Patent ID: 12245731

BRIEF DESCRIPTION

The invention generally relates to a surface cleaning apparatus with steam delivery. Aspects of the disclosure described herein are further related to an upright wet/dry vacuum cleaner or wet/dry multi-surface cleaner that can delivery liquid and/or steam to clean hard floor surfaces such as tile and hardwood and soft floor surfaces such as carpet.

As used herein, the term “dirt” includes dirt, soil, dust, hair, stains, and other debris, unless otherwise noted.

As used herein, the term “cleaning fluid” may encompass liquid, steam, or a mixture of both liquid and steam, and may include the presence of a surface cleaning and/or treatment agent. Examples of cleaning fluids are water or solutions containing water (like water mixed with a cleaning chemistry, fragrance, etc.),

As used herein, the term “steam” includes a cleaning fluid at least partially converted to a gas or vapor phase. The cleaning fluid can be boiled or otherwise at least partially converted to the gas or vapor phase by heating a cleaning fluid with a heat source on board the floor cleaner. The cleaning fluid can be heated to around 100±10° C., alternately about 90 to 100° C., alternatively about 95 to 98° C. Alternatively, steam may be produced by a mechanical action like nebulizing. The steam can be invisible to the naked eye, in the form of a visible vapor that can be observed by the naked eye, or combinations thereof.

The steam can have a steam quality of 100% or less, alternatively about 50% or greater, alternatively about 60% or greater, alternatively about 70% or greater, alternatively about 80% or greater, alternatively about 90% or greater, alternatively about 90-100%. As used herein, “steam quality” is the proportion of saturated steam in a saturated condensate (liquid) and steam mixture. For example, saturated steam vapor has a steam quality of 100%, and saturated liquid has a steam quality of 0%.

As used herein, the terms “visible vapor,” “visible steam,” or “visible steam vapor” includes steam that can be observed by the naked eye and is therefore visible to a user of the floor cleaner.

As used herein, the term “liquid” includes a cleaning fluid having a temperature below the temperature of steam, including but not limited to 32 to 55° C. The liquid may or may not be heated by a heat source on board the surface cleaning apparatus. The liquid may have a steam quality of 0%.

The functional systems of the surface cleaning apparatus can be arranged into any desired configuration, such as an upright device having a base and an upright body for directing the base across the surface to be cleaned, a canister device having a cleaning implement connected to a wheeled base by a vacuum hose, a portable device adapted to be hand carried by a user for cleaning relatively small areas, or a commercial device. Any of the aforementioned cleaners can be adapted to include a flexible vacuum hose, which can form a portion of the working air conduit between a nozzle and the suction source. As used herein, the term “multi-surface” or “wet/dry” vacuum cleaner includes a vacuum cleaner that can be used to clean hard floor surfaces such as tile and hardwood and soft floor surfaces such as carpet.

FIG.1is a perspective view of a surface cleaning apparatus or floor cleaner10according to one aspect of the present disclosure. As discussed in further detail below, the floor cleaner10is provided with various features and improvements, which are described in further detail below. The floor cleaner10can include multiple cleaning systems, including a liquid delivery system, a steam delivery system, and a recovery system. With both steam and liquid delivery systems, the floor cleaner10can selectively deliver liquid and/or steam to the surface to be cleaned.

As illustrated herein, the floor cleaner10can be an upright floor cleaner having a housing that includes a cleaning head in the form of a base14adapted to move over a surface to be cleaned and an upper housing in the form of an upright body12coupled with the base14to direct the base14over the surface to be cleaned. The various cleaning systems and components thereof can be supported by either or both the base14and the upright body12. 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 disclosure as oriented inFIG.1from the perspective of a user behind the floor cleaner10, which defines the rear of the floor cleaner10. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary.

As used herein, the term upright floor cleaner is intended to refer to various types of floor cleaners including, but not limited to, upright floor cleaners, stick floor cleaners, convertible floor cleaners (e.g., a floor cleaner capable of being used as an upright- or stick-type cleaner as well as a handheld cleaner), lift-off floor cleaners (e.g., a floor cleaner capable of being used as an upright-type cleaner as well as a canister type cleaner), and the like, or combinations thereof. In one embodiment, the upright floor cleaner is an upright multi-surface wet vacuum cleaner.

The base14can comprise any type of base, foot, or other cleaning head suitable for the purposes described herein, including being moved over a floor surface to be cleaned. The base14may include any of a suction nozzle, an agitator (e.g. a brushroll, a pad, etc.), a squeegee, a wheel, a pump, a heater, a motor, a tank, a filter, a dispenser, a battery, a wireless communication module, a hose, and the like, or any combination thereof.

The upright body12can comprise any type of elongated handle, wand, body, or combination thereof suitable for the purposes described herein, including for a user to maneuver the floor cleaner10over a floor surface to be cleaned. The upright body12can include a handle16and a frame18. The frame18can comprise a main support section supporting at least a supply tank20and a recovery tank22, and may further support additional components of the body12. The floor cleaner10can include a fluid delivery or supply pathway, including and at least partially defined by the supply tank20, for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned and a recovery pathway, including and at least partially defined by the recovery tank22, for removing the spent cleaning fluid and debris from the surface to be cleaned and storing the spent cleaning fluid and debris until emptied by the user.

Optionally, the body12can have a carry handle24to facilitate lifting and carrying the entire floor cleaner10. The carry handle24can be disposed on a top and/or upper side of the frame18, generally lower than the handle16, although the carry handle24may, in some embodiments, partially overlap the handle16.

The handle16can include a hand grip26and a trigger28mounted to the hand grip26, which controls fluid delivery from the supply tank20via an electronic or mechanical coupling with the tank20. The trigger28can project at least partially exteriorly of the hand grip26for user access. Other actuators, such as a thumb switch, can be provided to control fluid delivery instead of the trigger28. In yet other embodiments, separate actuators for liquid and steam delivery can be provided.

Other components of the body12may include any of a pump, a motor, a filter, a dispenser, a battery, a wireless communication module, a wand, a hose, and the like, or any combination thereof.

The floor cleaner10may include at least one user interface (“UI”) through which a user can interact with the floor cleaner10to accomplish one or more functions. In some embodiments, the floor cleaner10may include a first UI30and a second UI32. One UI30can be provided on the body12and the other UI32can be provided on the base14. The UIs30,32can, among other abilities, accept user inputs for controlling the cleaning system and/or function as a communication output device for the cleaning system.

To accept user inputs, the UIs30,32can have at least one user input control operably connected to one or more components or systems of the floor cleaner10to affect and control its operation. Non-limiting examples of input controls include buttons, triggers, toggles, keys, switches, or the like, or any combination thereof.

To communicate output to the user, the UIs30,32can have at least one status indicator, or a status display including a plurality of status indicators, that communicates a condition or status of the floor cleaner10, including systems and components thereof, to the user. Non-limiting examples of status indicators include visual indicators such as lights (e.g., LEDs), icon displays, textual displays, graphical displays, or the like, or any combination thereof. The UIs30,32can also include an auditory output component, such as a speaker.

In one embodiment, the first UI30is an input UI configured to accept user inputs to control the floor cleaner10, including systems or components thereof and the second UI32is an output UI configured to indicate status information relating to the floor cleaner10, including systems or components thereof. For example, the first UI30can include multiple input controls to affect and control the operation of the liquid delivery system, the steam delivery system, the recovery system, or any combination thereof. As yet another example, the input controls may affect and control the operation of a motor, a brushroll, a liquid dispenser, a steam dispenser, a pump, a filter, a supply tank, a recovery tank, a battery, a wireless communication module, and the like, or any combination thereof. The second UI32can include a display may indicate a cleaning mode of the floor cleaner10, a Wi-Fi connection status of the floor cleaner, and the like, or any combination thereof. As another example, the display may indicate that status of the liquid delivery system, the steam delivery system, the recovery system, or any combination thereof. As yet another example, the display may indicate that status of a motor, a brushroll, a liquid dispenser, a steam dispenser, a pump, a filter, a supply tank, a recovery tank, a battery, a wireless communication module, and the like, or any combination thereof.

While the first UI30is referred to herein as an input UI, in some embodiments the first UI30may have an output functionality as well. For example, the first UI30may, in some embodiments, include at least one status indicator that communicates a condition or status of the floor cleaner, including systems and components thereof, to the user. In other embodiments, the first UI30solely accepts input, and does not provide outputs to the user.

Likewise, while the second UI32is referred to herein as an output UI, in some embodiments the second UI32may have an input functionality as well. For example, the second UI32may, in some embodiments, include at least one user input control operably connected to one or more components or systems of the floor cleaner10to affect and control its operation. In other embodiments, the second UI32solely provides output, and does not accept inputs from the user.

The first and second UIs30,32are separate from each other, and are located on different areas of the floor cleaner10. The upright body12, or more particularly the handle16, or more particularly the hand grip26, can include the first UI30. The first UI30can conveniently be located adjacent to the grip26, so that a user may hold the grip26in one hand and operate the first UI30with the same hand. For example, a user may wrap their palm and fingers around the grip26, and operate the first UI30using the thumb of the same hand. Similarly, the trigger28can conveniently be located adjacent to the grip26and first UI30. For example, the user may operate the trigger28using the forefinger of the same hand holding the grip26. Conveniently, in one arrangement, the UI30is disposed on a front side of the grip26and the trigger28is disposed on a rear side of the grip26.

Other locations for the first UI30are possible, including locations where the user must hold the grip26in one hand and operate the first UI30with their other hand. It may be preferred that the first UI30is in a location that the user holding the grip26may operate the first UI30without having to bend down or take their hand off the grip26. Such locations include, but are not limited to, on a portion of the handle16other than the grip26, on the carry handle24, or on an upper portion of the frame18. In other embodiments, the first UI30may be distributed across multiple portions of the floor cleaner10, such as including a first portion on the grip26and another portion on the handle16, carry handle25, or frame18, for example.

The base14can include the second UI32. The second UI32can conveniently be located in a field of view of the user operating the floor cleaner, e.g. in an observable area a person can see through their eyes. When operating the floor cleaner10, the user commonly looks down the apparatus toward a surface being cleaned and/or toward the base14moving over the surface. For example, to operate the floor cleaner10, the user may stand generally behind the floor cleaner10and hold the grip26in one hand. During operation, the user commonly looks down the floor cleaner10toward a floor surface being cleaned. As such, their field of view includes the base14of the floor cleaner10. Locating the second UI32on the base14positions the second UI in the user's field of view. During operation of the floor cleaner10, the user can quickly glance back and forth between the floor surface being cleaned and the second UI32. Even when the user's attention is focused on the floor surface, changes displayed on the second UI32are within the user's field of view, and so may readily draw the user's attention to the information conveyed by second UI32.

Although shown on the base14, and particularly on a top side of the base14, other locations for the second UI32are possible. It may be preferred that the second UI32is in a location that the user holding the grip26may view the second UI32without having to bend down or take their hand off the grip26. Such locations include, but are not limited to, a lower front portion of the frame18.

A moveable joint assembly34can connect the base14to the upright body12for movement of the upright body12about at least one axis. In the embodiment shown herein, the upright body12can pivot up and down about a first axis X relative to the base14. Optionally, the joint assembly34can be configured such that the upright body12can swivel about a second axis Y in addition to pivoting about the first axis X. The upright body12can pivot, via the joint assembly34, between the upright or storage position, an example of which is shown inFIG.1, and a reclined or use position, an example of which is shown inFIG.2, in which the upright body12is pivoted rearwardly to form an acute angle with the surface to be cleaned. Wiring and/or conduits can optionally supply electricity, air, liquid and/or steam between the upright body12and the base14, or vice versa, and can extend though the joint assembly34. As such, in some embodiments, a portion of the cleaning systems can extend through the joint assembly34.

A joint lock36(FIG.5) can selectively engage and lock the upright body12in the upright or storage position. When locked in the upright/storage position, the joint assembly34is locked-out and the upright body12is not moveable about the at least one axis. When reclined, the joint assembly34is released and the upright body12can move relative to the base14about the at least one axis. Aside from this function, the joint lock36is not particularly limited, and may comprise any components and/or configurations suitable for use in/as a joint lock. In one embodiment, the joint lock36is a detent mechanism. By way of non-limiting example, the detent mechanism can include a spring-biased detent on the base14that engages a portion of the upright body12automatically by the action of raising the upright body12to the upright storage position. A user can disengage the detent mechanism to recline the upright body12, for example, by pressing down on the base14while pulling the upright body12rearwardly. In another example, the base14can include an actuator, such as a pedal, button, or lever that a user may press to disengage the detent mechanism.

FIG.3Ais a schematic view of various functional systems of the floor cleaner10. The liquid delivery system includes the supply tank20configured to hold a source of cleaning fluid, at least one liquid dispenser38supplied with liquid cleaning fluid from the supply tank20, and a liquid supply path40from the supply tank20to the liquid dispenser38.

The supply tank20can store cleaning fluid in liquid form. The cleaning fluid can comprise one or more of any suitable cleaning fluids, including, but not limited to, water, compositions, concentrated detergent, diluted detergent, etc., and mixtures thereof. For example, the cleaning fluid can comprise water. In another example, the cleaning fluid can comprise a mixture of water and concentrated detergent.

