Patent ID: 12213633

DETAILED DESCRIPTION

Aspects of the disclosure generally relate to a cordless surface cleaning apparatus, which may be in the form of a multi-surface wet vacuum cleaner.

FIG.1is a perspective view illustrating one non-limiting example of a surface cleaning apparatus in the form of multi-surface wet surface cleaning apparatus10, according to one example of the invention. As illustrated herein, the multi-surface wet surface cleaning apparatus10is an upright multi-surface wet vacuum cleaner having a housing that includes an upright body or handle assembly12and a base14pivotally and/or swivel mounted to the upright handle assembly12and adapted for movement across a surface to be cleaned. For purposes of description related to the figures, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inner,” “outer,” and derivatives thereof shall relate to the invention as oriented inFIG.1from the perspective of a user behind the multi-surface wet surface cleaning apparatus10, which defines the rear of the multi-surface wet surface cleaning apparatus10. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary.

The upright handle assembly12includes an upper handle16and a frame18. Upper handle16includes a handle assembly100. Frame18includes a main support section or body assembly200supporting at least a clean tank assembly300and a dirty tank assembly400, and may further support additional components of the handle assembly12. The base14includes a foot assembly500. The multi-surface wet surface cleaning apparatus10can include a fluid delivery or supply pathway, including and at least partially defined by the clean tank assembly300, for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned and a fluid recovery pathway, including and at least partially defined by the dirty tank assembly400, 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.

A pivotable swivel joint assembly570is formed at a lower end of the frame18and moveably mounts the base14to the upright assembly12. In the example shown herein, the base14can pivot up and down about at least one axis relative to the upright assembly12. The pivotable swivel joint assembly570can alternatively include a universal joint, such that the base14can pivot about at least two axes relative to the upright assembly12. Wiring and/or conduits supplying air and/or liquid between the base14and the upright assembly12, or vice versa, can extend though the pivotable swivel joint assembly570. A swivel locking mechanism586(FIG.2) can be provided to lock and/or release the swivel joint assembly570for movement.

FIG.2is a cross-sectional view of the surface cleaning apparatus10through line II-IIFIG.1according to one aspect of the present disclosure. The handle assembly100generally includes a handgrip119and a user interface assembly120. In other examples, the user interface assembly120can be provided elsewhere on the surface cleaning apparatus10, such as on the body assembly200. In the present example, handle assembly100further includes a hollow handle pipe104that extends vertically and connects the handle assembly100to the body assembly200. The user interface assembly120can be any configuration of actuating controls such as but not limited to buttons, triggers, toggles, switches, or the like, operably connected to systems in the apparatus10to affect and control function. In the present example, a trigger113is mounted to the handgrip119and operably communicates with the fluid delivery system of the surface cleaning apparatus10to control fluid delivery from the surface cleaning apparatus10. Other actuators, such as a thumb switch, can be provided instead of the trigger113.

The lower end of handle pipe104terminates into the body assembly200in the upper portion of the frame18. Body assembly200generally includes a support frame to support the components of the fluid delivery system and the recovery system described forFIG.1. In the present example, body assembly200includes a central body201, a front cover203and a rear cover202. Additionally, a battery housing24(FIG.20) can be coupled with the body assembly200. Front cover203can be mounted to central body201to form a front cavity235. Rear cover202can be mounted to central body201to form a rear cavity240. A motor housing assembly250can be mounted to an upper portion of the front cover203. A carry handle78can be disposed on the body assembly, forwardly of the handle assembly100, at an angle relative to the hollow handle pipe104to facilitate manual lifting and carrying of the multi-surface wet surface cleaning apparatus10. Motor housing assembly250further includes a cover206disposed beneath carry handle78, a lower motor bracket233, and a suction motor/fan assembly205positioned between the cover206and the motor bracket233in fluid communication with the dirty tank assembly400.

Rear cavity240includes a receiving support223at the upper end of rear cavity240for receiving the clean tank assembly300, and a pump assembly140beneath and in fluid communication with the clean tank assembly300.

Clean tank assembly300can be mounted to the frame18in any configuration. In the present example, clean tank assembly300is removably mounted to the body assembly200such that it partially rests in the upper rear portion of the central body201of body assembly200and can be removed for filling and/or cleaning.

Dirty tank assembly400can be removably mounted to the front of the body assembly200, below the motor housing assembly250, and is in fluid communication with the suction motor/fan assembly205when mounted to the surface cleaning apparatus10. A flexible conduit hose518couples the dirty tank assembly400to the foot assembly500and passes through the swivel joint assembly570.

Optionally, a heater (not shown) can be provided for heating the cleaning fluid prior to delivering the cleaning fluid to the surface to be cleaned. In one example, an in-line heater can be located downstream of the clean tank assembly300, and upstream or downstream of the pump assembly140. Other types of heaters can also be used. In yet another example, the cleaning fluid can be heated using exhaust air from a motor-cooling pathway for the suction motor/fan assembly205.

Foot assembly500includes a removable suction nozzle assembly580that can be adapted to be adjacent the surface to be cleaned as the base14moves across the surface and is in fluid communication with dirty tank assembly400through flexible conduit518. An agitator546can be provided in suction nozzle assembly580for agitating the surface to be cleaned. Some examples of agitators include, but are not limited to, a horizontally-rotating brushroll, dual horizontally-rotating brushrolls, one or more vertically-rotating brushrolls, or a stationary brush. A pair of rear wheels539are positioned for rotational movement about a central axis on the rearward portion of the foot assembly500for maneuvering the multi-surface wet surface cleaning apparatus10over a surface to be cleaned.

In the present example, agitator546can be a hybrid brushroll positioned within a brushroll chamber565for rotational movement about a central rotational axis, which is discussed in more detail below. A single brushroll546is illustrated; however, it is within the scope of aspects described herein for dual rotating brushrolls to be used. Moreover, it is within the scope of aspects described herein for the brushroll546to be mounted within the brushroll chamber565in a fixed or floating vertical position relative to the chamber565.

FIG.3is an exploded perspective view of the handle assembly100. Handgrip119can include a front handle101and a back handle102mated fixedly to the handle pipe104. The user interface assembly120can be provided on the front handle101. The user interface assembly120of the illustrated example includes a control panel111connected to a floating key109and mounted with a water proof seal108through the front portion of front handle101to engage a printed circuit board assembly (PCBA)110and a bracket112provided on the back side of front handle101. Bracket112engages a spring114that biases the trigger113mounted to the back handle102, with a portion of the trigger113projecting inward in the recess formed by the mating of front handle101to back handle102. The trigger113can electronically communicate with the fluid delivery system. The trigger113alternatively can mechanically communicate with the fluid delivery system, such as via a push rod (not shown) that runs through the handle pipe104. Hollow handle pipe104terminates in the frame18(FIG.1) by a bracket connection formed by a right bracket106, a left bracket105, and a female connector107joined together at the terminal end of handle pipe104.

