured to allow liquid to flow into the recovery tank, inhibit the flow of liquid out of the recovery tank, and/or inhibit liquid from reaching the fan entrance.

In some configurations, the separator element is a funnel located at the tank inlet of the recovery tank. The funnel extends from the tank inlet into the recovery tank, such that the funnel blocks liquid from leaving the recovery tank during operation outside of an operating zone range or partial inversion of the handheld extraction cleaner. Some configurations may include a check valve within the funnel, such that the check valve is configured to close and inhibit flow from the recovery tank when the handheld extraction cleaner is outside of an operating zone range and is configured to open, and allow flow into the recovery tank, when the handheld extraction cleaner is within the operating zone range. Options for the check valve include a ball valve or a flapper valve.

In some configurations, the separator element is a fan separator adjacent the suction fan. The fan separator is configured to direct liquid outward, away from the fan separator, within the handheld extraction cleaner, such that liquid is moved away from the suction fan. The fan separator and the suction fan may be commonly driven by the vacuum motor. The fan separator may also include a funnel located at the tank inlet of the recovery tank, such that the funnel extends from the tank inlet into the recovery tank and blocks liquid from leaving the recovery tank during operation outside of an operating zone range of the handheld extraction cleaner.

In some configurations, the separator element is a butterfly valve configured to selectively close the fan entrance. An orientation sensor may be configured to sense an angle of the handheld extraction cleaner. The orientation sensor is configured to close the butterfly valve when the sensed angle is outside of an operating zone range and is configured to open the butterfly valve when the sensed angle is within the operating zone range. The butterfly valve may also include a funnel located at the tank inlet of the recovery tank, such that the funnel extends from the tank inlet into the recovery tank and blocks liquid from leaving the recovery tank during operation outside of an operating zone range of the handheld extraction cleaner.

It should be understood that even though in the figures embodiments may be separately described, single features thereof may be combined to additional embodiments.

Referring to the drawings, like reference numbers refer to similar components, wherever possible. All figure descriptions simultaneously refer to all other figures. <FIG> is a perspective view of a handheld or hand-carriable extraction cleaner <NUM>, which may be referred to simply as cleaner <NUM>, according to one embodiment of the disclosure. The handheld extraction cleaner <NUM> can have a unitary body <NUM>, or simply body <NUM>, provided with a carry handle <NUM> attached to the unitary body <NUM>, and is small enough to be transported by one user 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 extraction cleaner <NUM> 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 a 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 disclosure may assume various alternative orientations, except where expressly specified to the contrary, and directional terms should not be interpreted to limit the disclosure to any specific orientation.

The unitary body <NUM> can include the housing <NUM> that carries various components and 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. In being carried by the unitary body <NUM> or housing <NUM>, the various components and functional systems are conveyed along with the unitary body <NUM> as it is transported by the user to or from an area to be cleaned. Such components and systems can be removable or non-removable from the body <NUM> or housing <NUM>. 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 or other fluids 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 an initial separator <NUM> for separating liquid and entrained debris from the working airstream.

The initial 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>. In many configurations, the recovery tank <NUM> will be emptied prior to storage of the extraction cleaner <NUM>.

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, liquid, compositions, one or more treating agents, concentrated detergent, diluted detergent, etc., or mixtures thereof. For example, the fluid can comprise a mixture of liquid and concentrated detergent.

The fluid delivery system can include 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>, 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 suction nozzle <NUM> via the initial separator <NUM>. As shown, the motor/fan assembly includes a suction motor or vacuum motor <NUM> and a suction fan or fan <NUM> driven by the vacuum motor <NUM>. An inlet or fan entrance of the fan <NUM> is in fluid communication with air outlet of the initial separator <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 brush <NUM>. The brush <NUM> can be provided at a forward portion of the unitary body <NUM>, rearward of the suction nozzle <NUM>. The brush <NUM> is stationary, i.e., fixedly mounted and non-rotating. In another configuration, the agitator for the handheld extraction cleaner <NUM> can comprise a powered, rotating brush or brush roll.

Referring to <FIG>, the extraction cleaner <NUM> can include at least one user interface (UI) <NUM> through which a user can interact with the extraction cleaner <NUM> to operate and control the extraction cleaner <NUM>. The UI <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 UI <NUM> can include one or more input controls <NUM>, <NUM>, which can comprise a button, trigger, toggle, key, switch, touch screen, or the like, or any combination thereof. The UI <NUM> can include at least one status indicator <NUM> that conveys information about an event or change related to the operation of the extraction cleaner <NUM> or its operating environment, including operational status, diagnostic information, and/or various error and fault codes.

The UI <NUM> can be provided on the body <NUM> at a forward end of the carry handle <NUM>. The input controls <NUM>, <NUM> can conveniently be provided above 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>. Likewise, the status indicator <NUM> can be provided above the handle <NUM>, at a forward end thereof so that a user can conveniently see the status indicator <NUM> in a typical operational position of the extraction cleaner <NUM>.

In the embodiment shown herein, one input control <NUM> is a power input control that controls the supply of power to the vacuum motor <NUM>, another input control <NUM> is a dispensing input control that controls the supply of power to the pump <NUM> or otherwise controls dispensing of cleaning fluid via the flow control system <NUM>. Thus, suction and fluid delivery can be implemented individually, or in combination, by operation of the input controls <NUM>, <NUM>. The power input control <NUM> can comprise a toggle switch that allows the user to change the power setting between "off' and "on" states. The fluid input control <NUM> can comprise a momentary switch that is only engaged while it is being depressed.

In the embodiment shown, the input controls <NUM>, <NUM> can comprise buttons in register with switches on a printed circuit board (PCB) <NUM> (<FIG>). The PCB <NUM> can include one or more LEDs that illuminate the status indicator <NUM>, for example via at least one light pipe <NUM>.

Electrical power can be provided by a source of main electricity or by a battery or battery pack. In the present embodiment, the extraction cleaner <NUM> comprises a rechargeable battery <NUM>. The status indicator <NUM> can display a battery life or charge status of the battery <NUM>. In another exemplary arrangement, the battery <NUM> can comprise a user replaceable battery. In yet another embodiment, the extraction cleaner <NUM> can comprise a power cord that is pluggable into a household outlet for corded operation.

With a rechargeable battery <NUM>, a charging port <NUM> can be provided on the housing <NUM> and can be electrically coupled with the battery <NUM>. In the illustrated embodiment, the charging port <NUM> is provided on one side of the body <NUM>, at a forward end of the carry handle <NUM> and below the UI <NUM>. A recharging cable (not shown) couples with the charging port <NUM> and can be plugged into a suitable electrical outlet for recharging the battery <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 <NUM>.