The liquid delivery system can include a flow controller for controlling the flow of fluid from the supply tank20to the liquid dispenser38. In one configuration, the flow controller can comprise a pump44, which pressurizes the supply path40and controls the delivery of liquid cleaning fluid to the liquid dispenser38. In one example, the pump44can be a centrifugal pump. In another example, the pump44can be a solenoid pump.

The release of cleaning liquid from the liquid dispenser38can be controlled by the trigger28. The trigger28can operate the liquid pump44in the path40, where depressing the trigger28turns the pump44on to pressurize the path40, thereby providing cleaning liquid to the dispenser38. Release of the trigger28de-activates the pump44and stops liquid dispensing. As described in further detail below, in some embodiments, operation of the pump44upon depression of the trigger28can be mode-dependent. In other words, depending on a selected cleaning mode of the floor cleaner10, depression of the trigger28may or may not activate the pump44.

The liquid dispenser38can comprise various structures, such as a nozzle, a spray tip, or a manifold, and can comprise at least one liquid outlet for dispensing liquid cleaning fluid to the surface to be cleaned. The dispenser38can be positioned to deliver liquid cleaning fluid directly to the surface to be cleaned, or indirectly by delivering liquid cleaning fluid onto an agitator (not shown). In one non-limiting example, the dispenser38delivers liquid cleaning fluid onto a brushroll. In another non-limiting example, the dispenser38delivers liquid cleaning fluid between two horizontally-rotating brushrolls.

The liquid delivery system can include other conduits, ducts, tubing, hoses, connectors, valves, etc. fluidly coupling the components of the liquid delivery system together and providing the liquid supply path40.

In the embodiment shown inFIG.3A, the liquid delivery system includes a single supply tank20for storing a supply of cleaning fluid. In another embodiment, the liquid delivery system can have an additional supply container (not shown) for storing another cleaning fluid. For example, the supply tank20can store water and the second supply container can store a cleaning agent such as detergent. In embodiments where multiple supply containers are provided, the floor cleaner10can have a mixing system for controlling the composition of the cleaning fluid that is delivered to the surface.

The steam delivery system includes a source of cleaning fluid, a heater46for heating the cleaning fluid, a steam dispenser48to dispense steam, and a steam supply path50from the source of cleaning fluid to the steam dispenser48. The heater46preferably heats the cleaning fluid to around 100±10° C., alternately about 90 to 100° C., alternatively about 95 to 98° C. This temperature may be the temperature at an outlet of the heater46. The heater46itself may operate at a higher temperature, such as around 130° C. Some heat loss between the heater46and the steam dispenser48is possible, particularly when the system and its components are heating up and pressurizing. Once a “steady state” is reached, the temperature of the steam may be about 90 to 100° C., alternatively about 95 to 98° C. Some non-limiting examples of a suitable heater46include, but are not limited to, a flash heater, a boiler, an immersion heater, and a flow-through steam generator.

The steam produced by the heater46may include a mixture of vapor phase and liquid phase. For example, the steam output by the heater46can have a steam quality of 50% or greater, alternatively about 60% or greater, alternatively about 70% or greater, alternatively about 80% or greater, alternatively about 90% or greater, alternatively about 90-100%. It is noted that the steam quality of the heated fluid that reaches the steam dispenser48may change over time, for example depending on how long the trigger28or other control actuator is depressed. When the trigger28is initially depressed, the steam quality may be higher and may decrease until a steady state is reached.

The steam delivery system can share the same fluid source, e.g. supply tank20, as the liquid delivery system. In another embodiment, the floor cleaner10can include a separate supply container (not shown) for storing a cleaning fluid for the steam delivery system. In embodiments where the supply tank20is shared, a manifold splitter54splits liquid between the steam supply path50and the liquid supply path40.

The steam delivery system can include a flow controller to control the flow of fluid from the supply tank20to the heater46. In one configuration, the flow controller can comprise a pump56that pressurizes the path50and controls the delivery of heated fluid to the steam dispenser48. In one example, the pump56can be a centrifugal pump. In another example, the pump56can be a solenoid pump.

The release of steam from the steam dispenser48can be controlled by the trigger28. The trigger28can activate the steam pump56in the path50, where depressing the trigger28turns the pump56on to pressurize the path50, thereby providing liquid to the heater46, which in turn generates steam, and providing the generated steam to the steam dispenser48. Release of the trigger28de-activates the pump56and stops steam dispensing. As described in further detail below, in some embodiments, operation of the steam pump56upon depression of the trigger28can be mode-dependent. In other words, depending on a selected cleaning mode of the floor cleaner10, depression of the trigger28may or may not activate the steam pump56. For example, depending on the cleaning mode, operation of the trigger28may activate the liquid pump44only, the steam pump56only, or both pumps44,56.

In yet another embodiment, a separate steam input control60selectively operates the steam pump56to control steam dispensing, while the trigger28selectively operates the liquid pump44to control liquid dispensing. A user may operate both controls28,60at the same time for simultaneous liquid and steam dispensing.

The steam dispenser48can comprise various structures, such as a nozzle or a manifold, and can comprise at least one steam outlet for dispensing steam toward the surface to be cleaned. The dispenser48can be positioned to deliver steam directly to the surface to be cleaned, or indirectly by delivering steam onto an agitator or cleaning pad. In one non-limiting example, the steam dispenser48delivers steam onto the surface to be cleaned in front of an agitator, such as a brushroll.

The steam delivery system can include other conduits, ducts, tubing, hoses, connectors, valves, etc. fluidly coupling the components of the system together and providing the supply path50from the supply tank20to the steam dispenser48.

In certain embodiments, the liquid provided to the liquid dispenser38does not pass through the heater46and/or is otherwise unheated, and is at the same temperature as the fluid stored in the supply tank20. In other embodiments, the liquid provided to the liquid dispenser38passes through a heater (not shown) or is otherwise heated to a temperature that is less than the temperature of the steam dispensed by the steam dispenser48. Such a heater can be located downstream of the supply tank20and upstream of the pump44. In yet another example, exhaust air from a motor-cooling pathway for a motor/fan assembly can be applied to the liquid supply path40to heat the liquid.

The recovery system can include a recovery path66through the cleaner10having a path inlet and a path outlet, a suction source including a vacuum motor64in fluid communication with the path inlet for generating a working air stream through a recovery path66, and the recovery tank22for separating and collecting fluid and dirt from the working airstream for later disposal. A separator68can be formed in a portion of the recovery tank22for separating fluid and entrained dirt from the working airstream.

In one embodiment, the path inlet can include a suction inlet port62disposed on the cleaning head or base14, and the path inlet can be defined by a suction nozzle, a brush chamber, and/or a brushroll cover, or any combination thereof, as described in more detail below.

The floor cleaner10can include at least one agitator to agitate the surface to be cleaned. In one embodiment, the agitator is a rotating brushroll70. The liquid dispenser38delivers liquid cleaning fluid directly onto the brushroll70. In one non-limiting example, the suction inlet port62is positioned in close proximity to the brushroll70to collect liquid and debris directly from the brushroll70. Other examples of agitators include, but are not limited to, dual horizontally-rotating brushrolls, one or more vertically-rotating brushes, a stationary brush, or a cleaning pad.

A drive assembly including a brushroll motor72can drive the brushroll70. A drive transmission (not shown) operably connects the motor72with the brushroll70for transmitting rotational motion of the motor72to the brushroll70. In other embodiment, a drive transmission can operably connect the brushroll70with the vacuum motor64to transmit rotational motion of the motor64to the brushroll70.

The floor cleaner10can be provided with above-the-floor cleaning features (not shown), including, but not limited to, an accessory hose and an above-the floor cleaning tool with its own suction inlet and/or fluid dispenser.

Electrical components of the floor cleaner10, including the heater46, pumps44,56, vacuum motor64, brushroll motor72, or any combination thereof, are electrically coupled to a power source74, which can comprise a power cord plugged into a household electrical outlet or a battery for cordless operation. In one embodiment, the power source74comprises a power cord. At least one of the UIs30,32(FIG.1) can have appropriate input controls for user control of one or more of the heater46, pumps44,56, vacuum motor64, and brushroll motor72, thereby controlling the cleaning systems of the floor cleaner10. For example, cleaning modes can have associated operating parameters for the heater46, pumps44,56, vacuum motor64, and/or brushroll motor72, such that user selection of a cleaning mode will operate those components according to the associated operating parameters. At least one of the UIs30,32(FIG.1) can output status information regarding the selected cleaning modes to the user.

The floor cleaner10can include a main controller76operably coupled with the various function systems and components of the floor cleaner10. In one embodiment the main controller76can comprise a printed circuit board (“PCB”). As used herein, unless otherwise noted, the term “PCB” includes a printed circuit board having a plurality of electrical and electronic components that provide operational control to the floor cleaner10. The PCB includes, for example, a processing unit (e.g., a microprocessor, a microcontroller, or another suitable programmable device) and a memory (e.g., a read-only memory (“ROM”), a random access memory (“RAM”), an electrically erasable programmable read-only memory (“EEPROM”), a flash memory, or another suitable magnetic, optical, physical, or electronic memory device). The processing unit is connected to the memory and executes instructions (e.g., software) that is capable of being stored in the RAM (e.g., during execution), the ROM (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Additionally or alternatively, the memory is included in the processing unit (e.g., as part of a microcontroller). Software stored in memory includes, for example, firmware, program data, one or more program modules, and other executable instructions. The processing unit is configured to retrieve from memory and execute, among other things, instructions related to the control processes and methods described herein. The PCB can also include, among other things, a plurality of additional passive and active components such as resistors, capacitors, inductors, integrated circuits, and amplifiers. These components are arranged and connected to provide a plurality of electrical functions to the PCB including, among other things, signal conditioning or voltage regulation. For descriptive purposes, a PCB and the electrical components populated on the PCB are collectively referred to as a controller. Thus, the main PCB and the electrical components populated on the main PCB may be referred to as main controller76.

FIG.3Bshows another embodiment of the functional systems of the floor cleaner10, where the liquid and steam delivery systems have flow controllers including valves42,58in the supply paths40,50respectively. The trigger28can selectively operate the valves42,58, where depressing the trigger28opens at least one of the valves42,58to release liquid and/or steam to the associated dispenser38,48. Release of the trigger28closes the valve42,58and stops dispensing. In some embodiments, operation of the valve42upon depression of the trigger28can be mode-dependent. In other words, depending on a selected cleaning mode of the floor cleaner10, depression of the trigger28may or may not open one of the valves42,58. For example, depending on the cleaning mode, operation of the trigger28may open the liquid valve42only, the steam valve58only, or both the valves42,58.

Various locations and configurations for the valves42,58are possible. In one embodiment, the liquid valve42is located in the supply path40between the liquid pump44and the liquid dispenser38and the steam valve58is located in the supply path50between the heater46and the steam dispenser48. The valves42,58may be, for example a solenoid valve or an,50other electronic valve. Aside from the function of controlling fluid flow through the paths40, the valves42,58are not particularly limited, and may comprise any component and/or configuration suitable for use in/as a fluid control valve.

In yet another configuration of the liquid delivery system, the pump44can be eliminated and the flow controller can comprise a gravity-feed system having the valve42fluidly coupled with an outlet of the supply tank20, whereby when the valve42is open, fluid will flow under the force of gravity to the liquid dispenser38.

FIG.4shows an architectural layout for the upright body12according to one aspect of the disclosure, including locations and relative positions for components of the liquid, steam, and recovery systems. Components including the supply tank20, heater46, steam pump56, and vacuum motor64are included on the upright body12. The components of the upright body12are arranged with relative positioning that provides an architecture that is well-balanced and comfortable for the user to operate as the floor cleaner10is moved along a surface to be cleaned. For example, the heater46is disposed in a lower end of the frame18and the vacuum motor64is disposed in an upper end of the frame18to arrange these heavier components in a generally linear, stacked orientation that can provide a slim upright body12that is well-balanced and comfortable to hold in a reclined use position. The recovery tank22is disposed on a lower front side of the frame18, forwardly of the heater46, with the supply tank20disposed on a rear side of the frame18above the heater46to provide a compact spatial arrangement for the upright body12. Smaller components such as the steam pump56are disposed in the available space between the vacuum motor64and the heater46. Other architectural layouts for the components of the upright body12are possible while providing a well-balanced and comfortably operable floor cleaner10.

FIG.5show an architectural layout for the base14according to one aspect of the disclosure, including locations and relative positions for components of the liquid, steam, and recovery systems. Components including the liquid pump44, brushroll70, and brushroll motor72are included on the base14. For clarity of the architectural layout, one or more housing pieces and component covers of the base14are not shown inFIG.5.

In one embodiment, the base14includes a plurality of sides, including, for example, a front side78F, a first lateral or right side78R, a second lateral or left side78L, and a rear side78B. The base14can include a base housing80supporting the components of the base14, the base housing80including one or more housing pieces and/or covers assembled together, and, in some embodiments, defining one or more of the sides of the base14. Wheels84can at least partially support the base housing80for movement over the surface to be cleaned.