FIG.4is an exploded perspective view of the body assembly200. Body assembly200includes front cover203, central body201, and rear cover202, and terminates with a bottom cover216. Front cover203and rear cover202can mount to central body201forming at least partially enclosed cavities235and240. In the present example, front cavity235generally contains electrical components such as a printed circuit board217(PCB) and other required circuitry215electrically connected to various component parts of the fluid delivery and recovery systems. Pump assembly140can include a connector219, a pump226, a clamp220and a gasket218and can be mounted in front cavity235. Alternatively, pump assembly140can be mounted in rear cavity240, or partially mounted in both front and rear cavities235and240respectively. The pump226can be a solenoid pump having a single, dual, or variable speed.

In the present example, rear cavity240generally contains a receiving assembly245for the clean tank assembly300(FIG.2). Receiving assembly245can include the receiving support223, a spring insert227, a clamp224, a receiving body222, a receiving gasket231and a clamp cover225at the upper portion of rear cavity240for receiving the clean tank assembly300. The pump assembly140can be mounted beneath and in fluid communication with the receiving assembly245.

FIG.5is an exploded perspective view of the motor housing assembly250. Carry handle78includes a handle top209mounted to a handle bottom207with a gasket230mounted therebetween, and is secured to the cover206. Motor housing assembly250can further include an upper motor housing body204and a lower motor housing body208, and a vacuum motor cover228provided therebetween to partially enclose the suction motor/fan assembly205. A top motor gasket229and a rubber gasket221are provided on the upper portion of the suction motor/fan assembly205, and lower vacuum motor gaskets210and211are provided on the lower portion of the suction motor/fan assembly205. A clean air outlet of the working air path through the vacuum cleaner can be defined by a left vent213and a right vent214in the lower motor housing body.

FIG.6is an exploded perspective view of the clean tank assembly300. Clean tank assembly300generally includes at least one supply tank301and a supply valve assembly320controlling fluid flow through an outlet311of the supply tank301. Alternatively, clean tank assembly300can include multiple supply chambers, such as one chamber containing water and another chamber containing a cleaning agent. A check valve310and a check valve umbrella309can be provided on supply tank301. Supply valve assembly320mates with the receiving assembly245and can be configured to automatically open when seated. The supply valve assembly320includes an assembly outlet302that is mounted to the outlet of the fluid supply tank301by a threadable cap303, a rod release insert304held in place with the assembly outlet302by an O-ring305, and an insert spring308inside a spring housing306biasing the valve assembly320to a closed position. When the valve assembly320is coupled with the receiving assembly245, the valve assembly320opens to release fluid to the fluid delivery pathway. A screen mesh insert307can be provided between the tank outlet and the valve outlet to prevent particulates of a certain size from entering the pump assembly140.

FIG.7is an exploded perspective view of the dirty tank assembly400. The dirty tank assembly400generally includes the collection container for the fluid recovery system. In the present example, dirty tank assembly400includes a recovery tank401with an integral hollow standpipe420(FIG.2) formed therein. The standpipe420is oriented such that it is generally coincident with a longitudinal axis of the recovery tank401. The standpipe420forms a flow path between an inlet422(FIG.2) formed at a lower end of the recovery tank401and an outlet423(FIG.2) on the interior of the recovery tank401. When the recovery tank401is mounted to the body assembly200(FIG.2), the inlet422is aligned with the flexible conduit hose518to establish fluid communication between the foot assembly500and the recovery tank401. A lid402sized for receipt on the recovery tank401supports a pleated filter405in a filter cover plate403mounted to the lid402with a mesh screen406therebetween. Preferably, the pleated filter405is made of a material that remains porous when wet. The surface cleaning apparatus10can also be provided with one or more additional filters upstream or downstream. A gasket411positioned between mating surfaces of the lid402and the recovery tank401creates a seal therebetween for prevention of leaks.

A shut-off valve can be provided for interrupting suction when fluid in the recovery tank401reaches a predetermined level. The shut-off valve includes a float bracket412fixedly attached to a bottom wall416of the lid402in a position offset from the standpipe420and a moveable float410carried by the float bracket412. The float410is buoyant and oriented so that the top of the float410can selectively seal an air outlet415of the recovery tank401leading to the downstream suction source when the fluid in the recovery tank401reaches a predetermined level.

A releasable latch430is provided to facilitate removal of the dirty tank assembly400for emptying and/or cleaning, and can be positioned in an aperture417on a front side of the lid402. The releasable latch430can include a latch button407held within a latch bracket404and biased with latch spring408toward an engaged or latched position. The latch button407releasably engages with the front cover203to removably secure the dirty tank assembly400to the body assembly200(FIG.2). A hand grip419can be provided on the recovery tank401and located below the latch407to facilitate handling of the dirty tank assembly400g.

FIG.8is an exploded perspective view of the foot assembly500. Foot assembly500generally includes a housing supporting at least some of the components of the fluid delivery system and fluid recovery system. In the present example, the housing includes an upper cover542and a lower cover501coupled with the upper cover542and defining a partially enclosed cavity561therebetween for receiving at least some components of the fluid delivery and recovery pathways. The housing can further include a cover base537coupled with a lower forward portion of the lower cover to defined a portion of the brushroll chamber565(FIG.10). The upper cover542extends from approximately the middle to rear of foot assembly500and can have decorative panels543and544mounted to an upper surface. Upper cover542can be configured to releasably receive the suction nozzle assembly580.

Suction nozzle assembly580can be configured to include at least one inlet nozzle for recovering fluid and debris from the surface to be cleaned and at least one outlet for delivering fluid to the surface to be cleaned. In one example, suction nozzle assembly580can include a nozzle housing551and a nozzle cover552, which mate to form a pair of fluid delivery channels40therebetween that are each fluidly connected to a spray connector528at one terminal end. At the opposite, or second terminal, end of each fluid delivery channel40, a fluid dispenser554is configured with at least one outlet to deliver fluid to the surface to be cleaned. Fluid dispenser554may be include of one or more spray tips configured to deliver cleaning fluid from the fluid delivery channel40to the brush chamber565. In the present example, fluid dispenser554is a pair of spray tips fluidly connected to the fluid delivery channel40. Spray tip554is mounted in the nozzle housing551and has an outlet in fluid communication with the brush chamber565. Nozzle cover552can have a decorative cover553, and one or both can be composed of a translucent or transparent material. Nozzle housing551can further include a front interference wiper560mounted at a forward position relative to the brushroll chamber565and disposed horizontally.

The lower cover501further includes a plurality of upstanding bosses562that project into cavity561for mounting interior components thereto. A rear portion of the lower cover501pivotally mounts to swivel joint assembly570for maneuvering the multi-surface wet surface cleaning apparatus10over a surface to be cleaned. The rear wheels539are positioned for rotational movement about a central axis on opposite sides of the lower cover501for maneuvering the multi-surface wet surface cleaning apparatus10over a surface to be cleaned. Swivel joint assembly570can include swivel joint519, covers520and521, and a swivel locking mechanism586for releasing the swivel joint assembly570for pivoting and swivel movements.