<FIG> is a side view of the handheld extraction cleaner <NUM> from <FIG>. The suction nozzle <NUM> is disposed at a forward end <NUM> of the body <NUM> while the supply tank <NUM>, is disposed at a rearward end <NUM> of the body <NUM>. The recovery tank <NUM> can be disposed on the housing <NUM> behind the suction nozzle <NUM> and in front of the suction source <NUM>, shown in phantom line in <FIG>. The battery <NUM>, shown in phantom line in <FIG> can be disposed forwardly of the supply tank <NUM> and behind the suction source <NUM>. The pump <NUM>, shown in phantom line in <FIG>, is disposed below the battery <NUM>, and also behind the suction source <NUM>. The carry handle <NUM> extends in the longitudinal direction between the UI <NUM> and the supply tank <NUM>, and is disposed above the battery <NUM> and pump <NUM>. The carry handle <NUM> includes a hand grip portion and a finger receiving area, which can be a closed volume, e.g. a closed loop handgrip. The majority of the carry handle <NUM> and the closed volume can be disposed behind the suction source <NUM>. This arrangement of component parts of the extraction cleaner <NUM> offers a compact unit with a balanced weight-in-hand for the user, and a comfortable carrying and operational position. Other arrangements of component parts for the extraction cleaner <NUM> are possible.

In <FIG>, the handheld extraction cleaner <NUM> is 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 forward end <NUM>, particularly the suction nozzle <NUM> and brush <NUM>, against the surface to be cleaned. The user may hold and manipulate the cleaner <NUM> via the carry handle <NUM>. With the suction source <NUM>, which can constitute the heaviest component of the extraction cleaner <NUM>, disposed between the carry handle <NUM> and the forward end <NUM>, more of the weight of the cleaner <NUM> can be supported by the surface S to cleaned, and less by the user.

The carry handle <NUM> may define a handle axis H along which the carry handle <NUM> is longitudinally extended. In the operative or normal use position, the handle axis H may be generally horizontal, or inclined from the horizontal, with "horizontal" being defined as parallel to the surface to be cleaned S. Having a substantially horizontal handle axis H positions the user's hand and wrist in an ergonomic position with more grip strength for holding the extraction cleaner <NUM> at an optimal cleaning angle.

The handheld extraction cleaner <NUM> can rest in a stable manner on the surface S in a horizontal position, without leakage from either tank <NUM>, <NUM>. In a self-standing or at rest position, the extraction cleaner <NUM> can be supported on a substantially flat resting surface <NUM> on a bottom of the body <NUM>. With the resting surface <NUM> lying on the surface to be cleaned S, the forward end <NUM> is supported away from the surface S. A user can therefore 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 brush <NUM> in contact with the surface S, and any residual fluid or dirt on the brush <NUM> will not transfer to the surface S. Heavy components (relative to the weight of other components of the cleaner <NUM>) such as the pump <NUM> and battery <NUM> can be disposed above the resting surface <NUM>, which increases stability in the horizontal position.

It is noted that, while the extraction cleaner <NUM> is shown and described in <FIG> in relation to a horizontal surface S to be cleaned, the extraction cleaner <NUM> may also be used to clean angled surfaces, such as stairs, upholstered furniture, car seats, and the like. Therefore, it is understood that various use orientations are possible.

<FIG> is a schematic view of the fluid delivery system of the handheld extraction cleaner <NUM>, shown in isolation from the other components of the 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 supply tank <NUM> to the fluid distributor <NUM>. For example, a first conduit <NUM> can connect an outlet of the supply tank <NUM> with an inlet of the pump <NUM> and a second conduit <NUM> can connect an outlet of the pump <NUM> with an inlet of the fluid distributor <NUM>. The conduits <NUM>, <NUM> can comprise flexible tubing as shown in <FIG>, but it is understood that any of the conduits can comprise molded rigid conduits, or a combination of conduits, ducts, tubing, hoses, connectors, etc..

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.

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 the user can clearly see where fluid is being applied. See, for example, line CF in <FIG> representing one possible spray path for the distributor <NUM>. In another embodiment, the outlet <NUM> can deliver fluid onto the brush <NUM>. In yet another embodiment, the outlet <NUM> can deliver fluid behind the suction nozzle <NUM> and brush <NUM>.

The distributor <NUM> can comprise any structure, such as a nozzle or spray tip. Multiple distributors <NUM> can also be provided in other embodiments of the extraction cleaner <NUM>. As illustrated in the figures, the distributor <NUM> can comprise one spray tip provided on the front of the body <NUM> that distributes cleaning fluid to the surface to be cleaned in front of the suction nozzle <NUM>.

<FIG> is a close-up sectional view showing the supply tank <NUM>. The supply tank <NUM> shown is a non-removable blow-molded part, and includes a hollow tank body <NUM> defining a supply chamber <NUM> for holding a supply of cleaning liquid. In being non-removable, the supply tank <NUM> is not intended to be removed from the body <NUM>, and is refillable in place on the body <NUM>. This can eliminate potential leakage points, since the supply tank <NUM> does not need to be repeatedly coupled and uncoupled to the fluid pathway of the extraction cleaner <NUM>.

The tank body <NUM> can include a fill opening <NUM> through which cleaning liquid can be poured into the supply chamber <NUM>. The fill opening <NUM> can be provided at the rearward end of the body <NUM>, rearward of the handle <NUM>, and is accessible to a user when the housing <NUM> is resting on a surface. A fill cap <NUM> selectively closes the fill opening <NUM>.

The fill cap <NUM> can be pivotally coupled to the housing <NUM> of the cleaner body <NUM> by a hinge <NUM> or other rotating connection and can be opened to expose the fill opening <NUM>. The pivotable coupling ensures the fill cap <NUM> will not completely separate from the cleaner body <NUM> during filling. In another aspect, the fill cap <NUM> can be pivotally coupled with the tank body <NUM>.

The fill cap <NUM> can fit over the fill opening <NUM> when closed to seal the fill opening <NUM> for a fluid-tight closure, such that the supply tank <NUM> does not leak when the fill cap <NUM> is closed. One example of a closed position of the fill cap <NUM> is shown in <FIG>.