The components of the base14are arranged with relative positioning that provides an architecture that is low-profile and easily maneuvered along a surface to be cleaned. For example, the liquid pump44and brushroll motor72are disposed rearwardly of the brushroll70. As another example, the liquid pump44and brushroll motor72are located on opposing sides of the swivel axis Y, and forwardly of the pivot axis X. A conduit152can pass between the pump44and the brush motor72, and can generally bisect a rear portion of the base14into a pump cavity in which the pump44is located and a brush motor cavity in which the brush motor72is located.

Other architectural layouts for the components of the base14are possible while providing an easily maneuverable floor cleaner10.

FIGS.6-7show details related to the heater46, according to one aspect of the disclosure. The heater46can be disposed in a heater cavity86on a lower end of the frame18, the heater cavity86closeable by a heater cover88. The heater cover88can define a rear side of the upright body12. The heater46includes a heater inlet90fluidly connected to the supply tank20(FIG.3A), for example via the steam pump56(shown in phantom line), and a heater outlet92fluidly connected to the steam dispenser48(FIG.3A).

The heater46can be oriented with the inlet90and outlet92at a lower end94of the heater46, which can maximize liquid dwell time within the heater46. For example, by pumping liquid through the heater46initially in an upward direction, e.g., against gravity, dwell time increases. The heater inlet and outlet90,92can accordingly be disposed at a lower end of the heater cavity86. The steam pump56can be disposed at an upper end96of or above the heater46, and may accordingly be disposed at an upper end of or above the heater cavity86.

Referring toFIG.7, the heater46includes a fluid-conducting tube98encased in a body100with an electric heating element102. The tube98can be constructed of stainless steel or other suitable corrosion-resistant and/or oxidation-resistant material and the body100can be constructed of aluminum or other suitable thermally conductive material. The tube98, body100, and heating element102can be enclosed within a heater box104. The heater box104is shown herein as including two halves; other configurations for the heater box104are possible.

The heating element102uniformly heats the cleaning fluid as it passes through the tube98. The heating element102may, for example, be selected to effectively deliver approximately 800 watts of power to heat the cleaning fluid in the tube98to a temperature of around 100±10° C., alternately about 90 to 100° C., alternatively about 95 to 98° C.

The tube98can have a single 180 degree bend110between the inlet90and the outlet92. In other embodiments, the tube98has more than one bend, and may comprise a serpentine channel with multiple bends. With the heater inlet and outlet90,92at the lower end94of the heater46, the bend110in the tube98can accordingly be disposed at the upper end96of the heater46.

In one embodiment, the heater inlet90can comprise an inlet fitting106fluidly connected to an inlet end of the tube98and the heater outlet92can comprise an outlet fitting108fluidly connected to an outlet end of the tube98. The inlet fitting106can be fluidly connected to an inlet conduit (not shown) to conduct pressurized cleaning fluid from the steam pump56to the tube98. The outlet fitting108can be fluidly connected to a steam conduit344(FIG.21) to conduct cleaning fluid from the tube98to the steam dispenser48(FIG.3A). The steam conduit344may pass from the upright body12to the base14, for example by passing through or around the joint assembly34.

A pressure relief device112controls or limits the pressure in the steam delivery system. The pressure relief device112opens at a predetermined set pressure to protect the system from being subjected to high pressures that exceed their design criteria. When the set pressure is met or exceeded, the pressure relief device112opens and vents steam outside the floor cleaner10. Aside from this function, the pressure relief device112is not particularly limited, and may comprise any components and/or configurations suitable for use in/as a pressure relief. In one embodiment, the pressure relief device112is a spring valve that opens at a predetermined set pressure.

In one embodiment, the pressure relief device112can be incorporated into the heater outlet92, including, but limited to, being incorporated into the outlet fitting108. In other embodiments, the pressure relief device112can be disposed elsewhere in the steam supply path50, e.g. separate from the heater46. In one non-limiting example, the pressure relief device112can vent steam to outside the floor cleaner10via a vent port114in the upright body12. The vent port114can be oriented to direct vented steam generally rearwardly and downwardly, relative to the upright body12. Optionally, the vent port114can be hidden by the heater cover88, with the heater cover88including a vent116for venting excess heat from the heater cavity86and steam from the vent port114

During steam generation, pressure will build in the steam system unless the pressure is released. Pressure is released, for example, when steam is dispensed from the steam dispenser48. When the steam path50is blocked or steam is otherwise held within the steam path50for a period of time, pressure will build in the system as liquid is heated and steam is generated. When the pressure in the path50reaches the set pressure, the pressure relief device112opens. Once pressure in the path50drops below the set pressure, such as may occur if steam is released or if the floor cleaner10is powered off, the pressure relief device112closes. The set pressure may be, for example, about 6 PSI, alternately about 7 PSI, although it is understood that the set pressure may vary depending on the design limits of the floor cleaner10.

FIGS.4and8show details related to the main controller76, according to one aspect of the disclosure. Various locations for the main controller76are possible. In one embodiment, the controller76is located in the frame18of the upright body12, below the supply tank20. The main controller76can comprise a PCB118and can be enclosed within a controller housing120. The controller housing120can be sealed to shield the controller76from moisture exposure. In particular, sealing the controller76within the controller housing120can prevent cleaning fluid, which may leak from the supply tank20, from intrusion into the PCB118. The controller76can further be below the vacuum motor64in order to reduce electromagnetic interference. Additional electromagnetic interference shielding can be provided by the controller housing120.

Referring toFIG.8, in one embodiment, the controller housing120can include two housing halves122,124that are assembled around the PCB118and sealed with an overmolded seal126. Wires (not shown) that connect to the PCB118can exit the controller housing120through grommets128to prevent liquid intrusion at the wire exit points.

Referring toFIG.4, the supply and recovery tanks20,22can be provided on the upright body12, and can be mounted to the frame18in any configuration. In the present embodiment, the upright body12comprises tank sockets or receivers130,132for respectively receiving the supply and recovery tanks20,22. As shown herein, in one embodiment the tank receivers130,132can be defined by portions of the frame18, and can be provided on opposing sides of the frame18, and more particularly on rear and front sides of the frame18, respectively. The frame18can include an upper rear receiver130for receiving the supply tank20therein and a lower front receiver132for receiving the recovery tank22therein. The recovery tank receiver132can be disposed generally below the supply tank receiver130.

The supply tank20includes a tank body134having a plurality of walls and defining a supply chamber for storing a cleaning liquid. In one embodiment, the tank body134is blow-molded. The supply tank20includes an outlet valve136controlling fluid flow through an outlet of the tank body134. The outlet valve136mates with a valve receiver138in the tank receiver130and can be configured to automatically open when seated and release cleaning fluid to the supply paths40,50. A check valve140can be mounted to the tank body134and is adapted to selectively vent excess gas within the supply tank20. The supply tank20can also include a pressure relief valve (not shown) that is adapted to vent ambient atmospheric air into the chamber126as cleaning fluid therein is released through the outlet valve136.

The recovery tank22can include a recovery tank body142, which forms a collection chamber144for the recovery system, with a hollow standpipe146therein. The standpipe146forms a flow path between a tank inlet148formed at a lower end of the tank body142and a tank outlet150at the upper end of the standpipe146within the interior of the tank body142. When the recovery tank22is mounted to the frame18, the inlet148is aligned with the conduit152, which forms a portion of the recovery path66(FIG.3A), to establish fluid communication between the base14and the recovery tank22. The standpipe146can be integrally formed with the tank body142, or may be removeably connected thereto.

FIG.9is an exploded view of the recovery tank22. The recovery tank22includes a lid154configured to be seated on the top of the tank body142. The lid154at least partially encloses an open top of the tank body142, and can further define an air outlet156of the recovery tank22. A gasket158is positioned between mating surfaces of the lid154and the tank body142and creates a seal therebetween for prevention of leaks.

A recovery tank latch160can optionally be supported by the lid154for securing the recovery tank22to the upright body12within the recovery tank receiver132. The latch160is configured to releasably lock the recovery tank22to the upright body12, such that a user must actuate the latch160before pulling the tank22off the frame18. A hand grip162on the recovery tank22can be located below the latch160and can facilitate removal of the recovery tank22from the frame18. In another embodiment, the latch160can releasably latch or retain, but not lock, the tank22on the frame18, such that a user can conveniently apply sufficient force to the tank22itself to pull the tank22off the frame18.

A float-style shut-off can be provided for interrupting suction when liquid in the recovery tank22reaches a predetermined level. The shut-off includes a float bracket164fixedly attached to an inner side of the lid154in a position offset from the standpipe146and a moveable float166carried by the float bracket164. The float166is buoyant and oriented so that the top of the float166can selectively seal the air outlet156when the liquid in the recovery tank22reaches a predetermined level. In another embodiment, the recovery tank22can include an electronic sensing system configured to detect liquid at one or more levels within the recovery tank22and determine when to shut-off or otherwise interrupt the recovery system.

The recovery tank22can include a removable strainer168configured to strain large debris and hair out of the tank body142prior to emptying. The strainer168is configured to be manually lifted out of the tank body142and to collect the large debris and hair while draining liquid and smaller debris back into the tank body142.

The recovery tank22can further include a filter assembly170provided at the air outlet156. The filter assembly170can be supported by the lid154and the lid154can include a filter receiver172on an upwardly-facing side thereof that is sized to receive the filter assembly170. The filter assembly170is removably mounted in the filter receiver172.

In one embodiment, the filter assembly170can include a filter174and a filter frame176having an open area through which air may pass, with the filter174supported within the frame176. The filter174can comprise any suitable type or combination of types of filter media suitable for filtering particles entrained within an airstream. Non-limiting examples of filter media include paper, cellulosic material, non-woven material, spunbond material, pleated filter media, open cell foam, polyester type matrix (e.g., polyethylene terephthalate), and combinations thereof. The filter media can also be a reusable or washable type of media such as a non-woven or foam type filter media, for example. It will be understood that the particle filtration size of the filter will vary depending on the floor cleaner10in which the filter assembly170is intended for use. For the embodiment of the multi-surface wet/dry floor cleaner10shown, the filter174is a pleated filter, and can be made of a material that remains porous when wet, e.g., air can still flow through the filter174when wet (unlike conventional paper filters).

In certain embodiments, the filter assembly170may comprise at least one additional filter media upstream of the filter174. In the depicted embodiment, a mesh screen178is disposed on an upstream inlet side of the filter174, and has a larger pore size than the filter174. When referring to the filter174or mesh screen178, the pore size is the size of the largest particles that can successfully pass through that element. The pore size may be an effective pore size or an average of pore sizes across the media. The mesh screen178can be pivotally coupled with the filter frame176, and can swing open, e.g. away from the filter174.

A seal182on the frame176blocks the escape of air from the recovery pathway66. A ceiling of the tank receiver132(FIG.4) can be configured to fit tightly against the seal182, and optionally also with the lid154, to provide a sealed pathway from the filter assembly170to the vacuum motor64.

The filter assembly170can have a poka-yoke installation to prevent a user from inadvertent error in installing the filter assembly170in the filter receiver172, such as a projecting feature on the filter assembly170and/or on the filter receiver172that prevents a user from installing the filter assembly170incorrectly by interfering with the insertion of the filter assembly170into the filter receiver172.

The filter assembly170can have a gripping feature that is made to be grasped or held by the hand for easy removal of the filter assembly170. The gripping feature can comprise a pull tab184that projects from one side of the filter assembly to assist the user in lifting the filter assembly170out of the filter receiver172. The pull tab184can have a flat, low profile so that it is flush with or below an uppermost portion of the recovery tank22so that the pull tab184does not interfere with installation of recovery tank22. In one embodiment, the pull tab184is integrally formed with the seal182, for example by injection molding or other suitable forming method. In another embodiment, the pull tab184is formed on the frame176. In yet other embodiments, the pull tab184may be eliminated, and the filter assembly170may be liftable out of the filter receiver172by gripping the frame176alone.

In one aspect of the disclosure, the recovery tank22defines a first upstream portion of the recovery path66(FIG.3A) upstream of the vacuum motor64and defines a second portion of the recovery tank20downstream of the vacuum motor64. For example a portion of the working air exhaust path downstream of the vacuum motor64extends through a portion of the recovery tank20. In one embodiment, the recovery tank22can have at least one exhaust vent186defining the path outlet of the recovery path66e.g. a clean air outlet for the floor cleaner. In the illustrated embodiment, two exhaust vents186are provided on the opposing sides of the recovery tank22, although other numbers and locations for the exhaust vents186are possible.

In one embodiment, the exhaust vents186are incorporated into the lid154of the recovery tank22. The lid154can have an exhaust chamber188in fluid communication with each vent186. The chambers188can be disposed on opposing sides of the filter receiver172. The chambers188can extend between an outer side wall190of the lid154and the filter receiver172, with exhaust vents186disposed in the outer side wall190.

The exhaust chamber188on at least one side of the filter receiver172can be enlarged for easier grasping and removal of the filter assembly170from the filter receiver172. For example, the chamber188provided on a side of the filter receiver172corresponding to the pull tab184can be sized for insertion of a user's finger for easy filter removal. In the embodiment shown, the pull tab184projects at least partially over the top of the chamber188, and the chamber188is sufficiently large for a user to insert a finger into the chamber188and under the tab184to lift the filter assembly.