A conduit assembly585is partially disposed in cavity561and extends through the swivel joint519, along with the flexible conduit hose, to couple with components in the upper body assembly200(FIG.2). Conduit assembly585includes a fluid supply conduit532and a wiring conduit533. Fluid supply conduit532passes interiorly to swivel joint assembly570and fluidly connects the clean tank assembly300to the spray connectors528through a T-connector530having a pair spray tube connectors531. Wiring conduit533provides a passthrough for electrical wiring from the upright assembly12to the base14through swivel joint assembly570. For example, the wiring can be used to supply electrical power to at least one electrical component in the foot assembly500. One example of an electrical component is a brush motor503. Another example is an indicator light assembly. In the present example, the indicator light assembly includes an LED base516configured to mount a pair of indicator lights517and a pair of lenses545over the lights517. The lights517may include light emitting diodes (LED) or other illumination sources.

A central lower portion of the partially enclosed cavity561and a rearward lower portion of suction nozzle assembly580can be molded to form a foot conduit564of the fluid recovery pathway that is fluidly connected to the flexible conduit518. Flexible conduit518fluidly connects dirty tank assembly400(FIG.2) to suction nozzle assembly580.

The brushroll546can be provided at a forward portion of the lower cover501and received in brushroll chamber565. In the present example, the cover base537rotatably receives the brushroll546, and also mountably receives a wiper538positioned rearwardly of the brushroll546. Optionally, brushroll546can be configured to be removed by the user from the foot assembly500for cleaning and/or drying. A pair of forward wheels536are positioned for rotational movement about a central axis on the terminal surface of the cover base537for maneuvering the multi-surface wet surface cleaning apparatus10over a surface to be cleaned.

In the example, the brushroll546can be operably coupled to and driven by a drive assembly including a dedicated brush motor503disposed in the cavity561of the lower cover501and one or more belts, gears, shafts, pulleys or combinations thereof to provide the coupling. Here, a transmission510operably connects the motor503to the brushroll546for transmitting rotational motion of a motor shaft505to the brushroll546. In the present example, transmission510can include a drive belt511and one or more gears, shafts, pulleys, or combinations thereof. Alternatively, a single motor/fan assembly (not shown) can provide both vacuum suction and brushroll rotation in the multi-surface wet surface cleaning apparatus10. A brush motor exhaust tube515can be provided to the brush motor503and configured to exhaust air to the outside of the multi-surface wet surface cleaning apparatus10.

FIG.9is a perspective view of the hybrid brushroll546. Hybrid brushroll546is suitable for use on both hard and soft surfaces, and for wet or dry vacuum cleaning. In this exemplary aspect, brushroll546includes a dowel46, a plurality of tufted bristles48or unitary bristle strips extending from the dowel46, and microfiber material49provided on the dowel46, arranged between the bristles48. Dowel46can be constructed of a polymeric material such as acrylonitrile butatdiene styrene (ABS), polypropylene or styrene, or any other suitable material such as plastic, wood, or metal. Bristles48can be tufted or unitary bristle strips and constructed of nylon, or any other suitable synthetic or natural fiber. The microfiber material49can 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.

In one non-limiting example, dowel46is constructed of ABS and formed by injection molding in one or more parts. Bristle holes (not shown) can be formed in the dowel46by drilling into the dowel46after molding, or can be integrally molded with the dowel46. The bristles48are tufted and constructed of nylon with a 0.15 mm diameter. The bristles48can be assembled to the dowel46in a helical pattern by pressing bristles48into the bristle holes and securing the bristles48using a fastener (not shown), such as, but not limited to, a staple, wedge, or anchor. The microfiber material49is constructed of multiple strips of polyester treated with Microban© and glued onto the dowel46between bristles48. Alternatively, one continuous microfiber strip49can be used and sealed by hot wire to prevent the single strip from detaching from the dowel46. The polyester material can be 7-14 mm thick with weight of 912 g/m2. The polyester material can be an incipient absorption of 269 wt % and a total absorption of 1047 wt %.

FIG.10is a close-up sectional view through a forward section of the suction nozzle assembly580. The brushroll546is positioned for rotational movement in a direction R about a central rotational axis X. The suction nozzle assembly580includes a suction nozzle594defined within the brush chamber565that is in fluid communication with the foot conduit564and configured to extract liquid and debris from the brushroll546and the surface to be cleaned. The suction nozzle594defines a dirty air inlet of the working air path or recovery pathway through the vacuum cleaner. Suction nozzle594is further fluidly connected through the foot conduit564and the flexible hose conduit518, to dirty tank assembly400(seeFIG.16B). Front interference wiper560, mounted at a forward position of the nozzle housing551, is provided in the brush chamber565, and is configured to interface with a leading portion of the brushroll546, as defined by the direction of rotation R of the brushroll546. Spray tips554are mounted to the nozzle housing551with an outlet in the brushroll chamber565and oriented to spray fluid inwardly onto the brushroll546. The wetted portion brushroll546then rotates past the interference wiper560, which scrapes excess fluid off the brushroll546, before reaching the surface to be cleaned. Rear wiper squeegee538is mounted to the cover base537behind the brushroll546and is configured to contact the surface as the base14moves across the surface to be cleaned. The rear wiper squeegee538wipes residual liquid from the surface to be cleaned so that it can be drawn into the fluid recovery pathway via the suction nozzle594, thereby leaving a moisture and streak-free finish on the surface to be cleaned.

Front interference wiper560and rear wiper538can be squeegees constructed of a polymeric material such as polyvinyl chloride, a rubber copolymer such as nitrile butadiene rubber, or any material known in the art of sufficient rigidity to remain substantially undeformed during normal use of the surface cleaning apparatus10, and can be smooth or optionally include nubs on the ends thereof. Wiper560and wiper538can be constructed of the same material in the same manner or alternatively constructed of different materials providing different structure characteristics suitable for function.

FIG.11is a perspective view of the underside of the suction nozzle assembly580, with some portions cut away to show some internal features of the suction nozzle assembly580. Brushroll chamber565is defined on the underside of suction nozzle assembly580forward of the foot conduit564. A pair of spray tip outlets595can be provided in the brush chamber565. A latch mechanism587is provided at the rearward portion of suction nozzle assembly580and is configured to be received in the upper cover542(FIG.8). Latch mechanism587can be received in a latch receiving depression587a(FIG.8) provided on the upper cover542base14and is configured for a user to remove and/or lock the suction nozzle assembly580onto the base14. The suction nozzle assembly580can be biased by springs556to release suction nozzle assembly580away from foot assembly500when the latch mechanism587is actuated. A pair of spray connector inlets590are provided on the underside of nozzle housing551and are fluidly connected to the first terminal end of fluid delivery channels40on the upper side of the nozzle housing551(FIG.8). Front interference wiper560is provided in the forward most portion of brushroll chamber565.

FIG.12is a bottom perspective view of the foot assembly500. Rear wiper538is provided on the cover base537, rearward of brushroll546, and configured to contact the surface to be cleaned.

FIG.13Ais a perspective view of the underside of the nozzle cover552andFIG.13Bis an exploded perspective view of the suction nozzle assembly580. The nozzle cover552includes of two fluid channel portions40athat form an upper portion of the flow channels40when mated with nozzle housing551. The nozzle housing551includes two fluid channel portions40bthat form lower portions of the flow channels40when mated with the nozzle cover552. Fluid channel portions40aand40bmate to form the fluid delivery flow channels40therebetween containing the spray tips554at the second terminal ends partially therein.