In one configuration, the fill cap <NUM> can be a snap-on cap providing a fluid-tight engagement with the fill opening <NUM> when snapped onto the tank body <NUM>. The cap <NUM> can include a depending lip <NUM> with a snap <NUM> that extends from an inward side of the lip <NUM>, and the tank body <NUM> can include an outwardly extending bead <NUM>, with the snap <NUM> fitting tightly onto the bead <NUM> when the cap <NUM> is closed. A seal <NUM> can be provided on an inner side of the cap <NUM> that confronts the fill opening <NUM> when the cap <NUM> is closed to further provide a leak-proof engagement between the fill opening <NUM> and the fill cap <NUM>.

The fill cap <NUM> can be opened by lifting the lip <NUM> of the fill cap <NUM>, which can be spaced from the tank body <NUM> in the closed position so that a user can fit a finger between the tank body <NUM> and an underside of the lip <NUM>. When the fill cap <NUM> is open, liquid from a liquid source, such as a container, bottle, faucet, hose, vessel, etc. can be poured into the tank body <NUM> through the fill opening <NUM>.

The tank body <NUM> can include a tank outlet <NUM> in fluid communication with the first conduit <NUM>. A mesh screen insert <NUM> may be provided between the tank outlet <NUM> and the conduit <NUM> to prevent or inhibit particulates of a certain size from entering the pump <NUM>.

A first check valve <NUM> (<FIG>) is provided on the tank body <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 sealing at least one vent hole formed in the tank body <NUM>. As liquid is pumped out of the supply tank <NUM>, negative pressure inside the supply tank <NUM> opens the check valve <NUM>, drawing ambient air into the supply chamber <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 selectively sealing at least one vent hole in the tank body <NUM>. As excess gas forms in the supply tank <NUM>, positive pressure inside the supply tank <NUM> opens the check valve <NUM>, thereby venting the excess gas into the surrounding atmosphere. Once pressure equalizes, the check valve <NUM> closes.

<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 initial 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 a nozzle inlet <NUM> to the exhaust vents <NUM>.

In one configuration, working air separated from liquid and debris by the initial separator <NUM> can travel through a diffuser conduit <NUM> before reaching an inlet <NUM> of the suction source <NUM>. Either the diffuser conduit <NUM> or the inlet <NUM> may be referred to as a fan entrance. 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> may have an outlet port <NUM> in fluid communication with the inlet <NUM> of suction source <NUM>.

An air pathway <NUM> can connect a separator outlet <NUM> of the initial separator <NUM> with a conduit inlet <NUM>, which may also be referred to as the fan entrance, of the diffuser conduit <NUM> and can be formed by various conduits, ducts, housings, connectors, etc., fluidly coupling the separator outlet <NUM> and conduit inlet <NUM> together and providing an air path from the initial separator <NUM> to the diffuser conduit <NUM>. To improve air/liquid separation and sound attenuation, the pathway <NUM> may be a tortuous air pathway <NUM>, and may include baffles, guides, and other air-turning features that direct the working air and increase the length of the pathway <NUM>. In one example, the air pathway <NUM> can include a baffle <NUM> blocking a lower portion of the conduit inlet <NUM> so that working air is forced to flow around, and over, the baffle <NUM> to enter the conduit inlet <NUM>.

The recovery tank <NUM> comprises a hollow tank body <NUM> defining a collection chamber <NUM> for holding a recovered liquid and debris, with a tank inlet <NUM> that is in fluid communication with the separator outlet <NUM> and a tank outlet <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 tank outlet <NUM> can be closed by a drain plug <NUM> or other closure feature.

The tank inlet <NUM> to the recovery tank <NUM> can be formed as a tank opening <NUM>, which may also be referred to as the tank inlet, through a baffle wall <NUM> separating the collection chamber <NUM> from the tortuous air pathway <NUM>, with debris and liquid that is separated from the working airstream transferrable into the recovery tank <NUM> through the tank opening <NUM>. Other configurations for the tank inlet <NUM> are possible.

The baffle wall <NUM> can surround the tank opening <NUM> on multiple sides to block liquid from passing back through the tank inlet <NUM> when the extraction cleaner <NUM> is tipped sideways. In one configuration, the baffle wall <NUM> can surround the tank opening <NUM> on right and left sides, so that if the extraction cleaner <NUM> is tipped to the side, the baffle wall <NUM> keeps liquid out of the air pathway <NUM>. Optionally, in some configurations, the baffle wall <NUM> can also surround the tank opening <NUM> on forward and/or rearward sides. A portion of the baffle wall <NUM> may extend under the separator outlet <NUM>, and may be disposed at a downward angle when the extraction cleaner <NUM> is in the orientation of <FIG> to allow liquid to flow toward the tank inlet <NUM>.

Referring to <FIG>, the suction nozzle <NUM> can include a front nozzle cover <NUM> and a rear cover <NUM> defining a narrow suction pathway <NUM> therebetween, with an opening forming the nozzle inlet <NUM> at a lower end thereof. The suction pathway <NUM> is in fluid communication with the initial separator <NUM> leading to the recovery tank <NUM>. The front nozzle cover <NUM> can optionally include a transparent or translucent window, or can be formed by a transparent or translucent material, so the user can see liquid being taken up through the suction nozzle <NUM> and/or determine if the suction nozzle <NUM> is clogged.

Referring to <FIG>, an example of a user's perspective of the extraction cleaner <NUM> during operation is shown. Generally, during operation a user will grasp the extraction cleaner <NUM> by the carry handle <NUM> and engage the forward end <NUM> with the surface to be cleaned. The recovery tank <NUM> can be configured such that, in this use position, the user can view the fullness or fill level of the recovery tank <NUM>. The recovery tank <NUM> can further be configured to be equally viewable by a right-handed user and a left-handed user.

In one configuration, the recovery tank <NUM> has a tank body <NUM> with side portions <NUM>, <NUM> that extend outwardly with respect to the housing <NUM> so as to be visible from the user's perspective during operation. The housing <NUM> has a first lateral side <NUM> and a second lateral side <NUM>, which can comprise left and right lateral sides, respectively, (as viewed from the use position shown in <FIG>) and the tank body <NUM> can have a first side portion <NUM> which is disposed laterally outwardly with respect to the first lateral side <NUM> of the housing <NUM> and a second side portion <NUM> which is disposed laterally outwardly with respect to the second lateral side <NUM> of the housing <NUM>.

The flared side portions <NUM>, <NUM> can be disposed substantially in front of the carry handle <NUM>. The recovery tank <NUM>, and flared side portions <NUM>, <NUM>, are thus located closer to the forward end <NUM> of the extraction cleaner <NUM> than the rearward end <NUM> (<FIG>) so that a user has a clear view of the tank <NUM> and its fill level.