FIG.11shows a portion of the recovery path downstream of the recovery tank22and the filter assembly170, according to one aspect of the disclosure, where a working air flow path is generally indicated by arrows W. The recovery path can include a suction source192, which can be a motor/fan assembly including the vacuum motor64and a fan194. The suction source192can be positioned within a housing of the frame18, such as above the recovery tank22. In one embodiment, the suction source192is arranged within an enclosure196, and the vacuum motor64, fan194, and enclosure196, forms a self-contained module198. The working air path W routes through and is enclosed by the module198.

The enclosure196includes an upper motor housing200and a lower motor housing202. A gasket204seals the interface between the housings200,202to provide a fluid-tight joint therebetween. The vacuum motor64is enclosed within the housings200,202, with a substantial portion (e.g., over half) of the motor64disposed in the upper motor housing200. The fan194is enclosed within the lower motor housing202. The enclosure196further includes a grille housing206that routes working air into and out of the lower motor housing202.

The enclosure196can include an air inlet through which working air can enter the enclosure196. In one embodiment, the enclosure air inlet is formed by a grille210in the grille housing206. The grille210is configured for fluid communication with the air outlet156of the recovery tank22. In one embodiment, the grille housing206forms a ceiling212of the tank receiver180(FIG.4), and the outlet side of the filter assembly170can be generally aligned with the grille210when the tank22is mounted in the receiver180, such that air passes from the filter assembly170directly into the enclosure196through the grille210. Other configurations for the enclosure air inlet are possible.

The lower motor housing202includes at least one fan inlet214for drawing working air into a fan chamber216in which the fan194is disposed. The fan inlet214can be generally aligned with the grille210.

A first cushioning member, such as a first gasket218, can be provided at the interface between the upper motor housing200and the suction source192, near the top of the motor64. A second cushioning member, such as a second gasket220, can be provided at the interface between the lower motor housing202and the suction source192, near the bottom of the fan194. The gaskets218,220dampen vibration to reduce noise due to mechanical vibrations of the motor64.

The lower motor housing202includes at least one fan outlet222through which air is driven from the chamber216by the fan194. The fan chamber216can be generally circular as shown, and a plurality of fan outlets222can be disposed at a periphery of the chamber216. In the illustrated embodiment, the lower motor housing202includes two diametrically-opposed fan outlets222. Other arrangement for fan outlets in the lower motor housing202are possible.

The structure of the lower motor housing202and grille housing210can vary, but preferably, the housings202,210cooperatively form a first closed path224to guide working air W from the grille210to the fan inlet214and a second closed path226to guide exhaust air from the fan outlet222to an enclosure air outlet228. Various walls, baffles, or channel structures can define the closed paths224,226and fluidly isolate the portions of the paths224,226within the housings202,210. In one embodiment, the lower motor housing202and grille housing210cooperatively form a center inlet duct230that extends from the grill210to the fan inlet214to form the first closed path224. The lower motor housing202and grille housing210cooperatively form lateral outlet duct232that extend from the fan outlets222to the enclosure air outlets228to form the second closed path226. The enclosure air outlets228are open to the exhaust chambers188in the recovery tank lid154, such that the working air W exiting the enclosure196enters the recovery tank lid154before exiting through the exhaust vents186.

FIGS.11and13show a motor cooling air path according to one aspect of the disclosure. The motor cooling air path is provided for supplying cooling air to the vacuum motor64and for removing heated cooling air (also referred to herein as “heated air”) from the vacuum motor64. InFIGS.11and13, the cooling air path is generally indicated by arrows C.

Referring toFIG.11, the motor cooling air path includes a cooling air inlet234and a cooling air outlet236, both of which are in fluid communication with the ambient air outside the floor cleaner10. Ambient air is drawn into the floor cleaner10through the cooling air inlet234, passes through the vacuum motor64, and is subsequently exhausted through the cooling air outlet236. In the embodiment illustrated, the cooling air inlet234is defined by an inlet vent on one side of the frame18and the cooling air outlet236is defined by an outlet vent on an opposing side of the frame18.

Referring toFIG.13, the enclosure196includes at least one inlet aperture242for cooling air and at least one outlet aperture246for heated cooling air. In one embodiment, the upper motor housing200includes the inlet aperture242to allow cooling air to enter the enclosure196and pass by the vacuum motor64. The inlet aperture242is in fluid communication with the cooling air inlet234(FIG.11), such as via an at least one cooling air inlet duct244. The cooling air inlet duct244can be formed internally within the upright body12, and more specifically can be formed by housings forming the frame18.

In one embodiment, the inlet aperture242is disposed on a rear upper side of the motor housing200, and at a least a portion of the inlet duct244can be formed by a rearward-extending portion240of the motor housing200.

The upper motor housing200also includes at least one outlet aperture246through which heated cooling air is transported away from the vacuum motor64and exhausted from the enclosure196. The outlet aperture246is in fluid communication with the cooling air outlet236, such as via an at least one heated air exhaust duct248. The heated air exhaust duct248can be formed internally within the upright body12, and more specifically can be formed by housings forming the frame18. Routing the heated air exhaust internally within the frame18reduces noise from the vacuum motor64. Optionally, the exhaust duct248can define a tortuous exhaust path to damped motor and airflow noise generated by the floor cleaner10during operation. The tortuous exhaust path can comprise multiple turns of 90 degrees or more.

In one embodiment, the outlet aperture246is defined by multiple exhaust ports disposed on a front lower side of the motor housing200, and at a least a portion of the cooling exhaust duct248can be formed by a forwardly-extending portion250of the motor housing200.

In one embodiment, a brush motor cooling air path is provided for supplying cooling air to the brush motor72(FIG.5) and for removing heated cooling air (also referred to herein as “heated air”) from the brush motor72. The brush motor cooling air path can be defined by a conduit252, a portion of which is shown inFIG.12, for allowing heated air to be transported away from the brush motor72, with the a first end of the conduit252in fluid communication with the brush motor72and a second end of the conduit252in fluid communication with the lower motor housing202. From the lower motor housing202, the heated air from the brush motor72can join the working air flow path through the enclosure196. From the base14, the conduit252can extend through the joint assembly34, and through the frame18to connect with the enclosure196.

FIGS.14-15show the base14, including the brushroll70and a brushroll cover according to one aspect of the disclosure. The brushroll70can be provided at a forward portion of the base14and received in a brush chamber254on the base14. The brushroll70is positioned for rotational movement in a direction256about rotational axis258. The brush chamber254can be disposed at a forward section of the base14. At least an outlet of the liquid dispenser38can be disposed in the brush chamber254to dispense liquid onto the brushroll70.

The base14can comprise a brush cover260on the base housing80that at least partially defines the brush chamber254. For example, an interior surface of the cover260can define at least a top wall260T and a portion260U of a front wall of the brush chamber254, with the interior surface of the cover260proximate to the brushroll70.

The cover260can be removable from the base housing80without the use of tools. Optionally, a cover latch262releasably secures the cover260on the base housing80, and can be configured to releasably lock the cover260to the base housing80. The cover260can have hooks264that are insertable into slots266on the base housing80. Insertion of the hooks264into the slots266forms a hinge about which the cover260pivots to engage the latch262. Other configurations for attaching the cover260to the base housing80are possible, including, but not limited to, a hook on the cover260that snaps into engagement with a detent on the base housing80, or vice versa, or other configurations where the cover260installed by a translating or sliding action rather than a rotational action.

With reference toFIG.15, the portion260U of a front wall of the brush chamber254formed by the cover260may be an upper portion of the front wall. A lower portion260L of the front wall may be formed by a portion of the base housing80that is not removable, e.g. the lower portion260L remains with the base14when the cover260is removed. A first seal265at the interface between the upper and lower portions260U,260L can prevent the escape of air or liquid from the brush chamber254at the front thereof. A second seal267at the interface between a rear portion of the cover260carrying the latch262and the base housing80can prevent the escape of air or liquid from the brush chamber254at the rear thereof. By way of non-limiting example, the seals265,267can be mounted on and removable with the cover260.

In the present embodiment, the suction inlet port62is configured to extract liquid and debris from the brushroll70and from the surface to be cleaned. The suction inlet port62can be in fluid communication with the brush chamber254and positioned in close proximity to the brushroll70. By way of non-limiting example, the suction inlet port62can be disposed rearwardly of the brushroll70, and can open to the conduit152. The brush cover260can form at least in part, a suction nozzle surrounding the brushroll70.

The brushroll70can be a hybrid brushroll suitable for use on both hard and soft surfaces, and for wet or dry vacuum cleaning. In one embodiment, the brushroll70comprises a dowel268supporting at least one agitation element. The agitation element can comprise a plurality of bristles270extending from the dowel268and microfiber material272provided on the dowel268and arranged between the bristles270. Bristles270can be tufted or unitary bristle strips and constructed of nylon, or any other suitable synthetic or natural fiber. The microfiber material272can 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. The dowel268can 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.

Other embodiments of brushrolls for the floor cleaner10are possible including a bristle brushroll suitable for use on soft surfaces, and that comprises bristles and no microfiber material, and/or a microfiber brushroll suitable for use on hard surfaces and that comprises microfiber material and no bristles. In one embodiment, the floor cleaner10can be provided with multiple, interchangeable brushrolls, which allows for the selection of a brushroll depending on the cleaning task to be performed or depending on the floor type of be cleaned.

Optionally, the brushroll70can be configured to be removed by the user from the base14, such as for cleaning and/or drying the brushroll70. The brushroll70can be removably mounted in the brush chamber254by a brushroll latch274, a portion of which can be provided on or attached to the dowel268, with a mating portion provided in the brush chamber254. A grip276can extend from the brushroll70to aid in removal of the brushroll70from the brush chamber254.

An interference wiper278is mounted at a forward portion of the brush chamber254and is configured to interface with a leading portion of the brushroll70, as defined by the direction of rotation256of the brushroll70. The interference wiper278is generally below the liquid dispenser38, such that the wetted portion brushroll70rotates past the interference wiper278, which scrapes excess liquid off the brushroll70, before reaching the surface to be cleaned. Optionally, the interference wiper278can be disposed generally parallel to the surface to be cleaned. Other locations for the wiper278in relation to the brushroll70, where the wiper278is configured to interface with a portion of the brushroll70, are possible. By way of non-limiting example, the wiper278can be integrally formed with the brush cover260, such as with the lower portion260L of the front wall.

The wiper278can be rigid, i.e. stiff, and non-flexible, so the wiper278does not yield or flex by engagement with the brushroll70. Optionally, the wiper278can be formed of rigid thermoplastic material, such as poly(methyl methacrylate) (PMMA), polycarbonate, or acrylonitrile butadiene styrene (ABS). In other embodiments, the wiper278can be flexible.

A squeegee280is mounted to an underside of the base14and is configured to contact the surface to be cleaned as the base14moves across the surface. The squeegee280wipes residual liquid from the surface so that it can be drawn into the recovery pathway via the suction inlet port62, thereby leaving a moisture and streak-free finish on the surface to be cleaned.

To reduce streaking, the squeegee280can be located close to the brush chamber254on a rear side of the brushroll70. In one embodiment, the squeegee280is disposed partially below the brushroll70to position the squeegee280close to the brush chamber254. For example, the brushroll70can define a rear radius257as the horizontal distance between the rotational axis258and a rearmost side of the brushroll70, and the squeegee280is disposed within the rear radius257of the brushroll70. Optionally, the squeegee280can be disposed generally orthogonal to the surface to be cleaned, or vertically. It is noted thatFIG.15shows the squeegee280in an undeformed state, out of contact with a surface to be cleaned. In operation, the squeegee280is deformed by contact with the surface to be cleaned, and flexes back and forth depending on a direction of movement of the base14.

The squeegee280has a geometry, hardness, flexibility, and resilience to bend readily to conform to the contour of the surface to be cleaned to suit its intended purpose of wiping up residual liquid, yet not leave debris behind on the floor surface, particularly on forward strokes of the base14. The squeegee280is preferably formed from a resilient material, such as plastics, elastomers, rubber or rubber-like materials, having a hardness of about 70 Shore A or less, alternatively about 50 Shore A.

Referring additionally toFIG.16, the squeegee280can have a flexible lip282projecting from an underside of the base14, the lip282configured to flex back and forth depending on the direction of movement of the base14. For example, the lip282will flex backwardly on a forward stroke of the base14and flex forwardly on a rearward stroke of the base14. The lip282is fixed at its upper end284to a support286or another portion of the base14, and extends generally downwardly to a free lower end288. The maximum thickness T of the lip282is preferably about 1.0 mm or less, alternatively about 0.6 mm.

The lip282defines a longitudinally squeegee axis290between the upper end284and the lower end288. To help roll-over on forward cleaning strokes, in an undeformed state, an example of which is shown inFIG.16, the lip282can curve backwardly, such that the squeegee axis290at the lower end288is rearwardly displaced from the squeegee axis290at the upper end284. On a forward stroke of the base14, the lip282flexes backwardly, increasing the rearward displacement of the lower end288. On a rearward stroke of the base14, the lip282flexes forwardly, against the direction of curvature, and the lower end288flips into being displaced forwardly relative to the upper end284.