The nozzle housing551can define a lens for the brush chamber565and can include a translucent or transparent material to allow the brushroll546to be viewed therethrough. Likewise, the nozzle cover552can define a lens cover, and can include a translucent or transparent material, which permits a user to view the flow of fluid through the flow channels40.

FIG.14is a partially exploded view of the base. InFIG.14, suction nozzle assembly580is removed to expose the indicator lights517. The indicator lights517can be configured to activate in combination with the pump assembly140when trigger113is depressed to deliver fluid (FIG.2). A portion of the base can form a light tube or light pipe578that is illuminated by the indicator lights517when fluid is delivered, indicating to the user that fluid is being delivered to the surface underneath the base14. The light pipe578can be any physical structure capable of transporting or distributing light from the indicator lights517. The light pipe578can 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 pipes578are solid structures formed on the suction nozzle assembly580and are elongated to extend along the fluid delivery channels40and configured to distribute of light over its length. More specifically, the light pipes578are embodied as raised rails molded onto the surface of the nozzle cover552, generally above the fluid delivery channels40.

FIG.15is a cross-sectional view of the foot assembly500through line XV-XV ofFIG.1, with portion A enlarged for a close up view of a fluid dispenser in the form of the spray tip554. The spray tip554is mounted in each of the terminal ends of each of the fluid delivery flow channels40of the suction nozzle assembly580and can be configured to terminate in the brush chamber565. Each spray tip554includes an orifice595oriented to spray onto the brushroll546as depicted by the solid arrows inFIG.15. The spray tips554can be oriented to spray along a horizontal axis which may be parallel to the rotational axis X of the brushroll546or at a substantially horizontal angle relative to the rotational axis X in order to wet the entire length of the brushroll546during fluid dispensing. By “substantially horizontal” the angle of spray of the orifice595can be 0 to 30 degrees, depending on the length of the brushroll and the spacing of the spray tips554in order to cover the entire brushroll546with fluid. The angle of the spray tips554may be static or adjustable while the multi-surface wet surface cleaning apparatus10is in operation or prior to operation. The spray tip outlet orifice595can have any diameter suitable to deliver fluid at the desired pressure, pattern, and/or volume from the spray tip554. In the present example, spray tips554have an outlet orifice diameter of 1.0 mm and are oriented to spray inwardly onto a top of the brushroll546at an angle of 15 degrees from the horizontal.

FIG.16Ais a schematic diagram of a fluid supply pathway of the surface cleaning apparatus10. The arrows present designate the directional flow of fluid in the fluid supply pathway according to the present example. The fluid supply pathway can include the supply tank301for storing a supply of fluid. The fluid can include 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 fluid can include a mixture of water and concentrated detergent.

The fluid supply pathway can further include a flow control system705for controlling the flow of fluid from the supply tank301to fluid supply conduit532. In one configuration, the flow control system705can include pump226, which pressurizes the system, and supply valve assembly320, which controls the delivery of fluid to the fluid supply conduit532. In this configuration, fluid flows from the supply tank301, through pump226, to the fluid supply conduit532. A drain tube706provides a pathway for draining any fluid that may leak from the supply tank301while the surface cleaning apparatus10is not in active operation to a drain hole (not pictured) in foot assembly500to collect in a storage tray900(FIG.19). From the fluid supply conduit532, fluid flows sequentially through the spray connectors528, through the fluid delivery channels40, through the spray tips554, and onto the brushroll546(FIG.15), which applies the fluid to the surface to be cleaned.

The trigger113(FIG.2) can be depressed to actuate the flow control system705and dispense fluid to the fluid dispenser554. The trigger113can be operably coupled to the supply valve320such that pressing the trigger113will open the valve320. The valve320can be electrically actuated, such as by providing an electrical switch between the valve320and a power source22(FIG.18) that is selectively closed when the trigger113is pressed, thereby powering the valve320to move to an open position. In one example, the valve320can be a solenoid valve. The pump226can also be coupled with the power source22. In one example, the pump226can be a centrifugal pump. In another example, the pump226can be a solenoid pump.

In another configuration of the fluid supply pathway, the pump226can be eliminated and the flow control system705can include a gravity-feed system having a valve fluidly coupled with an outlet of the supply tank(s)301, whereby when valve is open, fluid will flow under the force of gravity to the fluid dispenser554. The valve320can be mechanically actuated or electrically actuated, as described above.

FIG.16Bis a schematic diagram of a fluid recovery pathway of the surface cleaning apparatus10. The arrows present designate the directional flow of fluid in the fluid recovery pathway. The fluid recovery pathway can include the suction nozzle assembly580, the foot conduit564, the flexible conduit hose518, the suction motor/fan assembly205in fluid communication the suction nozzle assembly580for generating a working air steam, and recovery tank401for separating and collecting fluid and debris from the working airstream for later disposal. Standpipe420can be formed in a portion of recovery tank401for separating fluid and debris from the working airstream. The suction motor/fan assembly205provides a vacuum source in fluid communication with the suction nozzle assembly580to draw the fluid and debris from the surface to be cleaned through the flexible hose conduit518to the recovery tank401.

FIG.17is a rear perspective view of the surface cleaning apparatus10with portions removed to show the conduit assembly585. In the present example, flexible conduit hose518couples dirty tank assembly400to foot assembly500through a forward portion of pivotable swivel joint assembly570. Fluid supply conduit532and wiring conduit533can be provided rearward of flexible conduit hose518. Fluid supply conduit532fluidly couples the pump226the T-connector530in the foot assembly500.

FIG.18is a schematic circuit diagram of the surface cleaning apparatus10. User interface assembly120can be operably connected to the various components of cleaner10directly or through a central control unit750. User interface assembly120can include one or more actuators and be configured with any combination of buttons, switches, toggles, triggers, or the like to allow a user to select multiple cleaning modes and/or control the fluid delivery and recovery systems. A power source22, such as a battery22can be electrically coupled to the electrical components of the surface cleaning apparatus10, including the motors205,503and pump226. Therefore, the surface cleaning apparatus10can be considered cordless. A suction power switch25between the suction motor/fan assembly205and the power source22can be selectively closed by the user, thereby activating the suction motor/fan assembly205. Furthermore, a brush power switch27between the brush motor503and the power source22can be selectively closed by the user, thereby activating the brush motor503. User interface assembly120can be operably coupled to the pump226such that an actuator, such as trigger113, can activate the pump226when engaged, thereby powering the pump226to deliver fluid to the fluid supply pathway. Actuation of the pump226can be operably connected to the LED lights517such that actuation of trigger113additionally powers LED indicator lights517to provide user feedback that fluid is being delivered to the fluid supply pathway.

In one example, user interface assembly120of surface cleaning apparatus10can be provided with actuators122for selecting multiple cleaning modes to be selected by the user. Actuators122send a signal to the central control unit750, which can include a PCBA. The output from the central control unit750adjusts the frequency of the solenoid pump226to generate the desired flow rate depending on the mode selected. For instance, the surface cleaning apparatus10can have a hard floor cleaning mode and a carpet cleaning mode. In the hard floor cleaning mode, the liquid flow rate to the fluid dispenser554is less than in the carpet cleaning mode. The liquid flow rate is controlled by the speed of the pump226. In one non-limiting example, the speed of the pump226is controlled in the hard floor cleaning mode so that the liquid flow rate is approximately 50 ml/min and the speed of the pump226is controlled in the carpet cleaning mode so that the liquid flow rate is approximately 100 ml/min. Optionally, the surface cleaning apparatus10can have a wet scrubbing mode in which the suction motor/fan assembly205can be inoperative while brush motor503is activated so that the soiled cleaning solution is not removed from the surface to be cleaned.