The side portions <NUM>, <NUM> of the tank body <NUM> can flare outwardly from a longitudinal centerline of the extraction cleaner <NUM>, which in some configurations of the extraction cleaner <NUM> may be defined by the handle axis H. In the embodiment shown, the side portions <NUM>, <NUM> are mirror images of each other and can be equal in volume, although it is understood that differences in shape, volume, etc., of the side portions <NUM>, <NUM> is possible.

With flared side portions <NUM>, <NUM> on both lateral sides <NUM>, <NUM> of the housing <NUM>, the recovery tank <NUM> is equally viewable by a right-handed user and a left-handed user, and a user can observe the recovery tank <NUM> even if the extraction cleaner <NUM> is tipped sideways. The flared shape of the recovery tank <NUM> can also increase the collection capacity of the tank body <NUM>. The flared side portions <NUM>, <NUM> allow the volume of collected liquid to spread out laterally, which can reduce the height of collected liquid.

Another benefit to having flared side portions <NUM>, <NUM> on both sides of the recovery tank <NUM> is an increase in volume available on each side of the tank <NUM> when the extraction cleaner <NUM> is tipped sideways. <FIG> are cross-sectional views taken through line VIII-VIII of <FIG> showing a liquid level indicated by phantom line L for a given volume of liquid in the tank <NUM> when the extraction cleaner <NUM> is in two different exemplary orientations. <FIG> shows the liquid level L when the extraction cleaner <NUM> is in the orientation of <FIG> and operating on a horizontal surface S to be cleaned. <FIG> shows the liquid level L for the same volume of liquid when the extraction cleaner <NUM> is tipped to the left. In the tipped position, a greater portion of the liquid moves into the space defined by the first side portion <NUM>. When the extraction cleaner <NUM> is tipped to the right, a greater portion of the liquid can move into the space defined by the second side portion <NUM>. When tipped, as shown in <FIG>, the liquid level L does not rise up to the height of the tank inlet <NUM>, but rather spreads into the corresponding side portion <NUM>, <NUM>. Therefore, there is less likelihood of ingestion of liquid into the air pathway <NUM>.

To help inhibit or prevent the liquid from reaching the air pathway <NUM>, the baffle wall <NUM> in the tank <NUM> can block the liquid when the extraction cleaner <NUM> is tipped sideways. Below a certain level of liquid and at certain degrees of tip, liquid in the tank <NUM> cannot reach the tank inlet <NUM>. With the provision of the flared side portions <NUM>, <NUM> and/or the baffle wall <NUM>, the recovery tank <NUM> does not require an in-tank float-style shut off. In other words, the recovery tank <NUM> shown in the figures is a float-less tank.

Various shapes for the flared side portions <NUM>, <NUM> are possible. Referring to <FIG>, one embodiment of the first side portion <NUM> is disclosed. It is understood that the second side portion <NUM> may have the same or a similar configuration.

The tank body <NUM> can have a tank side wall <NUM> and the first side portion <NUM> can extend outwardly from the tank side wall <NUM>. The tank side wall <NUM> can be flush with or recessed to the first lateral side <NUM> of the housing <NUM>, such that the tank side wall <NUM> is disposed substantially in line with or laterally inwardly of the first lateral side <NUM>. At a bottom end thereof, the flared side portion <NUM> can turn back in toward the housing <NUM> and may meet a bottom wall <NUM> of the tank body <NUM>.

Referring to <FIG>, the first side portion <NUM> can include at least an upper wall <NUM>, an outer wall <NUM>, and a lower wall <NUM>. One or more of these walls can be angled so that the first side portion <NUM> has a contour that can encourage liquid to move toward the tank outlet <NUM>, which is closed by the drain plug <NUM> in <FIG>. For example, the upper and lower walls <NUM>, <NUM> can taper toward the outer wall <NUM> so that the first side portion <NUM> has a double beveled contour when viewed from the front or from the rear. With a contour that tapers downwardly and toward the center of the tank <NUM>, liquid is encouraged to move downwardly along the walls <NUM>-<NUM> and toward the tank outlet <NUM>. Referring to <FIG>, the first side portion <NUM> can include a front wall <NUM> at a forward end of the outer wall <NUM> and a rear wall <NUM> at a rearward end of the outer wall <NUM>. These walls <NUM>, <NUM> can also be angled to encourage liquid to move downwardly along the walls <NUM>, <NUM>.

The bottom wall <NUM> can also have a shape which improves cleaning liquid drainage and usable tank volume, such as by sloping rearwardly toward the tank outlet <NUM> when the extraction cleaner <NUM> is at rest on the resting surface <NUM>, as shown in <FIG>, which directs dirty liquid away from the tank inlet <NUM> and toward the tank outlet <NUM>. Similarly, when the recovery assembly - formed from portions of the recovery tank <NUM> and the suction nozzle <NUM> as a unit - is removed and rested on a surface, the recovery assembly is supportable on a bottom edge of the drain plug <NUM> and the brush <NUM>, and the bottom wall <NUM> is oriented to slope rearwardly toward the tank outlet <NUM>.

A level viewing window <NUM>, <NUM> can be located on one or both side portions <NUM>, <NUM> of the recovery tank <NUM> with the viewing windows <NUM>, <NUM> providing information to the user on the fill level within the recovery tank. With viewing windows <NUM>, <NUM> on both lateral sides <NUM>, <NUM> of the housing <NUM>, a user can be informed of the fill level regardless of whether the extraction cleaner <NUM> is held in their right or left hand, and even if the extraction cleaner <NUM> is tipped sideways.

The viewing windows <NUM>, <NUM> can be a transparent or translucent portion of the recovery tank <NUM> through which the fill level in the recovery tank <NUM> can be visually determined. In one embodiment, the recovery tank <NUM> can be a blow-molded part made from a transparent or translucent material, with the viewing windows <NUM>, <NUM> comprising molded features in the tank body <NUM>. In another embodiment, the viewing windows <NUM>, <NUM> can be formed by inserting a transparent or translucent cover into a corresponding window opening in the tank body <NUM>.