To aid the squeegee280in flexing back and forth, the squeegee280includes a plurality of protrusions292. These protrusions292are arranged at or near the lower end288of the lip282. More specifically, the protrusions292are arranged on a rear side294of the lip282that faces away from the brushroll70. The protrusions292protrude from said rear side294. The protrusions292are herein also referred to as nubs. On a rearward stroke of the base14, where the lip282flexes forwardly, the protrusions292contact the surface to be cleaned, and space the lip282away from the surface to be cleaned.

To reduce flip-over, the squeegee280can include a triangular feature296arranged on a front side298of the lip282that faces toward the brushroll70. The triangular feature296includes a top end face300of the feature296projecting generally orthogonally from the front side298of the lip282, and an angled front face302of the feature angling downwardly from the top end face300to meet the front side298of the lip282. On a forward stroke of the base14, the lip282flexes backwardly, and the triangular feature296is positioned above and not in contact with the floor, and provides localized stiffness to the squeegee280. On the backward stroke the triangular feature296is positioned near but not in contact with the brushroll70, and provides localized stiffness in the squeegee280to prevent the squeegee280from contacting the brushroll70.

FIG.17shows a portion of the base14including the liquid dispenser38and the liquid pump44according to one aspect of the disclosure The liquid dispenser38is coupled to the liquid pump44by a portion of the liquid supply path40routed through the base14. The liquid dispenser38, in one embodiment, can include at least one spray manifold304disposed at a rear wall306of the brush chamber254. Accordingly the spray manifold304is disposed generally rearwardly of the brushroll70, and can direct a spray of cleaning fluid toward an upper rear portion of the brushroll70. From the perspective ofFIG.17, the spray manifold304is disposed above the brushroll axis258and rearwardly of the brushroll axis258, so that liquid is contacts the brushroll70above and to the rear of the brushroll axis258, e.g. at an upper rear quadrant of the brushroll70.

The spray manifold304can include at least one spray outlet308. The spray outlet308can be disposed on a front side310of the manifold304. According to one exemplary embodiment, the front side310can define a portion of the rear wall306of the brush chamber254, with the outlet308projecting into the brush chamber254. In alternative embodiments, the front side310can be recessed in the rear wall306or may project beyond the rear wall306. As shown inFIG.17, the outlet308can be located close to the brushroll70on a rear, upper side of the brushroll70. In one embodiment, the outlet308is disposed partially above the brushroll70to position the apertures close to the brushroll70. For example, the outlet308is disposed within the rear radius257of the brushroll70.

Referring toFIGS.5and18, to accommodate for the suction inlet port62(FIG.5), the liquid dispenser38can comprise two spray manifolds304, each manifold304disposed on an opposing side of the suction inlet port62. The pump44can supply liquid through a pump conduit312to a Y-connector314having connector outlets316for each spray manifold304. A delivery conduit318is fluidly connected between each connector outlet316and an inlet connector320of the spray manifold304. The pump conduit312and delivery conduits318can comprise flexible hose or tubing, and are shown schematically inFIG.18. By way of non-limiting example, the inlet connectors320can supply liquid through a rear side324of the spray manifold304, with the spray outlets308on the front, e.g. forward-facing, side310of the spray manifold304.

Referring toFIG.19, the spray manifold304can be laterally elongated and/or comprise multiple spray outlets308laterally spaced from each other to provide coverage across the brushroll70. By way of non-limiting example, the spray manifold304can include two spray outlets308. An internal channel326within the manifold304fluidly connects the inlet connector320with the spray outlets308. The channel326can be transversely-elongated to encourage liquid to spread across the length thereof to distribute liquid evenly to each outlet308. By way of non-limiting example, the channel326can be formed by front and rear covers327F,327R of the spray manifold304, the rear side324of the spray manifold304defined by the rear cover327R and the front side310of the spray manifold304defined by the front cover327F.

In one embodiment, each spray outlet308includes a plurality of discharge ports328for directing the flow of liquid from the spray manifold304onto the brushroll70. Any suitable number, size, configuration, and angle of discharge ports328may be selected for facilitating distribution of liquid onto the brushroll70. For example, according to the illustrated embodiment, each outlet308includes two discharge ports328oriented at an angle relative to the rear wall306in order to ensure the flow of liquid is directed across the entire, or substantially the entire, length of the brushroll70. According to one exemplary embodiment, there is about 140 degrees between the discharge ports328, with the ports280directing a spray of liquid at an angle of about 20 degrees from parallel to the rear wall306. In addition, according to alternative embodiments, each discharge port328may have a different angle than adjacent discharge ports328. Other spray configurations are possible and within the scope of the present subject matter.

Referring toFIG.17, according to one aspect of the disclosure, the steam dispenser48is disposed on the base14and includes a floor steam outlet330that dispenses steam toward the floor and a visible vapor outlet332dispenses steam as visible vapor that can be observed by a user of the floor cleaner10. In other embodiments, the steam dispenser48does not include the visible vapor outlet332, and may dispense all steam through the floor steam outlet330. Yet other configurations for the steam dispenser48are possible.

In one embodiment, generally, the steam dispenser48is disposed forwardly of the brushroll70, brush chamber254, and the liquid dispenser38. More specifically, the floor steam outlet330of the steam dispenser48is forward of the brushroll70, brush chamber254, and the liquid dispenser38, and the vapor outlet332of the steam dispenser48is forward of the floor steam outlet330.

The floor steam outlet330can face downwardly, e.g. can open toward the floor surface, in front of the brushroll70. As such, on a forward stroke of the base14, steam is dispensed to the surface to be cleaned in front of, and before the surface is agitated by, the brushroll70. In this location, the steam adds wet heat to the surface to be cleaned, which can pre-wet and soften stains and soils. As such, when moving the base14in a forward cleaning stoke, steam is dispensed to the surface to be cleaned before the surface is agitated by the brushroll70or suction is applied by the suction inlet port62(FIG.15).

The visible vapor outlet332can face upwardly, e.g. can open away from the floor surface. The visible vapor outlet332generally dispenses steam vapor upwardly from the base14, so that the steam vapor exiting the outlet332rises away from the surface to be cleaned.

In another embodiment, the outlet332can face forwardly to a dispense steam vapor forwardly from the base14. In yet another embodiment, the outlet332can face downwardly to a dispense steam vapor generally toward the surface to be cleaned, although it is understood that the steam vapor may or may not reach the surface to be cleaned, as at least a portion of the steam vapor exiting the downwardly-facing outlet332may rise away from the surface.

The visible vapor outlet332can be disposed at the front side78F of the base14. In this location, the steam vapor is output within a line of sight of the user, thereby offering a visual confirmation to the user that steam is being generated and dispensed by the floor cleaner10. Further, since the floor steam outlets330are hidden under the base14, the visible steam vapor also offers a visual confirmation to the user that steam is being generated and dispensed by the floor cleaner10. Visible steam could additionally or alternatively be routed to lateral sides78R,78L or rear side78B of the base14. Providing at least a portion of the visible steam at the front side78F of the base14may be preferred, as this is within a clear line of sight of the user operating the floor cleaner10.

Various configurations for the steam dispenser48are possible. In some embodiments, the floor steam outlet330and the visible vapor outlet332may be integrated with each other on the base14, e.g. a single molded or integral steam dispenser assembly. In other embodiments, the floor steam outlet330may be remote from the visible vapor outlet332. For example, the visible vapor outlet332can be located at a distance from the floor steam outlet330, and require conduits, ducts, tubing, hoses, etc. routed through the floor cleaner10to fluidly couple the heater46to the outlets330,332.

FIGS.20-21shows an embodiment of the steam dispenser48including a steam bar334comprising multiple floor steam outlets330and multiple vapor outlets332. The steam bar334includes a first manifold336having multiple vapor outlets332and a second manifold338having multiple floor steam outlets330. The first manifold336includes an inlet port340and an outlet port342opening to the second manifold338. The inlet port340is in fluid communication with the heater46(FIG.3A) through a steam supply conduit344. The steam supply conduit344can comprise flexible hose or tubing, and is shown schematically inFIG.21. The steam supply conduit344may pass from the upright body12to the base14, for example by passing through or around the joint assembly34.

The first manifold336can be configured to create back pressure that helps expel steam from the outlets332as visible steam. Without back pressure, the steam may be pulled out of the steam manifold by the vacuum suction. The back pressure created by the first manifold336isolates the visible steam ports from the vacuum suction to allow at least some, or all, of the steam to escape via the visible steam ports. It is noted that, in some embodiments, the steam quality of the visible steam may be higher than the steam dispensed to the floor. In other embodiments, the steam quality of the visible steam and the steam dispensed to the floor may be about the same.

By way of non-limiting example, the steam bar334can be formed by front and rear covers346,348, with a rear side350of the steam bar334defined by the rear cover348and a front side352of the steam bar334defined by the front cover346.

In the embodiment shown inFIG.21, the manifolds336,338are integrated into one steam bar334, e.g. as a single molded or integral component. In another embodiment, the steam dispenser48can include two or more steam bars, such as one including the first manifold336and one including the second manifold338.

Various relative orientations for the manifolds336,338are possible. In one embodiment, the first manifold336is disposed above the second manifold338. The first manifold336can be vertically stacked with the second manifold338, with a dividing wall354separating the two manifolds336,338. The outlet port342can be formed in the dividing wall354. In another embodiment, the one manifold can be disposed in front of the other manifold, e.g. can be horizontally stacked. Vertically stacking the manifolds336,338has the advantage of minimizing the distance between the front the base14and the front of the brushroll70. This allows cleaning to happen closer to the front edge of the base14. In the vertically stacked configuration shown inFIG.20-21, the rear side350of the steam bar334defines a rear side or wall of the manifolds336,338and the front side352of the steam bar334defines a front side or wall of the manifolds336,338.

The inlet port340can be disposed at one end356of the steam bar334. By way of non-limiting example, the inlet port340can supply steam through the rear side350of the manifold336.

The outlet port342feeds steam from the first manifold336to the second manifold338. To provide a generally even steam distribution to the vapor outlets332and the floor steam outlets330, the outlet port342can have an equivalent hydraulic diameter to the vapor outlets332. In other words, the outlet port342can have an opening size that is about equal to the total opening size of the vapor outlet332.

The outlet port342can be disposed at a central portion358of the steam bar334. For example, the outlet port342can be disposed at a center of the second manifold338. Depending on the relative lengths of the two manifolds336,338, the outlet port342may be offset from the center of the first manifold chamber336, as shown inFIG.21. For example, in one embodiment, the second manifold338is longer than the first manifold336. In other embodiments, the outlet port342may be disposed at the center of both manifolds336,338.

Referring toFIG.21, the first manifold336can be laterally elongated and/or comprise multiple outlets332laterally spaced from each other to provide multiple points for visible vapor to exit across the front of the base14. By way of non-limiting example, the manifold336can include two outlets332. An internal channel360within the manifold336fluidly connects the inlet port340with the outlets332. The channel360can be transversely-elongated to encourage steam to spread across the length thereof to distribute steam evenly to each outlet332.

In one embodiment, the manifold336includes at least one discharge port362for directing the flow of visible steam from the channel360toward each outlet332. Any suitable number, size, configuration, and angle of discharge port362may be selected for facilitating exit of visible steam from the channel360. By way of non-limiting example, the discharge port362can supply steam through the front, e.g. forward-facing, side352of the manifold336. For example, according to the illustrated embodiment, each outlet332includes an associated discharge port362in the front side352of the manifold336, as best seen inFIGS.20and22. The discharge ports362can be formed as small openings in the front side or wall352. Alternatively the discharge ports362can comprise narrow slit-like openings, or openings of other shapes, including a plurality of openings of uniform or varying size, defining the ports362.

Various walls, baffles, or channel structures can guide steam from the discharge port362to the steam vapor outlet332. In one embodiment, a baffle364directs steam vapor forwardly and upwardly from the port362to the outlet332. The baffle364can extend from below the port362in a forward direction, curving upwardly toward the outlet332. As best seen inFIG.21, the baffles364can define, at least in part, a baffle chamber366that extends from the front side352of the manifold336to direct the output of visible vapor outwardly from the manifold336. To redirect steam from the discharge port362to the outlet332, the baffle364can have at least one turn between the port362and outlet332, with the baffle364changing the direction by at least 90°. Other baffle configurations are possible and within the scope of the present subject matter.

Any suitable number, size, configuration, and angle of steam vapor outlet332may be selected for facilitating exit of steam vapor from the baffle chamber366. By way of non-limiting example, the steam vapor outlets332can supply steam through a top, e.g. upward-facing, side368of the baffle chamber366. For example, according to the illustrated embodiment, each outlet332can be formed as an opening through the top side368. Alternatively the outlets332can comprise narrow slit-like openings, or openings of other shapes, including a plurality of openings of uniform or varying size. In another embodiment, alternatively to having a plurality of outlets332, the steam dispenser48can have a single, narrow slit-like outlet defining the outlet332.

Referring toFIG.21, the second manifold338can be laterally elongated and/or comprise multiple outlets330laterally spaced from each other to provide coverage across a width equal to, including substantially equal to, the brushroll70. By way of non-limiting example, the manifold338can include twenty-nine floor steam outlets330. An internal channel370within the manifold338fluidly connects the outlet port342with the floor steam outlets330. The channel370can be transversely-elongated to encourage steam to spread across the length thereof to distribute steam evenly to each outlet330.