FIG.19is a perspective view of a storage tray900for the surface cleaning apparatus10. Storage tray900can be configured to receive the base14of the surface cleaning apparatus10in an upright, stored position. Storage tray900can optionally be adapted to contain a liquid for the purposes of cleaning the interior parts of cleaner10and/or receiving liquid from the drain tube706(FIG.16A). In the present example, storage tray900is adapted to receive the base14and includes a removable brushroll holder905provided on an exterior side wall of the tray900. Alternatively, storage tray900can be configured with an integral brushroll holder905. Here, the brushroll holder905can be secured to the storage tray900by a retention latch910. Retention latch910can include a sliding lock, clamp, brace, or any other mechanism in which to secure brushroll holder905to its position on storage tray900while in use and can be biased or otherwise configured to allow a user to release a lock and remove the brushroll holder905from storage tray900. Brushroll holder905can be adapted to removably receive one or more brushrolls546for the purposes of storage and/or drying. Brushroll holder905can include one or more brushroll slots915to securely receive brushrolls546in a vertical fixed position for drying and storage. Brushroll slots915can be fixed or adjustable and can include clamps, rods, or molded receiving positions that can accommodate brushroll546with or without the dowel46inserted. Alternatively, brushroll holder905can include a series of horizontal storage positions such racks, hooks, or clamps (not shown) to secure brushrolls546in a horizontal position.

FIG.20is a side view of the storage tray900for the surface cleaning apparatus10more clearly illustrating a charging unit920provided on the storage tray900. The charging unit920can electrically couple the battery22when the surface cleaning apparatus10base14is seated onto the storage tray900. Therefore, the storage tray900functions as a charging base or a charging tray. An electric coupler921can be provided at the rear of the charging unit920. The electric coupler921can electrically couple the charging unit920to a power source including, but not limited to, a household outlet. In one example, a cord (not shown) can be coupled with the electric coupler921that can connect the electric coupler921to the power source.

Also better illustrated in the side view is that a battery housing24can be provided on the handle assembly12to protect the battery22and retain the battery22on the surface cleaning apparatus10. The battery housing24can be integral with the handle assembly12such that the battery housing24forms a portion of the handle assembly12. Alternatively, the battery housing24can be removably coupled with the handle assembly12. The battery housing24and the charging unit920of the storage tray900can include complementary shapes. In this manner, the battery housing24fits against the charging unit920in order to couple the battery housing24and the charging unit920.

FIG.21is a perspective view of the storage tray900without the surface cleaning apparatus10and without the removable brushroll holder905. A self-cleaning reservoir926is provided on the storage tray900for use in self-cleaning modes of the surface cleaning apparatus10. The self-cleaning reservoir926can be formed as a recess in the storage tray900. The reservoir926is shaped to fit a brush roll546(FIG.2) when the brush roll546is coupled with the surface cleaning apparatus10and to retain a cleaning solution. Wheel holders928can be formed on the storage tray900in order to retain the rear wheels539(FIG.20). The wheel holders928can be formed as a recess, or groove in the storage tray900and can include a wheel block930. The wheel block930can be a raised portion configured to prevent the rear wheels539from rolling out of the wheel holders928.

FIG.22shows a rear, perspective view of a lower portion of the handle assembly12including the battery housing24. A battery cover932can be disposed on top of the battery22to protect the components of the battery22. In the current embodiment, the battery22is fixed or non-removable. A DC jack934having a charging contact942(FIG.24) can be provided in the battery22and can include a DC jack socket936. WhileFIG.22illustrates a non-removable battery22, it is also possible for aspects described herein to include a battery that can be removable from the battery housing24such that the battery22can be replaced, by a user, with a new battery22if need be.

FIG.23illustrates the battery22without the battery cover932in order to more clearly show the components of the battery22. The DC jack socket936can be covered, or closed with a DC jack cover940by way of a spring938. The spring938can be compressed, or retained, by the battery cover932(FIG.22) when the battery cover932is mounted to the battery22. Thus, the spring938under compression can provide a force on the DC jack cover940to hold the DC jack cover940in the closed position.FIG.23shows the DC jack cover940is in the closed position such that the DC jack cover940is in alignment with the DC jack socket936, shielding the DC jack charging contact942such that liquid can be prevented from entering the DC jack934. The spring938is partially compressed and normally forces the DC jack cover940into the closed position.

FIG.24illustrates the DC jack cover940in an open position, where the DC jack cover940is moved out of alignment with the DC jack socket936thereby exposing the DC jack charging contact942. To move the DC jack cover940from the closed position to the open position, a force can push against a ramp954of the DC jack cover940to move, or slide, the DC jack cover940out of alignment with the DC jack socket936. While a ramp954is shown, the surface cleaning apparatus10can include any suitable mating feature configurable to move the DC jack cover940. In the open position, the spring938is further compressed.

FIG.25illustrates an exploded view of the charging unit920more clearly showing the components of the charging unit920. A bracket944is provided in the charging unit920and includes a charger plug946and a plug cover948. Springs950bias the plug cover948into a closed position. The closed position (FIG.26) can include covering, or closing off the charger plug946.FIG.26is a cutaway view of the charging unit920more clearly showing the charger plug946covered by the plug cover948such that the plug cover948shields electrical contacts (not shown) provided on the charger plug946.

In order to dock the surface cleaning apparatus10within the storage tray900for charging, the surface cleaning apparatus10is lowered into the storage tray900and rear lower portion24a(FIG.22) of the battery housing24can push against a ramp952on the plug cover948, sliding the plug cover948rearwardly to expose the charger plug946. While a ramp952is shown, the storage tray900can include any suitable mating feature configurable to move the plug cover948. The rearwardly positioned plug cover948and exposed charger plug946are illustrated inFIG.27. As the surface cleaning apparatus10continues to be lowered onto the storage tray900, the charger plug946is received within the DC jack socket936(FIG.24). The charger plug946can push against the ramp954(FIG.24) on the DC jack cover940and force the DC jack cover940to slide into the open position (FIG.24), further compressing the spring938, such that the DC jack charging contact942is exposed and coupled with the charger plug946(FIG.27). The charging plug946on the storage tray900and DC jack934on the surface cleaning apparatus10become fully engaged, or electrically connected, when the surface cleaning apparatus10is fully seated on the storage tray900, which is illustrated inFIG.20. The DC jack socket936can be coupled with the charging unit920in order to charge the battery22via the DC jack934.FIG.28shows the surface cleaning apparatus10with the battery housing24and storage tray900removed to more clearly view the charging plug946coupled to the battery22.

The multi-surface wet surface cleaning apparatus10shown in the figures can be used to effectively his remove debris and fluid from the surface to be cleaned in accordance with the following method. The sequence of steps discussed is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be divided into multiple steps, without detracting from aspects described herein.