In the exemplary embodiment of <FIG>, viewing window <NUM> is located on two walls <NUM>, <NUM> of the tank body <NUM>, and wraps around a corner <NUM> between the two walls <NUM>, <NUM>. Locating the viewing window <NUM> on the upper wall <NUM> and outer side wall <NUM> of the side portion <NUM> places the viewing window <NUM> in the user's line of sight, with a user being able to see the viewing window <NUM> from a centered perspective shown in <FIG> or when the extraction cleaner <NUM> is tilted sideways for cleaning an angled surface. <FIG> shows an example of a user's perspective of the extraction cleaner <NUM> during operation, where the user has tilted the extraction cleaner <NUM> sideways.

The viewing window <NUM> may be recessed into the walls <NUM>, <NUM>. In an embodiment where the viewing window <NUM> is a molded feature in the tank body <NUM>, a beveled edge <NUM> can serve as a transition between the walls <NUM>, <NUM> and the recessed window <NUM>.

Optionally, the tank body <NUM> may have indicia markings associated with the viewing window <NUM>. One exemplary embodiment of such indicia markings is shown in <FIG>, where the viewing window <NUM> has a border marking <NUM>, which may be in a contrasting color to the tank body <NUM> that draws a user's attention to the viewing window <NUM>. Observing a fill level within the border marking <NUM> can signal to the user that a fill quantity in the recovery tank <NUM> is approaching a maximum level and/or is within a recommended range for emptying the tank <NUM>. The viewing window <NUM> can also have a maximum fill line <NUM> that indicates a recommended maximum fill quantity in the recovery tank <NUM>. The border marking <NUM> can wrap around the corner <NUM> and the maximum fill line <NUM> extend along the corner <NUM>, and preferably above the corner <NUM>. It is understood that the second viewing window <NUM> may have the same or similar indicia markings.

Referring to <FIG>, in addition to the recovery tank <NUM>, the suction nozzle <NUM>, distributor <NUM>, user interface <NUM>, brush <NUM>, or any combination thereof, may be in the line of sight of the user during normal operation of the extraction cleaner <NUM>. In the exemplary embodiment, the user interface <NUM> is not symmetrical about the handle axis H, but is convenient for use by a right-handed or left-handed user.

Gripping the carry handle <NUM> in one hand, whether left or right, allows both input controls <NUM>, <NUM> to be actuated by the thumb of that same hand. The end of the carry handle <NUM> toward the user interface <NUM> can have a recessed thumb rest <NUM> for the user's thumb, so that the thumb of the hand gripping the carry handle <NUM> has a home space or resting space, and does not accidentally bump the input controls <NUM>, <NUM>. The input controls <NUM>, <NUM> can be different in size, shape, color, tactile elements, and the like, so that a user can distinguish between them by sight or by feel.

<FIG> shows the extraction cleaner <NUM> in one non-limiting example of a generally optimal cleaning position in which the nozzle inlet <NUM> is substantially flat against the surface S. The optimal cleaning position for efficient extraction may vary depending on the relative disposition of the components of the cleaner <NUM>, such as, but not limited to, the body <NUM>, carry handle <NUM>, suction nozzle <NUM>, and nozzle inlet <NUM>. A user may not understand the angle for optimal extraction, and may not intuitively tip the extraction cleaner <NUM> far enough forward.

A cleaning angle guide skid <NUM> (better viewed in <FIG>) provides a structural element that encourages the user to naturally orient the cleaner <NUM> at an optimal angle for efficient extraction. As an added benefit, the cleaning angle guide skid <NUM> can help the extraction cleaner <NUM> glide over the surface S, which helps the user move the extraction cleaner <NUM> smoothly over the surface.

The guide skid <NUM> can include one or more skis, lips, runners, gliding surfaces, skids, or the like surrounding the nozzle inlet <NUM> and/or the brush <NUM>, and which may at least partially support the forward end <NUM> of the extraction cleaner <NUM> on the surface S to be cleaned. In one embodiment, the guide skid <NUM> can include at least a front ski <NUM> and side skis <NUM>, <NUM> behind the front ski <NUM>. The skis <NUM>-<NUM> can have substantially flat contact surfaces, or may be slightly tapered or curved, to help the suction nozzle <NUM> glide over the surface for easy movement of the cleaner <NUM> in a back and forth direction across the surface to be cleaned. Thus, the skis <NUM>-<NUM> of the guide skid <NUM> allow the suction nozzle <NUM> to glide over the surface S in a similar manner as a ski so that a user can pass or glide the extraction cleaner smoothly over a surface. While various configurations for the skis <NUM>-<NUM> are possible, the skis <NUM>-<NUM> can preferably have smoothly curved or angled surfaces, edges, corners, and the like, to reduce sliding friction.

With multiple skis <NUM>-<NUM> projecting in multiple directions around the periphery of the suction nozzle inlet <NUM>, the user is guided to position the cleaner <NUM> at an optimal angle for efficient extraction, particularly one in which the suction nozzle inlet <NUM> is flat or nearly flat against the surface to be cleaned. The front ski <NUM> can comprise an elongated, slender runner that extends substantially the width of the nozzle inlet <NUM> across the front of the suction nozzle <NUM>. In the embodiment shown, the front ski <NUM> can project from a forward edge of the front nozzle cover <NUM>. Where the nozzle cover <NUM> and front ski <NUM> are plastic, the front ski <NUM> can be integrally formed with the nozzle cover <NUM>.

In certain embodiments, the guide skid <NUM> can further include intermediate skis <NUM> that extend alongside the lateral ends of the nozzle inlet <NUM> and which can substantially bridge a gap between the front ski <NUM> and side skis <NUM>, <NUM>. In the embodiment shown, the intermediate skis <NUM> can be defined by bottom surfaces of the front nozzle cover <NUM>. Where the nozzle cover <NUM> and intermediate skis <NUM> are plastic, the intermediate skis <NUM> can be integrally formed with the nozzle cover <NUM>.

It is noted that nozzle inlet <NUM> can be single opening extending substantially the width of the suction nozzle <NUM>, or a plurality of smaller openings separated by dividers, such that the dividers serve to reinforce the suction nozzle <NUM>. The dividers can be flush with or recessed with respect to the guide skid <NUM>.

An inclined peripheral wall <NUM> can extend around the nozzle inlet <NUM>, the inclined peripheral wall <NUM> extending from the guide skid <NUM> downwardly and inwardly toward the openings. The peripheral wall <NUM> surrounding the nozzle inlet <NUM> may therefore project slightly with respect to the guide skid <NUM>. In other embodiments, the peripheral wall <NUM> surrounding the nozzle inlet <NUM> may not project relative to the guide skid <NUM> and may, for example and without limitation, be flush with the guide skid <NUM>.