Any suitable number, size, configuration, and angle of floor steam outlet330may be selected for facilitating exit of steam from the channel360. By way of non-limiting example, the floor steam outlets330can supply steam through a bottom, e.g. floor-facing, side372of the manifold338. For example, according to the illustrated embodiment, each outlet330can be formed as a small opening in the bottom side or wall372. Alternatively the outlets330can comprise narrow slit-like openings, or openings of other shapes, including a plurality of openings of uniform or varying size. In another embodiment, alternatively to having a plurality of outlets330, the steam dispenser48can have a single, narrow slit-like outlet defining the outlet330.

With reference toFIGS.17and22, the floor steam outlets330can be in close proximity to the bottom of the base14to heat the floor surface. For example, in some embodiments the steam dispensed from the outlets330may heat the floor surface to around 30° C. to 60° C., alternative may raise the temperature of the floor surface by around 10° C. to 40° C. In some embodiments, the floor steam outlets330can be disposed above an underside of the base14and/or an underside of the brushroll70, which accordingly spaces the outlets330vertically from the surface to be cleaned. This can prevent the dispensing steam from damaging certain types of floor surfaces, while still heating the floor surface to the temperature ranges noted above. In another embodiment, the floor steam outlets330can be at the underside of the base14and/or even with an underside of the brushroll70.

Referring toFIGS.17and20, the steam bar334is provided forwardly of the brush chamber254, and can be mounted within the base14, partially on an exterior of the base14, or fully on the exterior of the base14. In one embodiment, the steam bar334can be positioned between the brush chamber254and a portion of the base housing80. By way of non-limiting example, the base housing80can include a front cover374at least partially defining the front side78F of the base14. In some embodiments, the front cover374can include a bumper376for protecting the brush cover260and/or the steam bar334. As such, the front cover374may protrude forwardly when viewed from the side as inFIGS.17and20.

The front cover374can define, in part, the steam vapor outlets332. In one embodiment, the steam vapor outlets332include apertures378through the front cover374that are in fluid communication with the baffle chamber366. By way of non-limiting example, the front cover374can include a top edge380covering the open top side368of the baffle chamber366, with the apertures378formed in the top edge380and aligned with the baffle chamber366. In other embodiments, the steam vapor outlets332can be defined by the steam bar334alone, or by the steam bar334and the brush cover260, or by the steam bar334and another portion of the base14.

As noted above, the cover260can be removable from the base14. The steam bar334can be configured to remain with the base14when the cover260is removed. In another embodiment, the steam bar334can be removable with the brush cover260. For example, the steam bar334can be formed or integrated with, mounted or attached to, coupled, or otherwise joined to the front cover374and/or another portion of the base14. To mount the cover260on the base14, the cover260can optionally insert into a portion of the steam bar334and/or front cover374. For example, the front cover374can include the slots266in which the hooks264on the cover260are inserted (seeFIG.14).

Referring toFIG.3A, in one aspect of the disclosure, the floor cleaner10can have multiple, user-selectable cleaning modes. In one embodiment, the floor cleaner10has a hard floor mode, an area rug mode, a steam mode, and a self-cleaning mode. The steam mode can operate in conjunction with the hard floor mode or the area rug mode. The modes can have associated operating parameters for the pumps44,56, heater46, vacuum motor64, and/or brushroll motor72.

In one embodiment of the hard floor mode, the vacuum motor64, liquid pump44, and brush motor72are activated, with the vacuum motor64operating at a first power level, and depression of the trigger28turns the pump44on to dispense cleaning liquid at a first flow rate from the liquid dispenser38. In the hard floor mode, cleaning fluid can be dispensed at a rate of about 45 ml/min to about 70 ml/min, alternatively about 50 ml/min.

In one embodiment of the area rug mode, the vacuum motor64, liquid pump44, and brush motor72are activated, and depression of the trigger28turns the pump44on to dispense cleaning liquid at a second flow rate from the liquid dispenser38. The second flow rate can be higher than the first flow rate in the hard floor mode. In the area rug mode, cleaning fluid can be dispensed at a rate of about 95 ml/min to about 125 ml/min, alternatively about 100 ml/min. In another embodiment, the flow rate of liquid in the area rug mode is the same as in the hard floor mode.

In the area rug mode, the vacuum motor64can operate at a second power level, which can be the same as the first power level in the hard floor mode. In another embodiment, the second power level is higher than the first power to provide greater suction performance by the floor cleaner10in the area rug mode.

In one embodiment of the steam mode, the heater46and steam pump56are activated, and depression of the trigger28turns the pump56on to dispense steam from the steam dispenser48. In the steam mode, steam can be dispensed at a rate of about 20 ml/min to about 40 ml/min, alternatively about 35 ml/min, alternatively about 30 ml/min. In embodiments where the steam dispenser48includes the separate outlets330,332, the steam flow is divided between the outlets330,332.

In the steam mode, the steam dispenser48can produce visible steam, e.g., a visible vapor that can be observed by the naked eye. Producing visible steam offers a visual confirmation to the user that steam is being generated and dispensed by the floor cleaner10.

As noted above, the steam mode can be executed in conjunction with the hard floor mode or area rug mode. In such a case, the above-described operating parameters for the selected hard floor mode or area rug mode are also executed while the steam mode is in operation. The dual liquid and steam delivery applies wet heat to the surface to be cleaned to improve debris removal and cleaning efficiency. Application of steam can pre-treat the surface, and using high temperature fluid is particularly efficient at removing embedded soils on soft surfaces like area rugs and stuck-on debris on hard surfaces like wood and tile. The combination of heat, chemical, and mechanical (e.g. via the brushroll70) interacts to provide improved surface cleaning and reduce cleaning time. For example, a user may need to make fewer passes (e.g., forward/backward cleaning strokes) to remove embedded soils and stuck-on debris.

It is noted that the flow rate of liquid from the liquid dispenser38may drop during the steam mode. For example, the rate of liquid dispensing may drop by 5 ml/min or less during steam dispensing. In another embodiment, the flow rate of liquid from the liquid dispenser38is substantially the same regardless of whether steam is being dispensed.

With these available modes, the floor cleaner10is operable to clean a floor surface in four distinct combinations: (i) a first cleaning mode or hard floor only cleaning mode in which liquid is dispensed from the liquid dispenser at a first flow rate; (ii) a second cleaning mode or area rug only cleaning mode in which liquid is dispensed from the liquid dispenser at a second flow rate; (iii) a third cleaning mode or hard floor plus steam cleaning mode in which liquid is dispensed from the liquid dispenser at the first flow rate and steam is dispensed from the steam dispenser; and (iv) a fourth cleaning mode or area rug plus steam cleaning mode in which liquid is dispensed from the liquid dispenser at the second flow rate and steam is dispensed from the steam dispenser.

In one embodiment of the self-cleaning mode, the floor cleaner10executes an automatic, unattended clean-out cycle. During the clean-out cycle, the vacuum motor64, liquid pump44, and brush motor72are activated in an automated sequence, and cleaning liquid is sprayed on the brushroll70, the brushroll70rotates, and liquid is extracted and deposited into the recovery tank22, thereby also flushing out the brush chamber254and the recovery path66. The vacuum motor64, pump44, and brush motor72can be active individually or simultaneously, and for any predetermined times, including overlapping and non-overlapping times. For example, the vacuum motor64, pump44, and brush motor72can be activated at once. In another example, the pump44and brush motor72can be activated for a first predetermined period, and the vacuum motor64activated after. In yet another example, the pump44can be activated for a first predetermined period, the brush motor72can be activated for a second predetermined period after the pump44is de-activated, and the vacuum motor64activated during or after activation of the pump44and/or brush motor72. Yet other clean-out cycles are possible. The self-cleaning mode can be configured to last for a predetermined amount of time or until the cleaning liquid in the supply tank20has been depleted.

By way of non-limiting example, in one self-cleaning mode, the liquid pump44and brush motor72are activated for 10 seconds, then the brush motor72remains on for an additional 10 seconds while the pump44is de-activated to spin the brushroll70without additional liquid delivery, and finally the brush motor72remains on for an additional 20 seconds while vacuum motor64is activated. In total, the clean-out cycle lasts for 40 seconds. Steam is not dispensed during the self-cleaning mode, therefore the steam pump56is not activated.

In the self-cleaning mode, cleaning fluid can be dispensed at a rate of about 50 ml/min to about 1000 ml/min, alternatively about 480 ml/min. The self-cleaning mode can be designed to deposit a specific amount (e.g., 80 mL) of cleaning fluid into the tray in a predetermined amount of time (e.g., about 10 seconds).

In the self-cleaning mode, the vacuum motor64can operate at a third power level, which can be the same as the first power level in the hard floor mode and/or the same as the second power level in the area rug mode. In another embodiment, the third power level is higher than the first power and the second power level to provide greater suction performance by the floor cleaner10in the self-cleaning mode.

In another embodiment of the self-cleaning mode, at least some steam is dispensed in self-cleaning mode during an automatic, unattended clean-out cycle.

Table 1 below lists some non-limiting examples of operating parameters for the modes. Other operating parameters for the modes and other cleaning modes are possible.

TABLE 1LiquidSteamVacuumBrushModeDispensingDispensingMotorMotorHard FloorLOWOFFONONArea RugHIGHOFFONONSteamLOW/HIGHONONONSelf-CleaningHIGHOFFONON

In all manual cleaning modes (e.g. user-operated or attended modes), the release of cleaning fluid can be controlled by the trigger28. Alternatively, release of cleaning liquid can be controlled by the trigger28and release of steam can be controlled by the steam input control60. In the unattended self-cleaning mode, the release of cleaning fluid is automatic.

FIG.23is a schematic view showing one configuration of the UIs30,32for the floor cleaner10are shown, along with the handle16and base14. The first UI30has an on/off button, e.g. a power button382, to activate and de-active the vacuum motor64(FIG.3A). By default, pressing the power button382to activate the vacuum motor64can operate the floor cleaner10in the hard floor mode. In other embodiments, the default cleaning mode can be the area rug mode or the last mode selected before the floor cleaner10was last powered off. Other default operating modes for the floor cleaner10are possible, including a default mode in which pressing the power button382activates an electronic component of the floor cleaner10other than the vacuum motor64.

The first UI30has a mode select input control or mode button384to select between different modes when the floor cleaner10is on. For example, repeated pressing of the mode button384can cycle between the hard floor and the area rug modes. In another example, repeated pressing of the mode button384can cycle between the hard floor mode, area rug mode, hard floor+steam, area rug+steam, and/or self-cleaning mode, or any combination thereof, and in any order thereof.

The first UI30has a steam button386to select the steam mode. For example, repeated pressing of the steam button386can cycle the steam mode on and off. In one example, in the steam mode, the pump56(FIG.3A) is activated. Therefore, pressing the steam button386activates and de-actives the pump56. In other embodiments, a separate steam button386is not provided, and the steam mode can be selected via the mode button384.

Optionally, there is a warm-up period after turning the heater46on via the power button382during which steam is not available to be dispensed. By way of non-limiting example, the warm-up period may last up to about 30 seconds.

As noted above, the steam mode can be structured to operate in conjunction with the hard floor mode, area rug mode, or another cleaning mode. For example, pressing the steam button386to select a steam mode may include maintaining operation of the currently-selected hard floor or area rug mode. In another embodiment, pressing the steam button386to select the steam mode may deactivate the currently-selected mode.

Each button382,384,386is preferably provided with an icons388,390,392, respectively. The icons can be in the form of graphics, symbols, words, or a combination thereof. Various icons are possible, and preferably give the user an indication of the purpose of the button. The icons388,390,392can be formed on the button382,384,386via pad printing, attaching a label, adhering a graphic, or the like, or are otherwise visible at all times to the user. In another embodiment, the icons can next to the buttons rather than on the buttons.

Various arrangements of the buttons382,384,386are possible. In one embodiment, the buttons382,384,386are arranged accordingly to a predetermined frequency of use, with the steam button386disposed highest on the grip26, e.g. closest to the user, followed by the mode button384, and the power button382disposed lowest on the grip26, e.g. farthest from the user.

During operation, the user can select the mode button384and/or steam button386to toggle through multiple cleaning modes. With the arrangement of the UI30on the handle16the user can conveniently hold the handle grip26in one hand and use the thumb of the same hand to toggle the mode button384and/or steam button386until the desired mode is selected. The selected cleaning mode is displayed on the base14by the second UI32.

The second UI32includes a status display394on the base14with a plurality of status indicators396,398,400. The individual status indicators can each include at least one icon in the form of graphics, symbols, words, or a combination thereof. InFIG.23, for example, the second UI32is shown with three status indicators, including a hard floor mode status indicator comprising an icon396in the form of a graphic depicting a hard floor, an area rug status indicator comprising an icon398in the form of a graphic icon depicting a rug, and a steam status indicator comprising an icon400in the form of a graphic icon depicting steam.