In operation, the multi-surface wet surface cleaning apparatus10is prepared for use by coupling the surface cleaning apparatus10to the power source22, and by filling the supply tank301with cleaning fluid. A user selects the floor surface type to be cleaned through user interface assembly120. Cleaning fluid is selectively delivered to the surface to be cleaned via the fluid supply pathway by user-activation of the trigger113, while the surface cleaning apparatus10is moved back and forth over the surface. Pump226can be activated by user interface assembly120. User-activation of trigger113activates the pump226and fluid is released by clean tank assembly300into the fluid delivery pathway through spray tips554and onto brushroll546. The wetted brushroll546is wiped across the surface to be cleaned to remove dirt and debris present on the surface.

Activation of the trigger113also simultaneously activates LED indicator lights517which transmit light through the LED lenses545and into nozzle cover552along the light pipes578to provide an illuminated indication that fluid is being dispensed. The illumination of the LEDs517and light pipes578indicate to the user the fluid dispenser554has been activated and fluid has been dispensed onto the surface to be cleaned.

Simultaneously, brush power switch27can activate brushroll546to agitate or rotate cleaning fluid into the surface to be cleaned. Such interaction removes the adhered dirt, dust, and debris, which then become suspended in the cleaning fluid. As brushroll546rotates, front interference squeegee560confronts brushroll546in a manner so as to ensure the brush is wetted evenly and cleaning fluid is spread uniformly across the entire length of the brushroll546. Front interference squeegee560can also be configured to simultaneously scrape soiled fluid and debris off the brushroll546to be drawn into the suction nozzle assembly580and fluid recovery pathway. As the surface cleaning apparatus10moves over the surface to be cleaned, soiled cleaning fluid and dirt near the nozzle opening594is drawn into the suction nozzle assembly580and the fluid recovery pathway when suction motor/fan assembly205is activated. Additionally, cleaning fluid and dirt is scraped by the rear wiper squeegee538and drawn into the fluid recovery pathway.

Optionally, during operation of the brushroll546, the suction motor/fan assembly205can be inoperative which facilitates a wet scrubbing mode so that the soiled cleaning solution is not removed as the cleaner10is moved back and forth across the surface to be cleaned.

During operation of the fluid recovery pathway, the fluid and debris-laden working air passes through the suction nozzle assembly580and into the downstream recovery tank401where the fluid debris is substantially separated from the working air. The airstream then passes through the suction motor/fan assembly205prior to being exhausted from the surface cleaning apparatus10through the clean air outlet defined by the vents213,214. The recovery tank401can be periodically emptied of collected fluid and debris by actuating the latch430and removing the dirty tank assembly400from the body assembly200.

When operation has ceased, the surface cleaning apparatus10can be locked upright and placed into the storage tray900for storage or cleaning. If needed, the suction nozzle assembly580can be removed from the foot assembly500. Brushroll546can then be removed from the foot assembly500and placed in brushroll holder905.

The multi-surface wet surface cleaning apparatus10can optionally be provided with a self-cleaning mode. The self-cleaning mode can be used to clean the brushroll and internal components of the fluid recovery pathway of surface cleaning apparatus10. In one aspect, the multi-surface wet surface cleaning apparatus10is prepared for cleaning by coupling the surface cleaning apparatus10to the power source22, and by filling the storage tray900to a predesignated fill level with a cleaning fluid or water. The user selects the designated cleaning mode from the user interface assembly120. In one example, locking mechanism586is released to pivot upright assembly12rearward and the hard floor cleaning mode is selected from the user interface assembly120by the user. Brushroll546is activated by brush motor503while suction motor/fan assembly205provides suction to the suction nozzle assembly580which draws fluid in storage tray900and into the fluid recovery pathway for a predetermined amount of time or until the fluid in storage tray900has been depleted. When self-cleaning mode has been completed, surface cleaning apparatus10can be returned to the upright and locked position in storage tray900and brushroll546can be removed and stored as previously described.

An aspect of the disclosure also includes a self-cleaning mode. More specifically, the surface cleaning apparatus10can be docked within storage tray900. A user can fill the reservoir in the storage tray900with a cleaning fluid or water to a predetermined or predesignated fill level. It is contemplated that a provided cup can be used to provide the appropriate amount of fluid. Alternatively, a separate reservoir provided on the storage tray900or the surface cleaning apparatus10may contain the cleaning fluid or water, and when the surface cleaning apparatus10is docked within the storage tray900, a valve can be actuated that allows the reservoir in the storage tray900to fill with fluid from the separate reservoir. A momentary switch960(FIG.20) can be provided on the vacuum10for selectively actuating the brush motor503and the suction motor/fan assembly205. Selectively actuating can include pressing and holding a “Clean-Out” button (not shown) while the machine is docked in the storage tray900. When the button is pushed, the brushroll546is activated by brush motor503while the suction motor/fan assembly205provides suction to the suction nozzle assembly580. This draws fluid from the storage tray900into the fluid recovery pathway until the button is released. In this manner, the brushroll546and the suction motor/fan assembly205are operated simultaneously to clean the brushroll546and the air path. The battery of the vacuum10can begin to charge after 1 minute of idle time.

In yet another example of a self-cleaning mode, a control panel111(FIG.3) and a PCB110,217(FIG.4). can automatically energize the pump226, brush motor503and suction motor/fan assembly205according to a predetermined cycle. For example, when the surface cleaning apparatus10is docked within storage tray900, the storage tray900can send a signal to the surface cleaning apparatus10that docking is complete and a self-cleaning mode can be employed. A user can actuate the “Clean-Out” button (not shown), which can include a single press, and the surface cleaning apparatus10can automatically dispense a cleaning formula or water solution from the clean tank assembly300onto the rotating brushroll546and begin to fill the reservoir in the storage tray900. The dispensing can take approximately 30 seconds. Next, the suction motor/fan assembly205can turn on to extract dirty water and debris from the reservoir and brushroll, which can take approximately 10-15 seconds. The surface cleaning apparatus10can shut off after a predetermined amount of time, which can be approximately 45 seconds total and begin to charge after 1 minute of idle time.

While shown and described as an upright vacuum cleaner, it is also possible for aspects to include a robot (autonomous) vacuum cleaner configured to dock within a storage tray.FIG.29is a schematic view of an autonomous vacuum cleaner2010. The autonomous vacuum cleaner2010has been illustrated as a robotic vacuum cleaner that mounts the components various functional systems of the vacuum cleaner in an autonomously moveable unit or housing2012, including components of a vacuum collection system for generating a working air flow for removing dirt (including dust, hair, and other debris) from the surface to be cleaned and storing the dirt in a collection space on the vacuum cleaner, and a drive system for autonomously moving the vacuum cleaner over the surface to be cleaned. While not illustrated, the autonomous floor cleaner2010could be provided with additional functional systems, such as a navigation system for guiding the movement of the vacuum cleaner over the surface to be cleaned, a mapping system for generating and storing maps of the surface to be cleaned and recording status or other environmental variable information, and/or a dispensing system for applying a treating agent stored on the vacuum cleaner to the surface to be cleaned. The autonomous or robotic vacuum cleaner can have similar properties to the autonomous or robotic vacuum cleaner described in U.S. Patent Application Publication No. 2018/0078106, published Mar. 22, 2018, now U.S. Pat. No. 10,595,694, and incorporated herein by reference