Referring to <FIG>, the side skis <NUM>, <NUM> may generally lie within a common plane P, thereby being flush with each other. At least a portion of the front ski <NUM> may lie in the same plane P. In the embodiment shown, the intermediate skis <NUM> can lie within the plane P, and the front ski <NUM> may turn upwardly away from the plane P. The peripheral wall <NUM> surrounding the nozzle inlet <NUM> extend below the plane P.

An agitation element <NUM>, such as bristles <NUM>, may extend below the guide skid <NUM>, such as with tips <NUM> of the bristles <NUM> in particular extending below the side skis <NUM>, <NUM>, e.g., below the plane P. With the guide skid <NUM> pressed against the surface S, such that the cleaner <NUM> is properly oriented, the agitation element <NUM> can dig into the surface S, providing enhanced scrubbing action.

In certain embodiments, the agitation element <NUM> is angled with respect to the guide skid <NUM> to resist movement on a forward stroke of the extraction cleaner <NUM> and to ease the resistance on a backward stroke of the extraction cleaner <NUM>. For example, the agitation element <NUM> can define an agitation element axis B that intersects the plane P at an oblique angle A. The agitation element axis B can be defined by the bristles <NUM>, a tuft of bristles <NUM>, or a hole <NUM> supporting a tuft of bristles <NUM>. In the case of the brush <NUM>, the agitation element axis B can be defined by one of the tines, such that at least one of the tines, and alternatively multiple tines, are disposed at an oblique angle to the plane P, e.g., to the side skids <NUM>, <NUM>.

Referring to <FIG>, in the embodiment shown, the brush mount <NUM> includes holes <NUM> that support tufts of bristles <NUM> (not shown in <FIG> for clarity). At least one of the holes <NUM>, alternatively multiple holes <NUM>, can define the bristle axis B at a center of the hole <NUM>.

<FIG> illustrate additional configurations of the handheld extraction cleaner <NUM> that include separator elements configured to substantially inhibit, block, obstruct, or impede, movement of water or other liquids into the fan <NUM>, unintended movement of liquid out of the recovery tank <NUM>, or both. These separator elements may work in conjunction with, or act as replacements for, the initial separator <NUM>.

The separator elements operate to provide several possible benefits for the cleaner <NUM>. The benefits may include, without limitation: keeping liquid (often debris filled) in the recovery tank <NUM> until it is disposed of through the tank outlet <NUM>; limiting leaks caused by liquid moving outside of the recovery tank <NUM> into the forward end <NUM> of the housing <NUM>; and/or limiting liquid from entering the suction source <NUM>, which may impact operation of the vacuum motor <NUM>. Note that the separator elements may be used in other configurations of the handheld extraction cleaner <NUM>, including those with powered or spinning brush mechanisms.

<FIG> schematically illustrates the separator element as an actuated butterfly valve <NUM>, which is configured to selectively close the fan entrance. The butterfly valve <NUM> is configured to close when the handheld extraction cleaner <NUM> is moved into a particular orientation, such as sideways or upside down.

The butterfly valve <NUM> may have numerous control mechanisms, as recognized by those having ordinary skill in the art. One example control mechanism, without limitation, may utilize an orientation sensor <NUM> configured to sense an angle or position of the handheld extraction cleaner <NUM>. The orientation sensor <NUM> is shown schematically in <FIG> and may be located elsewhere, as will be recognized by skilled artisans, such as within the remainder of the controls for the cleaner <NUM> or incorporated into the housing <NUM>.

When the orientation sensor <NUM> determines that the position is outside of an operating zone range, the butterfly valve <NUM> is closed, such as by closing a valve element <NUM>, which may be generally circular or otherwise shaped. However, when the position is within the operating zone range the butterfly valve <NUM> is open. Note that the operating zone range may include several aspects, including, without limitation: tilting or rolling about the longitudinal axis, angles about the transverse/lateral axis, other factors identifiable by those having ordinary skill in the art, or combinations thereof.

One example of the operating zone range may be illustrated with respect to the orientation shown in <FIG> and, also, in <FIG>. <FIG> shows the handheld extraction cleaner <NUM> at a generally substantially horizontal angle relative to the surface to be cleaned. Note, however, that not all surfaces are substantially horizontal. In one example of intended operation, the handheld extraction cleaner <NUM> may generally be rotated approximately <NUM>-degrees counterclockwise or approximately <NUM>-degrees clockwise - with both rotation directions relative to the view and orientation shown in <FIG>. Therefore, without limitation, in one aspect, the operating zone range may be considered relative to approximately <NUM>-degrees counterclockwise, approximately <NUM>-degrees clockwise, or any angle between <NUM>-degrees and <NUM> degrees - with both rotation directions relative to the view and orientation shown in <FIG>.

Additionally, with respect to rotation about the longitudinal axis, as best illustrated by comparing <FIG>, the cleaner <NUM> may be rotated approximately <NUM>-degrees in either direction and still be within the example operating zone range. It is understood that the operating zone range, with respect to both the clockwise/counterclockwise rotation directions relative to <FIG> and the rotation about the longitudinal axis relative to <FIG> can be selected in concert based on a variety of factors, non-limiting examples of which include the intended use orientations, the size and shape of the recovery tank <NUM>, and/or the relative configuration of the initial separator <NUM>, the fan <NUM>, and the specific separator element.

The orientation sensor <NUM> may work in conjunction with a dedicated butterfly controller, may be configured to directly control the butterfly valve <NUM>, or another controller may actuate movement of the valve element <NUM> of the butterfly valve <NUM>. The orientation sensor <NUM> may sense or measure any number of axes or positions relative thereto. Furthermore, the orientation sensor <NUM> may be formed from several types of components or devices, including, without limitation: an accelerometer, an inertial sensor, a tilt switch, a micro-electromechanical systems (MEMS) sensor, other devices recognizable by those having ordinary skill in the art, or combinations thereof.

The fan <NUM> may sound different to the user when the butterfly valve <NUM> is closed. In many configurations, when the butterfly valve <NUM> closes, the user will hear a higher pitch noise from the fan <NUM>, as there will be limited airflow through the fan <NUM>. This higher pitch noise instructs the user that the handheld extraction cleaner <NUM> is no longer within the operating zone range, such that the user may learn how to keep the cleaner <NUM> in the intended orientation. Furthermore, the butterfly valve <NUM> may be closed, or actuated shut, when the cleaner is turned off in order to mitigate liquid leakage during the off state.