The second UI32can be structured so that when the floor cleaner10is off, the status display394is blank and the status indicators396,398,400are hidden or dead, e.g. not illuminated, and when the floor cleaner10is on, the status indicators396,398,400may selectively be illuminated and visible to the user. In one embodiment, the status indicators396,398,400can be back-lit icons that are hidden or dead, e.g. not illuminated, under a first condition and may selectively be illuminated and visible under a second condition. For example, the hard floor icon396can be hidden or dead, e.g. not illuminated when the floor cleaner10is not operating in the hard floor mode, and can be illuminated and visible when the hard floor mode is selected, e.g. using mode button384The area rug icon398can be hidden or dead, e.g. not illuminated when the floor cleaner10is not operating in the area rug mode, and can be illuminated and visible when the area rug mode is selected, e.g. using mode button384. The steam icon400can be hidden or dead, e.g. not illuminated when the floor cleaner10is not operating in the steam mode, and can be illuminated and visible when the steam mode is selected, e.g. using steam button386. The status display394therefore shows the selected cleaning mode on the base14, within the user's field of view where the user naturally looks while cleaning a surface. The different shapes of the icons396,398,400provide visual signal to the user that different modes are in operation. To provide a further visual distinction, in some embodiments the icons396,398,400may illuminate in different colors. For example, the hard floor and area rug icons396,398can illuminate in a first color (e.g., blue), and the steam icon400can illuminate in a second color (e.g., orange).

FIG.24is a cross-sectional view through the first UI30, a portion of the handle16, and the hand grip26. The first UI30may include a first UI controller402. The first UI controller404can include, in one embodiment, a PCB with switches406,408,410on a first surface thereof that are operated by the buttons382,384,386, respectively. By way of non-limiting example, the switches406,408,410may be toggle switches.

The first UI controller404can include a trigger switch412on a second surface of the PCB that is operated by the trigger28. The trigger switch412may be a momentary switch that is closed only as long as the user depresses the trigger28. Closure of the trigger switch412operates one or both of the pumps44,56. Alternatively, the trigger28can mechanically communicate with the fluid delivery system, such as via a push rod (not shown) that runs through the handle16.

The trigger28can conveniently be located adjacent to the UI30. For example, in one arrangement, the buttons382,384,386of the UI30are disposed on a front side414of the grip26and the trigger28is disposed on a rear side416of the grip26. Conveniently, a user may operate the trigger28using the forefinger and the buttons382,384,386using the thumb of the same hand holding the grip26. For a closed-loop grip26as shown inFIG.24, the front side414comprises an outwardly-facing side of the loop grip26and the rear side416comprises an inwardly-facing side of the loop grip26.

Optionally, the controller404can include illumination elements (e.g. LEDs) on the PCB that selectively emit light to illuminate the icons388,390,392(FIG.23) on the buttons382,384,386or status lights associated with the buttons382,384,386.

Various mounting arrangements for the UI30on the grip26are possible. In one embodiment, the controller404and buttons382,384,386are mounted within a cavity420of the hand grip26, with a grip cover422enclosing the cavity420and supporting the buttons382,384,386in operably alignment with the switches406,408,410. The grip cover422may at least partially define the front side414of the grip26. The controller404is supported within the cavity420by a rear bracket424and a front holder426. The holder426includes openings through which the switches406,408,410project to be actuatable by the buttons382,384,386. To protect the controller404from water, a seal428is provided between the buttons382,384,386and the holder426.

The trigger28is pivotally mounted to the hand grip26. A spring430biases the trigger28outwardly from the hand grip26, and is disposed between the bracket424and an inwardly-facing side of the trigger28.

Referring toFIG.26, the floor cleaner10has a clean-out cycle button432to activate and de-active the self-cleaning mode of the floor cleaner10in which the floor cleaner10executes the automatic, unattended clean-out cycle. The clean-out cycle button432can be disposed on the carry handle24. In another embodiment, the clean-out cycle button432can be disposed on the handle16, alternatively on the hand grip26as part of the first UI30(FIG.23). For example, the clean-out cycle button432can be located lower than the power button on the front side of the grip26. Yet other locations for the clean-out cycle button432are possible.

In some embodiments, when the self-cleaning feature is not available to the user, pressing the button432does not initiate the clean-out cycle. Optionally, the clean-out cycle button432can have a contextual or context-based icon434that is displayed when a clean-out cycle is needed and/or when a clean-out cycle is ready to be executed. When a clean-out cycle is not needed and/or when a clean-out cycle is not ready to be executed, the icon434is not visible to the user. Thus, the contextual icon434informs the user when the self-cleaning feature is available, and display of the contextual icon434to the user is associated with an enablement of the self-cleaning feature that allows the clean-out cycle to be executed.

The icon434can be a back-lit icon structured so that, when the clean-out cycle is available to the user, the icon434is hidden or dead, e.g. not illuminated by an LED or other illumination source, and when the clean-out cycle is available to the user, the icon434is illuminated and visible to the user. The back-lit icon434can be in the form of a graphic, symbol, word, or a combination thereof. For example, the button432can have a back-lit graphic on the button432. In another example, the carry handle24can have a back-lit dot or other symbol adjacent to the button432, which may itself include a graphic or other icon that is always visible.

FIG.28is a cross-sectional view through the second UI32and a portion of the base14. The second UI32may include a second UI controller436. The second UI controller436can include, in one embodiment, a PCB with illumination elements438,440,442(e.g. LEDs, shown in phantom line inFIG.27) on a first surface444thereof that selectively emit light to illuminate the icons396,398,400, respectively. While referred to herein as LEDs, it is understood any illumination element disclosed herein can comprise organic LEDs (OLEDs), chip-on-board LEDs, lasers or laser diodes, regular lamps (arc lamps, gas discharge lamps, etc.), bulbs, other light emitting devices, or combinations thereof, including comprising multiple light emitting devices.

According to an embodiment, each icon396,398,400is illuminated by a separate LED438,440,442, respectively. The LEDs can emit visible light in one or more colors, such as, but not limited to, white, blue, orange, red, green, yellow, and the like. The LEDs can be configured to emit light in specific colors, wavelength ranges, and or patterns to convey information to the user. Alternatively or in addition, the LEDs may be adjustable by the user to emit light in different wavelength ranges or colors.

The second UI32includes a portion on the base14that is translucent or transparent, i.e. it permits light from the LED438,440,442positioned internally of the base14to emit light therethrough. In the embodiment shown, the portion comprises a lens446, and the lens446forms an exterior surface of the base14. The lens446can, for example, be mounted to the base housing80, rearwardly of the cover260as shown inFIG.14.

A film448is disposed in the light path between the LEDs438,440,442and the lens446, and includes the icons396,398,400. A portion of the film448blocks light from the LEDs438,440,442in the base14and a portion of the film permits light to emit there though. For example, the desired icons for the second UI32can be etched or otherwise formed on the film448, such that light can proceed through the etched icons from the associated LED. The lens446covers and protects the film448. In one embodiment, the film448can be adhered to a rear side of the lens446. Various films are possible. In another embodiment, a masking layer, such as opaque paint, can be applied to an interior surface of the lens446, and the icons396,398,400are etched in the masking layer.

The second UI32includes a baffle assembly450that surrounds the LEDs438,440,442to restrict the light produced by each LED to its specific associated icon396,398,400, so that only one icon is illuminated by each LED. In one embodiment, the baffle assembly450comprises multiple individual baffle sections452, with each baffle section452defining a light chamber454. One icon396,398,400is aligned with an output opening456of one baffle section452. Each baffle section452comprises an input opening458through which light from one LED can be emitted and project out through the icon396,398,400via the output opening456. The baffle sections452are otherwise enclosed such that the light from an illuminated LED does not bleed over to the other icons, providing a clear indication to the user as to which mode is selected. At least a portion of the baffle sections452are opaque or otherwise impenetrable to light so as to not allow light from one baffle section452to pass through to another baffle section452.

With reference toFIG.28, which shows a cross-section of one representative baffle section452, in one embodiment, the output and input openings456,458of the baffle section452are positioned on different sides of the light chamber454. For example, the input opening458is positioned on a first side460of the light chamber454, which may be a forward side in some embodiments, and the output opening456is positioned on a second side462of the light chamber454, which may be an upper side in some embodiments. With this configuration, the LED438can be disposed forwardly of the light chamber454and the film448can be disposed above the light chamber454.

A reflector466can be provided in the baffle section452to reflect the light emitted by the LED438and evenly distribute the emitted light toward the output opening456. The reflector466can comprise one or more reflection surfaces468,470in the baffle section452. For example, one or more walls of the baffle section452may be reflective to form the reflection surfaces468,470. In another embodiment, a reflective film or coating is applied to one or more walls of the baffle section452to form the reflection surfaces468,470.

The shape of the reflector466can maximize the brightness of the back-lit icon400. For example, reflector466can be angled, curved, or otherwise shaped so as to focus light toward the icon400. Alternatively or additionally, reflector466may improve illumination uniformity of the back-lit icon400. In one embodiment, the reflector466includes angled reflective surfaces468,470generally positioned on a third side of the light chamber454, which may be positioned below the second side462of the light chamber454.

Referring toFIG.27, a controller bracket472mounts the controller436to the baffle assembly450. In one embodiment, the controller bracket472can include the baffle assembly450, a controller mount474to attach the controller436to the baffle assembly450, and a lens mount476to support the lens446over the baffle assembly450. An injection molding process can be used to form the controller bracket472. Alternatively, one or more of the baffle assembly450, controller mount474, and the lens mount476can be separately formed and assembled together.

With reference toFIG.14, the floor cleaner10can include a headlight assembly478on the base14that illuminates a surface to be cleaned, or floor surface, exterior of the base14. Various locations and configurations for the headlight assembly478are possible. In one embodiment, the headlight assembly478can be disposed on an upper side of the base14, making the emitted visible light easy to see from the typical operating position of the user behind and above the base14. In particular, the headlight assembly478is disposed above the brushroll70, and outside the brush chamber254.

In some embodiments, the headlight assembly478can be enclosed by the cover260. The cover260can be formed at least partially from a transparent, semi-transparent, or translucent material, and may, for example, allow a user to view visible light emitted from the headlight assembly478from the typical operating position of the user behind and above the base14.

Referring toFIG.27, in one embodiment, the headlight assembly478can comprise at least one illumination element480(e.g. headlight LED), on a second surface482of the controller436that selectively emits light. The second surface482can be opposite the first surface444, for example, with the first surface444facing rearwardly and the second surface482facing forwardly. Other orientations for the surfaces444,482are possible. Utilizing one PCB and providing illuminations elements on both sides thereof conserves space in the base14, minimizes cost, and simplifies the design of the base14. To protect the LED480, a headlight cover484is disposed over the LED480. The cover484is translucent or transparent, i.e. it permits light from the LED480to shine therethrough. In the illustrated embodiment, two headlight LEDs480and covers484are provided, although other numbers are possible.

The covers484protect the LEDs, particularly when the brush cover260is removed from the base housing80as shown inFIG.14. In addition to physical protection, the covers484can provide a fluid-tight barrier between the brush chamber254and the electronics of the controller436. Optionally, the covers484may additionally function as a lens to focus the emitted light.

With reference toFIG.28, in one embodiment, the brush cover260includes a light pipe486that transmits or conveys light from the LED480to the floor surface in front of the base14. Thus, the internal LED480and light pipe486can together function as the headlight assembly478for illuminating a surface to be cleaned. In one embodiment, the portion of the cover260defining the top wall260T of the brush chamber254can separate the light pipe486from the brush chamber254.

The light pipe486, in certain embodiments, can distribute light generated by the LEDs480across a width of the base14to increase the ability of the user to see the floor surface in front of the base14. Utilizing the removable brush cover260as a light pipe for the headlight assembly478enables the LEDs480and associated wiring to remain on the base housing80, while still providing light to the front of the base14via the removable cover260. This further allows the LEDs480and associated wiring to be isolated from exposure to wet areas of the base14.

The light pipe486can be any physical structure capable of transporting or distributing light from the LEDs480and that can be integrated with the cover260. The light pipe486can be a hollow structure that contain the light with a reflective lining, or a transparent solid structure that contain the light by total internal reflection. In the illustrated example, light pipe486is a solid structure formed with the cover260and configured to distribute light over its length by total internal reflection. In one such embodiment, the light pipe486is integrally formed with the cover260and, thus, would be considered as being “coupled to the nozzle” during the formation process of the cover, which can be an injection molding process or an additive manufacturing process, for example.

The light pipe486can have an entrance end488aligned with the cover484and an exit end490disposed proximate a front of the base14for propagating light along a front of the base14at a front portion thereof. The entrance end488can be shaped to allow light emitted by the LED480to easily enter the light pipe486and to propagate internally. The entrance end488can have a prism (not shown), for example comprising a series of undulating curves, or other suitable shapes, at a light input location of the cover260to diffuse light through the light pipe486. The light input location of the cover260can be an upper, rearward-facing end of the cover260disposed proximate to the headlight cover484when the cover260is mounted to the base housing80.

The exit end490can be shaped to emit light outward from the base14to illuminate the floor surface. The exit end490can form a light emitting lens surface that emits light beams configured to converge on the floor surface for enhanced illumination of the area to be cleaned. The exit end490can be diffused to provide a uniform illuminated surface. With additional reference toFIG.14, the cover260can include a stepped portion defining the exit end490, the stepped portion being elongated in a lateral direction, which is parallel to a front of the base14and generally perpendicular to a direction of forward movement of the floor cleaner10.