The vacuum collection system can include a working air path through the unit having an air inlet and an air outlet, a suction nozzle2014, a suction source2016in fluid communication with the suction nozzle2014for generating a working air stream, and a dirt bin2018for collecting dirt from the working airstream for later disposal. The suction nozzle2014can define the air inlet of the working air path. The suction source2016can be a motor/fan assembly carried by the unit2012, fluidly upstream of the air outlet, and can define a portion of the working air path. The dirt bin2018can also define a portion of the working air path, and include a dirt bin inlet in fluid communication with the air inlet. A separator2020can be formed in a portion of the dirt bin2018for separating fluid and entrained dirt from the working airstream. Some non-limiting examples of the separator include a cyclone separator, a filter screen, a foam filter, a HEPA filter, a filter bag, or combinations thereof. The suction source2016can be electrically coupled to a power source, such as a rechargeable battery2022. In one example, the rechargeable battery2022can be a lithium ion battery. A user interface2024having at least a suction power switch2026between the suction source2016and the rechargeable battery2022can be selectively closed by the user, thereby activating the suction source2016.

Charging contacts (not shown) for the rechargeable battery2022can be provided on the main housing2012. The charging contacts can be provided within a DC jack2934. The DC jack2934can include a DC jack socket2936and a DC jack cover2940to shield the charging contacts in the DC jack2934.

A controller2028is operably coupled with the various systems of the autonomous vacuum cleaner2010for controlling its operation. The controller2028is operably coupled with the user interface2024for receiving inputs from a user. The controller2028can further be operably coupled with various sensors2032,2034,2056,2108for receiving input about the environment and can use the sensor input to control the operation of the autonomous vacuum cleaner2010.

The controller2028can, for example, be operably coupled with the drive system for directing the autonomous movement of the vacuum cleaner over the surface to be cleaned. The drive system can include drive wheels2030for driving the unit across a surface to be cleaned. The sensors2032,2034and drive system are described in more detail below.

With reference toFIGS.29-31, the autonomous vacuum cleaner2010can include a brush chamber2036at a front of the autonomous unit2012in which an agitator such as a brushroll2038is mounted. As used herein, “front” or “forward” and variations thereof are defined relative to the direction of forward travel of the autonomous vacuum cleaner2010, unless otherwise specified. The brushroll2038is mounted for rotation about a substantially horizontal axis X, relative to the surface over which the unit2012moves. A sole plate2050can at least partially retain the brushroll2038in the brush chamber2036, and has an inlet opening defining the suction nozzle2014. A wiper blade2044can be provided adjacent a trailing edge of the suction nozzle2014, behind the brushroll2038in order to aid in dust collection. The wiper blade2044is an elongated blade that generally spans the width of the suction nozzle2014, and can be supported by the sole plate2050.

The brushroll2038is mounted at the front of the vacuum cleaner2010, whereas brushrolls on most autonomous vacuum cleaners are mounted near middle of housing and hidden under an opaque plastic housing. The housing2012of the illustrated surface cleaning apparatus10can be configured to accommodate the brushroll2038in the forward location, such as by having an overall “D-shape” when viewed from above, with the housing2012having a straight front edge2040and a rounded rear edge2042.

An agitator drive assembly2046including a separate, dedicated agitator drive motor2048can be provided within the unit2012to drive the brushroll2038and can include a drive belt (not shown) that operably connects a motor shaft of the agitator drive motor2048with the brushroll2038for transmitting rotational motion of the motor shaft to the brushroll2038. Alternatively, the brushroll2038can be driven by the suction source2016.

Due to the D-shaped housing2012and position of the brushroll2038at the front of the housing2012, the brushroll2038can be larger than brushrolls found on conventional autonomous vacuum cleaners. In one example, the brushroll2038can be a “full-size” brushroll that is typically found an upright vacuum cleaner. For example, a brushroll as described in U.S. Patent Application Publication No. 2016/0166052, now U.S. Pat. No. 9,983,779, published Jun. 16, 2016, is suitable for use on the autonomous vacuum cleaner2010shown. The brushroll2038can also be removable from the unit2012for cleaning and/or replacement.

The brushroll2038can have a diameter that is approximately 8× larger and a length that is approximately 2× larger than for a brushroll found in conventional autonomous vacuum cleaners. The brushroll2038can have a diameter of 48 mm and a length of 260.5 mm.

FIG.32illustrates a storage tray2900for receiving the autonomous vacuum cleaner2010for charging the autonomous vacuum cleaner2010. The storage tray2900is similar to the storage tray900; therefore, like parts will be identified with like numerals increased by 2000, with it being understood that the description of the like parts of the storage tray900applies to storage tray2900, unless otherwise noted.

The storage tray2900differs from the storage tray900with respect to the charging unit2920. The charging unit2920is located and configured to charge the autonomous vacuum cleaner2010. The charging unit2920can be provided with charging contacts within the charger plug (not shown) that correspond, or mate with, the charging contacts on the rechargeable battery2022for the autonomous vacuum cleaner2010in the same manner than the charging unit920can charge the battery22on the surface cleaning apparatus10. For example, the ramp2952on the plug cover2948on charging unit2920can be moved to expose the charger plug when the autonomous vacuum cleaner2010is docked in the storage tray2900. At the same time, the DC jack cover2940on the rechargeable battery2022can be moved to expose the charging contacts on the DC jack2934such that the rechargeable battery2022and the storage tray2900can be electrically coupled. The brushroll2038can be received in the self-cleaning reservoir2926in order to be cleaned as previously described for the storage tray900and the surface cleaning apparatus10.

Benefits of aspects described herein can include shielded contacts, i.e. mechanically-actuated retractable covers or shields that are configured to cover electrical contacts on the charging tray and the cleaning apparatus when the cleaning apparatus is not docked on the storage tray. In the illustrated examples, the DC jack cover and the tray cover are both spring-biased to normally block access to the electrical contacts when the vacuum cleaner, or unit, is not docked on the storage tray900. The plug cover948and the DC jack cover940prevent liquid from contacting the charging contacts942on the surface cleaning apparatus10and the charger plug946on the storage tray900. This also prevents user contact with the charging contacts.

FIG.33illustrates a cleaning apparatus3010according to another aspect of the present disclosure and which similar to the earlier described apparatus with it being understood that the description of the like parts applies unless otherwise noted.

As illustrated herein, the surface cleaning apparatus3010can be an upright multi-surface wet vacuum cleaner having a housing that includes an upright handle assembly or body3012and a cleaning head or base3014mounted to or coupled with the upright body3012and adapted for movement across a surface to be cleaned. The upright body3012can include a handle3016and a frame3018. The frame3018can include a main support section supporting at least a supply tank3020and a recovery tank3022, and may further support additional components of the body3012. The surface cleaning apparatus3010can include a fluid delivery or supply pathway, including and at least partially defined by the supply tank3020, 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 tank3022, for removing the spent cleaning fluid and debris from the surf ace to be cleaned and storing the spent cleaning fluid and debris until emptied by the user.