<FIG> and <FIG> schematically illustrate the separator element as a funnel <NUM>, which is configured to extend into the recovery tank <NUM>. <FIG> shows the handheld extraction cleaner <NUM> in a generally preferred orientation and <FIG> shows the handheld extraction cleaner <NUM> substantially upside down. Therefore, the funnel <NUM> blocks liquid from leaving the recovery tank <NUM> during inversion, tilting, or other orientations outside of an operating zone range, of the handheld extraction cleaner <NUM>.

The funnel <NUM> may include several elements to assist in allowing liquid to flow into the recovery tank <NUM> and to inhibit liquid from moving out of the recovery tank <NUM>. For example, the funnel <NUM> may have a mount flange <NUM> configured to secure the funnel <NUM> within the tank opening <NUM> of the baffle wall <NUM>. The mount flange <NUM> may further include one or more sealing elements, as recognized by skilled artisans.

Additional elements of the funnel <NUM> may include, without limitation, a funnel cone <NUM> and a funnel cylinder <NUM>. The funnel cone <NUM> and the funnel cylinder <NUM> extend downward, relative to gravity in the normal use position, into the recovery tank <NUM>, such that liquid is allowed to fall through the funnel <NUM> into the recovery tank <NUM>.

However, when the cleaner <NUM> is oriented outside of the operating zone range, the funnel cone <NUM> and the funnel cylinder <NUM> limit the ability of liquid to move out of the recovery tank <NUM> by forming a barrier to liquid flow. Even when the recovery tank <NUM> is upside down, the funnel <NUM> may inhibit debris-filled liquid from flowing out of the recovery tank <NUM>, particularly if the maximum fill quantity in the recovery tank <NUM> has not been exceeded. <FIG> illustrates the cleaner <NUM> turned substantially upside down. The highly exemplary liquid level L illustrates liquid within the recovery tank <NUM> in <FIG>. Note that the funnel cone <NUM> and the funnel cylinder <NUM> inhibit liquid from moving out of the recovery tank <NUM> toward the fan <NUM> or the suction nozzle <NUM>.

Note that alternative structures for the funnel <NUM> may be used, such that liquid is limited from leaving the recovery tank <NUM> and flowing back into the area above the recovery tank <NUM> where the liquid may then flow into undesirable locations within the cleaner <NUM>, such as the fan <NUM> or back into the nozzle <NUM>. The dimensions of the funnel <NUM>, including the dimensions of the funnel cone <NUM> and/or the funnel cylinder <NUM> may be selected based on factors such as the dimensions of the recovery tank <NUM>, the intended max fill volume of the recovery tank <NUM>, and/or the operating zone range.

In some cases, users may invert the cleaner <NUM> while moving it to empty the recovery tank <NUM> (for example, into a sink), as they are less likely to pay attention to the orientation of the cleaner <NUM> during such movement. The funnel <NUM> may be particularly beneficial during this time, as it limits movement of liquid out of the recovery tank <NUM> and into areas where liquid is not desired, such as the fan <NUM>. Note, however, that the funnel <NUM> still retains an opening through which fluid may pass, such that shaking or jostling of the cleaner <NUM> may cause liquid to move out of the recovery tank <NUM> into an undesirable direction (such as toward the fan <NUM> or the suction nozzle <NUM>).

<FIG> schematically illustrates the separator element as a funnel <NUM>, which is configured to extend into the recovery tank <NUM>. The funnel <NUM> may be configured similar to the funnel <NUM> described above and illustrated in <FIG> and <FIG>, but may include some differences, such as a check valve <NUM>. To further limit egress of liquid from the recovery tank <NUM>, some configurations of the cleaner <NUM> and the funnel <NUM> include the check valve <NUM>, which is configured to generally allow fluid to flow substantially in only one direction - i.e., downward when the cleaner is oriented as shown in <FIG> or <FIG>.

The funnel <NUM> includes a large funnel cone <NUM> that substantially replaces the baffle wall <NUM>, but that feature is not limiting, such that the funnel <NUM> may also include the smaller funnel cone <NUM> of the funnel <NUM> illustrated in <FIG> and <FIG> that the attaches to the baffle wall <NUM>. Note that the funnel <NUM> and check valve <NUM> may be configured so as to not inhibit flow of liquids out of the recovery tank <NUM> when the cleaner is oriented within a predetermined operating zone range.

However, the check valve <NUM> may slow or inhibit the flow of liquid out of the recovery tank <NUM> through the funnel <NUM> compared to the flow of liquid in the absence of the check valve <NUM>, even when the cleaner <NUM> is oriented within the predetermined operating zone range. In some examples, the funnel <NUM> and check valve <NUM> may be configured to inhibit the flow of liquid from the recovery tank <NUM> through the funnel <NUM> generally equally when the cleaner <NUM> is oriented within the predetermined operating zone range and outside the predetermined operating zone range. In other examples, the funnel <NUM> and check valve <NUM> may be configured to inhibit the flow of liquid from the recovery tank <NUM> through the funnel <NUM> to a greater extent when the cleaner <NUM> is oriented outside of the predetermined operating zone, as compared to within the predetermined operating zone range.

In the example of the funnel <NUM> shown, and without limitation, the check valve <NUM> is a ball or ball valve that is configured to close, and inhibit flow from the recovery tank <NUM> into the area above the recovery tank <NUM>, when the handheld extraction cleaner <NUM> is outside of an operating zone range, such as when rotated upside down. The check valve <NUM> is configured to open, and allow flow into the recovery tank <NUM>, when the handheld extraction cleaner <NUM> is within the operating zone range, such as the orientation shown in <FIG> to allow fluid and debris extracted during use of the cleaner <NUM> to be collected within the recovery tank <NUM>.

The ball valve forming the check valve <NUM> will move toward an opening <NUM> of the funnel <NUM> when the cleaner <NUM> is out of the predetermined operating zone range, such that it blocks the opening <NUM> and inhibits the flow of liquid out of the recovery tank <NUM> through the funnel <NUM>. In some configurations, the opening <NUM> may have an O-ring or other sealing device associated therewith to inhibit the flow of liquid out of the recovery tank <NUM> through the funnel <NUM>.

As an alternative configuration, and without limitation, the check valve <NUM> may be formed by a flapper valve. The flapper valve may be substantially linear and is configured to close or block the opening <NUM>, or some other portion of the funnel <NUM>, when the cleaner <NUM> is inverted or rotated outside of the operating zone range.