The headlight assembly478can be structured so that the headlight assembly478is not illuminated when the floor cleaner10is off and the headlight assembly478is illuminated when the floor cleaner10is on. Optionally, for a corded floor cleaner10, the headlight assembly478can be illuminated when the floor cleaner10is plugged in, and before the power button382(FIG.23) is pressed. For example, the headlight assembly478can illuminate at about 50% power when the floor cleaner10is plugged in and at 100% power when the power button382is pressed to turn the floor cleaner10on.

FIGS.23-28show but one configuration for the UIs30,32. It is understood that other layouts, buttons, status indicators, and/or icons are possible, including having the same buttons in a different layout, or having additional or fewer buttons, status indicators, and/or icons. For example, for a floor cleaner with fewer or more cleaning modes, the first UI30may accordingly include fewer or more mode buttons, and the second UI32may accordingly include fewer or more status indicators. In another example, rather than providing one mode button to toggle between different cleaning modes, a dedicated mode button for each cleaning mode may be provided. Other possible UI buttons, status indicators, and/or icons include, but are not limited to, other cleaning modes, battery status, Wi-Fi connection status, an empty supply container status, a full recovery container status, filter status, floor type, or any number of other status information.

Referring toFIG.1, the floor cleaner10can be provided with a tray492that can be used to store and/or to self-clean the floor cleaner10. The tray492can be configured to receive the base14of the floor cleaner10in an upright, stored position. The tray492can further be configured for further functionality, such as for charging the floor cleaner10in embodiments where the power source74(FIG.3A) of the floor cleaner10is a rechargeable battery.

FIG.29is a perspective view of one embodiment of the tray492. The tray492can include a tray base494and guide walls496extending upwardly from the tray base494that help to align the base14within the tray492. To help to properly align the base14on the tray492, the tray base494can comprise one or more wheel holders498that at least partially receive wheels of the floor cleaner10. A rear portion of the tray492can include a supporting rest500extending upwardly and configured to help align the base14within the tray492and prevent the floor cleaner10from tipping backward. For example, the joint assembly34and the supporting rest500can possess complementary shapes, with a rear side of the joint fitting against the rest500. Optionally the tray492can include an accessory holder502for storing one or more accessories for the floor cleaner10. The illustrated accessory holder502can removably receive the brushroll70and the filter assembly170for the purposes of storage and/or drying.

In some embodiments, the tray492can function as a cleaning tray during the self-cleaning mode. Self-cleaning using the tray492can save the user considerable time and may lead to more frequent use of the floor cleaner10. With reference toFIG.30, the tray492can have a recessed portion in the form of a sump504in register with at least one of the brush chamber254and brushroll70. Optionally, the sump504can create a closed loop between the fluid delivery and recovery systems of the floor cleaner10to flush out a recovery pathway between the suction inlet port62and the recovery tank22during self-cleaning.

In one aspect of the disclosure, operation of the self-cleaning mode may require that the floor cleaner10be docked on a tray492and/or another condition for self-cleaning be met. When not docked and/or when another condition for self-cleaning is not met, the clean-out cycle may be inoperable, e.g., selection of the clean-out cycle button432(FIG.1) will not activate the self-cleaning mode. In some embodiments, the floor cleaner10is also prepared for self-cleaning by ensuring that the supply tank20contains a sufficient amount of cleaning liquid, such as water.

FIG.30is a cross-sectional view showing the floor cleaner10docked on the tray492. When a floor cleaning operation has ceased, the floor cleaner10can be locked upright and placed onto the tray492for cleaning. The floor cleaner10can include a switch506to de-activate one or more components when the upright body12is in the upright stored position. When the upright body12is raised to and/or locked in the upright stored position, the switch506communicates with the main controller76to lock-out or disable fluid dispensing. Consequently, depressing the trigger28will not dispense liquid or steam. Aside from this function, the switch506is not particularly limited, and may comprise any components and/or configurations suitable for use in/as a switch. In one embodiment, the switch506is a normally-open (NO) switch disposed in a location to be closed when the upright body12is raised to and/or locked in the upright stored position. For example, the switch506can close when the joint lock36(FIG.5) engages and locks the upright body12in the stored position. The switch506can open when the upright body12is reclined.

In one embodiment, with the floor cleaner10parked, e.g., the switch506closed, the floor cleaner10enters a stand-by mode in which the floor cleaner10remains powered on and one or more components are turned off. In one embodiment, the brush motor72is turned off in the stand-by mode. The vacuum motor64may remain on in the stand-by mode. To end the stand-by mode, the upright body12can be reclined to open the switch506.

With reference toFIG.5, in one embodiment, the switch506is provided on a PCB508in the base14. The switch506can, for example be provided at a back corner510of the base, the back corner510being closer to the rear side78B than the front side78F, and closer to one lateral side78R than the other lateral side78L. The back corner510is preferably on a side of the base14opposite liquid-carrying components such as the pump44, thereby protecting the switch506from exposure to liquid.

The floor cleaner10can include a detection mechanism that detects docking of the floor cleaner10on the tray492. By detecting the tray492, the self-cleaning mode can accordingly be enabled. The self-cleaning mode can be disabled when the tray492is not detected. In another embodiment, the tray492can include the detection mechanism.

The detection mechanism can include or be operably coupled with a switch516configured to enable the self-cleaning mode when the floor cleaner10is docked on the tray492. If the floor cleaner10is not on the tray or incorrectly docked, the switch516is configured to open and disable the self-cleaning mode.

The detection mechanism can include various components for detecting when the floor cleaner10is docked and closing the activating switch516. In one embodiment, the detection mechanism can include a detectable component514, such as a permanent magnet, on the tray492and a sensing component, such as a Hall Effect sensor or a reed switch, on the floor cleaner10in a position to sense the detectable component when the floor cleaner10is docked on the tray492. In embodiments in which the sensing component is a Hall Effect sensor, the Hall sensor may be arranged to act as the activating switch516. When a magnetic field experienced by the Hall Effect sensor exceeds a pre-determined value, the Hall Effect sensor can change state. The Hall Effect sensor will again change state if a magnetic field experienced by the Hall Effect sensor falls below the pre-determined value. Thus, for purposes of the description reference numeral516may refer to the switch, sensing component, or Hall Effect sensor, although it is understood that in other embodiments, a separate activating switch and sensing component may be provided and is within the scope of the present subject matter.

The detectable component514is configured to be detected by the sensing component516within an effective sensing zone of the sensing component516. Direct physical contact between the detectable component514and sensing component516is not required, as the effective sensing zone can detect the detectable component514within a predetermined distance away from the sensing component516. The predetermined distance can be distance within which the detectable component514is spaced from the sensing component516when the floor cleaner10is correctly docked on the tray492.

The detection mechanism is configured to enable the self-cleaning mode when the detectable component514is detected by the sensing component516and to disable the self-cleaning mode when the detectable component514is not detected by the sensing component516. If the floor cleaner10is not on the tray492or incorrectly docked, the self-cleaning mode is prevented from operating.

In one embodiment, when the detectable component514is detected by the sensing component516, selection of the self-cleaning mode via the clean-out cycle button432(FIG.1) initiates the automated, unattended clean-out cycle. When the detectable component514is not detected by the sensing component516selection of the self-cleaning mode via the clean-out cycle button432does not initiate the automated, unattended clean-out cycle.

The main controller76detects the state of the switch, e.g. the state of the Hall Effect sensor516. The controller76is arranged selectively to enable or disable the self-cleaning mode depending upon the state of the sensor516. This in turn is dependent upon the distance between the Hall Effect sensor516and the permanent magnet514. In some embodiments, when the clean-out cycle button432(FIG.1) is pressed in an attempt to initiate the clean-out cycle, and the permanent magnet514is not detected by the Hall Effect sensor516, the Hall Effect sensor516can send a signal to the controller76to cause the floor cleaner10to provide a status update to the user. For example, the floor cleaner10can deliver a visual and/or audio message to the user. The message may indicate to the user that the floor cleaner10must be correctly docked on the tray492before self-cleaning.

In another embodiment, the detection mechanism can include a mechanical sensing component, such as a moveable actuator (not shown), provided on the floor cleaner10or on the tray492. When the floor cleaner10is docked, the actuator is forced to move and the activating switch516is closed.

In one embodiment, the magnet514is provided on an underside of the tray base494and is protected by a cover518, and the Hall Effect sensor516is provided on the same PCB508as the detent switch506. The PCB508can be disposed on a side of the base14opposite the pump and fluid lines, protecting the PCB508from exposure to liquid. For example, the PCB508can be disposed on the same side of the base14as the brush motor72. By providing the PCB508rearward of the brushroll70, brush chamber254, and brush motor72, the PCB508is less likely to become damaged or dirty.

FIG.31is an electrical system schematic for the floor cleaner10. Power to the heater46, liquid pump44, steam pump56, brush motor72, and vacuum motor64is controlled by the main controller76. Input from the main controller76is provided to the UI controllers404,463and detent controller508, and vice versa.

When the floor cleaner10turns on, e.g. by a user pressing the power button382(FIG.25) to close the power switch406, the main controller76can execute the default operating mode. The main controller76executes the other cleaning modes upon selection of the other buttons to operate the mode switch408and/or steam switch410.

Enablement of steam dispensing via the trigger28(FIG.3A) may be temperature-dependent. Power to the steam pump56is controlled by a temperature sensor520that provides input to the main controller76to control when the steam pump56energizes to limit any unheated water from coming out of the steam dispenser48at the beginning of operation. The temperature sensor520senses temperature at the heater46and provides temperature input to the main controller76. Such temperature input can be a signal or data corresponding to the actual temperature of the heater46. Aside from this function, the temperature sensor520is not particularly limited, and may comprise any components and/or configurations suitable for use in/as a temperature sensor. In one embodiment, the temperature sensor520is a thermistor on the heater46.

The main controller76can compare the temperature input to at least one threshold value, for example a predetermined minimum temperature. The minimum temperature can correspond to a minimum temperature at which a heated fluid having a minimum steam quality is produced by the heater46. When the minimum temperature is met or exceeded, the main controller76enables the selection of the steam mode and, when the steam mode is selected, enables the trigger28to power the steam pump56. Dispensing of steam is controlled by the trigger28, as described above.

The minimum temperature may be, for example, about 120° C., alternatively about 130° C., alternatively about 140° C., although it is understood that the minimum temperature may vary depending on the design limits of the floor cleaner10and the desired quality of the dispensed heated fluid. The minimum temperature may be set based on an expected minimum operating temperature for the heater46that will produce heated fluid with a desired stream quality. For example, the minimum temperature can be a minimum temperature at which heated fluid having a steam quality of around 70% is produced by the heater46.

The floor cleaner10can include at least one indicator to indicate to the user when the heater46is warming up and steam is ready and available for dispensing. The indicator can be mode-dependent. In one embodiment, the indicator is the steam icon400on the base14(FIG.23). During a warm-up period after turning the heater46on via the power button382during which steam is not available to be dispensed, the steam icon400can be illuminated in a first state. Once the heater46reaches the minimum temperature as determined by the temperature sensor520, and the main controller76powers the steam pump56, the steam icon400can be illuminated in a second state. Various illumination states are contemplated, including, but not limited to being illuminated in an animated state, e.g. with a change pattern and/or changing characteristics over time, during warm-up and in a steady state, e.g., with generally continuous, unchanging characteristics over a period of time, when steam is ready, and/or being illuminated in an first color during warm-up and in a second color when steam is ready. Various animations are contemplated, including, but not limited to, a flashing animation. In a flashing animation, light intensity generally varies in a square wave fashion or in some other non-sinusoidal manner. This change in state can be based on input from the temperature sensor520.

In some embodiments, the main controller76can compare the temperature input to at least one other threshold value, for example a predetermined maximum temperature. The maximum temperature can be a temperature at which the heater46may operate within the design limits of the surrounding components of the floor cleaner10, and may also be a threshold above which heater46need not operated to produce a desired steam output for effective cleaning. When the maximum temperature is met or exceeded, the main controller76cuts off power to the heater46to allow the heater46to cool. Once the temperature of the heater46drops below the maximum temperature, the controller76supplies power to the heater46and the heater46is energized.

The predetermined maximum temperature may be, for example, about 160° C., alternatively about 170° C., alternatively about 180° C., alternatively about 190° C., alternatively 192° C., although it is understood that the maximum temperature may vary depending on the design limits of the floor cleaner10and the desired characteristics of the dispensed steam.

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 surface cleaning apparatus 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. Thus, the various features of the different embodiments may be mixed and matched in various vacuum cleaner configurations as desired to form new embodiments, whether or not the new embodiments are expressly described.

The terms “comprising” or “comprise” are used herein in their broadest sense to mean and encompass the notions of “including,” “include,” “consist(ing) essentially of,” and “consist(ing) of. The use of “for example,” “e.g.,” “such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples.

The above description relates to general and specific embodiments of the disclosure. However, various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. As such, this disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. Any reference to elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.

Likewise, it is also to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments that fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.