A retaining element <NUM>, illustrated as a cap, is configured to prevent or inhibit the ball from falling into the recovery tank <NUM>. Other configurations may exist, such as an open slot in the funnel <NUM> or any configuration that prevents the ball from falling into the recovery tank <NUM>. The retaining element <NUM> may have several drain elements formed therein to allow liquid to drain into the recovery tank <NUM>, including, without limitation, holes or slots formed into the retaining element <NUM>. Note that the drain elements may not be easily viewable in <FIG>.

<FIG>, <FIG> schematically illustrate the separator element as a fan separator <NUM>, which is generally adjacent the suction fan <NUM>. The fan separator <NUM> is configured to move, throw, or direct liquid outward, away from the fan separator <NUM>. Additionally, the fan separator <NUM> is configured to limit liquids moving toward the fan entrance of the suction fan <NUM>, and thus inhibit the flow of liquid toward the components of the suction source <NUM>.

In this configuration of the handheld extraction cleaner <NUM>, there is no initial separator <NUM>, such as illustrated in <FIG>. Instead, the fan separator <NUM> sits in a similar location, near an exit conduit <NUM> of the suction nozzle <NUM>, and between the suction nozzle <NUM> and the suction fan <NUM>. As described above with respect to <FIG>, the suction source <NUM> is in fluid communication with the suction nozzle <NUM> for generating a working air stream containing fluid and debris. The fan separator <NUM> is disposed within the working air path and separates liquid and debris from the working air stream that is then collected within the recovery tank <NUM>. The fan separator <NUM> is in fluid communication with the inlet of the suction fan <NUM> such that the working air separated from the working air stream can be exhausted through the exhaust vents <NUM> defining the clean air outlet.

The fan separator <NUM> has a spinning fan-like element or spinning fan element <NUM>, which uses centrifugal force to direct liquids outward, and away from, the fan separator <NUM> and away from the suction fan <NUM>. In this manner, the fan separator <NUM> separates liquid and debris from the working air stream, while still allowing the separated working air to travel to the suction fan <NUM> and eventually be exhausted through the exhaust vents <NUM>. <FIG> shows an enlarged isometric view of the spinning fan element <NUM>. A face of the fan element <NUM> may be grooved and spiraling outward to assist in moving liquid or debris away from the center of the fan separator <NUM>. A plurality of separator blades <NUM> direct liquid outward through a plurality of holes <NUM>, as best viewed in <FIG>.

The liquid and debris separated by the spinning fan element <NUM> is directed away from the fan separator <NUM> by the separator blades <NUM>, such as through the holes <NUM> or other structures, including slots, into the remainder of the forward end <NUM> of the housing <NUM>, as shown in <FIG> and <FIG>. The liquid and debris then pools, collects, and flows downward toward the recovery tank <NUM>.

Skilled artisans will recognize numerous configurations for the spinning fan element <NUM> and the fan separator <NUM>, in addition to the example configurations shown in <FIG> and <FIG>, that can centrifugally expel liquid and debris from the incoming working air stream containing a mixture of air, liquid, and debris. The working air, after liquid and debris is substantially separated therefrom, may pass through gaps or holes formed in the spinning fan element <NUM>, through other passageways, or combinations thereof, to reach the suction fan <NUM> and be exhausted from the cleaner <NUM> through the exhaust vents <NUM>. Without being limited by any theory, it is believed that in some cases, air that is expelled outward by the spinning fan element <NUM> will also be slowed before entering the passages to the suction fan <NUM>, such that any remaining liquid/debris will likely drop out of the working air stream prior to reaching the suction fan <NUM> and other components of the suction source <NUM>.

In the configuration shown, the fan separator <NUM> is driven by the vacuum motor <NUM>. Therefore, the suction fan <NUM> and the fan separator <NUM> are driven by a common element, such as a shaft <NUM> extending from, or operatively connected to, the vacuum motor <NUM>. Additionally, a spacer element <NUM> includes a central column configured to support the shaft <NUM>. An enlarged view of the spacer element <NUM> is shown in <FIG>.

Around the central column, the spacer element <NUM> has X-shaped spacer walls <NUM> connecting to a cylinder, with hollow portions therebetween, such that air may pass through spacer gaps <NUM> in the spacer element <NUM> to the suction fan <NUM>. The section view of <FIG> cuts through one of the X-shaped spacer walls <NUM> of the spacer element <NUM>. However, the view of <FIG> better illustrates the X-shaped spacer walls <NUM>.

As viewed in <FIG>, four X-shaped fan walls <NUM> of the spinning fan element <NUM> are visible. Also viewable in <FIG> are fan gaps <NUM> through which separated working air may flow through the spinning fan element <NUM>, through the spacer gaps <NUM> in the spacer element <NUM>, and toward the suction fan <NUM>.

Configurations having either the butterfly valve <NUM> or the fan separator <NUM> may further include a funnel element extending into the recovery tank <NUM>, such as the funnel <NUM> or the funnel <NUM>. Additionally, strainers may be used to limit the size of debris exiting the suction nozzle <NUM>, such that any of the separator elements are less subject to large debris.

To assist and clarify the description of various embodiments, various terms may be defined herein. Additionally, all references referred to are incorporated herein in their entirety.

When used, the term "substantially" refers to relationships that are ideally perfect or complete, but where manufacturing realties prevent absolute perfection. Therefore, substantially denotes typical variance from perfection. For example, if height A is substantially equal to height B, it may be preferred that the two heights are <NUM>% equivalent, but manufacturing realities likely result in the distances varying from such perfection. Skilled artisans will recognize the amount of acceptable variance. For example, and without limitation, coverages, areas, or distances may generally be within <NUM>% of perfection for substantial equivalence. Similarly, relative alignments, such as parallel or perpendicular, may generally be considered to be within <NUM>%.

As used in this specification, the term "or" includes any one, and all, combinations of the associated listed items. The term "any of" is understood to include any possible combination of referenced items, including "any one of' the referenced items.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claim 1:
A handheld extraction cleaner (<NUM>), comprising:
a suction nozzle (<NUM>) defining an inlet path;
a suction fan (<NUM>) configured to provide suction to the inlet path, such that the inlet path brings liquid and air into the handheld extraction cleaner, wherein the suction fan (<NUM>) has a fan entrance;
an initial separator (<NUM>);
a recovery tank (<NUM>) spaced from the fan entrance; and
a separator element (<NUM>, <NUM>) configured to allow liquid to flow into the recovery tank (<NUM>), inhibit the flow of liquid out of the recovery tank, and/or inhibit liquid from reaching the fan entrance,
wherein the initial separator and the separator element are different components.