The handle3016can include a hand grip3026and a trigger3028mounted to the hand grip3026, which controls fluid delivery from the supply tank3020via an electronic or mechanical coupling with the tank3020. The trigger3028can project at least partially exteriorly of the hand grip3026for user access. A spring (not shown) can bias the trigger3028outwardly from the hand grip3026. Other actuators, such as a thumb switch, can be provided instead of the trigger3028.

The surface cleaning apparatus3010can include at least one user interface3030,3032through which a user can interact with the surface cleaning apparatus3010. The user interface3030can enable operation and control of the apparatus3010from the user's end, and can also provide feedback information from the apparatus3010to the user. The user interface3030,3032can be electrically coupled with electrical components, including, but not limited to, circuitry electrically connected to various components of the fluid delivery and recovery systems of the surface cleaning apparatus3010, as described in further detail below.

In the illustrated aspect, the surface cleaning apparatus3010includes a human-machine interface (HMI)3030having one or more input controls, such as but not limited to buttons, triggers, toggles, keys, switches, or the like, operably connected to systems in the apparatus3010to affect and control its operation. The surface cleaning apparatus IO also includes a status user interface (SUI)3032which communicates a condition or status of the apparatus3010to the user. The SUI3032can communicate visually and/or audibly, and can optionally include one or more input controls. The HMI3030and the SUI3032can be provided as separate interfaces or can be integrated with each other, such as in a composite use interface, graphical user interface, or multimedia user interface. As shown, the HMI3030can be provided at a front side of the hand grip3026, with the trigger3028provided on a rear side of the hand grip3026, opposite the HMI3030, and the SUI3032can be provided on a front side of the frame3018, below the handle3016and above the base3014, and optionally above the recovery tank3022. In other aspects, the HMI3030and SUI3032can be provided elsewhere on the surface cleaning apparatus3010.

A moveable joint assembly3042can be formed at a lower end of the frame3018and moveably mounts the base3014to the upright body3012. The joint assembly3042can alternatively include a universal joint, such that the upright body3012can pivot about at least two axes relative to the base3014. Wiring and/or conduits can optionally supply electricity, air and/or liquid (or other fluids) between the base3014and the upright body3012, or vice versa, and can extend though the joint assembly3042. The supply and recovery tanks3020,3022can be provided on the upright body3012. The supply tank3020can be mounted to the frame3018in any configuration. In the present aspect, the supply tank3020can be removably mounted at the rear of the frame3018such that the supply tank3020partially rests in the upper rear portion of the frame3018and is removable from the frame3018for filling. The recovery tank3022can be mounted to the frame3018in any configuration. In the present aspect, the recovery tank3022can be removably mounted at the front of the frame3018, below the supply tank3020, and is removable from the frame3018for emptying.

The fluid delivery system is configured to deliver cleaning fluid from the supply tank3020to a surface to be cleaned, and can include, as briefly discussed above, a fluid delivery or supply pathway. The cleaning fluid can include 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 fluid can include a mixture of water and concentrated detergent.

As better illustrated inFIG.34, the supply tank3020includes at least one supply chamber3046for holding cleaning fluid and a supply valve assembly3048controlling fluid flow through an outlet of the supply chamber3046. Alternatively, supply tank3020can include multiple supply chambers, such as one chamber containing water and another chamber containing a cleaning agent. For a removable supply tank3020, the supply valve assembly3048can mate with a receiving assembly on the frame3018and can be configured to automatically open when the supply tank3020is seated on the frame3018to release fluid to the fluid delivery pathway.

The recovery system is configured to remove spent cleaning fluid and debris from the surface to be cleaned and store the spent cleaning fluid and debris on the surface cleaning apparatus3010for later disposal, and can include, as briefly discussed above, a recovery pathway. The recovery pathway can include at least a dirty inlet3050and a clean air outlet3052(FIG.33). The pathway can be formed by, among other elements, a suction nozzle3054defining the dirty inlet, a suction source3056in fluid communication with the suction nozzle3054for generating a working air stream, the recovery tank3022, and at least one exhaust vent defining the clean air outlet3052.

The suction nozzle3054can be provided on the base3014and can be adapted to be adjacent the surface to be cleaned as the base3014moves across a surface. A brushroll3060can be provided adjacent to the suction nozzle3054for agitating the surface to be cleaned so that the debris is more easily ingested into the suction nozzle3054. While a horizontally-rotating brushroll3060is shown herein, in some aspects, dual horizontally-rotating brushrolls, one or more vertically-rotating brushrolls, or a stationary brush can be provided on the apparatus3010.

The suction nozzle3054is further in fluid communication with the recovery tank3022through a conduit3062. The conduit3062can pass through the joint assembly3042and can be flexible to accommodate the movement of the joint assembly3042.

The suction source3056, which can be a motor/fan assembly including a vacuum motor3064and a fan3066, is provided in fluid communication with the recovery tank3022. The suction source3056can be positioned within a housing of the frame3018, such as above the recovery tank3022and forwardly of the supply tank3020. The recovery system can also be provided with one or more additional filters upstream or downstream of the suction source3056. For example, in the illustrated aspect, a pre-motor filter3068is provided in the recovery pathway downstream of the recovery tank3022and upstream of the suction source3056. A post-motor filter (not shown) can be provided in the recovery pathway downstream of the suction source3056and upstream of the clean air outlet3052.

The base3014can include a base housing3070supporting at least some of the components of the fluid delivery system and fluid recovery system, and a pair of wheels3072for moving the apparatus3010over the surface to be cleaned. The wheels3072can be provided on a rearward portion of the base housing3070, rearward of components such as the brushroll3060and suction nozzle3054. A second pair of wheels3074can be provided on the base housing3070, forward of the first pair of wheels3072.

Electrical components of the surface cleaning apparatus3010, including the vacuum motor3064, the pump3094, and the brush motor3096for the brushroll3060, can be electrically coupled to a power source such as a battery3372or a power cord plugged into a household outlet. In the illustrated aspect, the power source includes a rechargeable battery3372.

In one example, the battery3372can be a lithium ion battery. In another exemplary arrangement, the battery3372can include a user replaceable battery. As discussed above, the power input control3034which controls the supply of power to one or more electrical components of the apparatus3010, and in the illustrated aspect controls the supply of power to at least the SUI3032, the vacuum motor3064, the pump3094, and the brush motor3096. The cleaning mode input control3036cycles the apparatus3010between a hard floor cleaning mode and a carpet cleaning mode. In one example of the hard floor cleaning mode, the vacuum motor3064, the pump3094, and the brush motor3096are activated, with the pump3094operating at a first flow rate. In the carpet cleaning mode, the vacuum motor3064, the pump3094, and the brush motor3096are activated, with the pump3094operating at a second flow rate which is greater than the first flow rate. The self-cleaning mode input control3040initiates a self-cleaning mode of operation, one aspect of which is described in detail below. Briefly, during the self-cleaning mode a cleanout cycle can run in which cleaning liquid is sprayed on the brushroll3060while the brushroll3060rotates. Liquid is extracted and deposited into the recovery tank3022, thereby also flushing out a portion of the recovery pathway.

With reference toFIG.34, the controller3308can be provided at various locations on the apparatus3010, and in the illustrated aspect is located in the upright body3012, within the frame3018, and is integrated with the SUI3032. Alternatively, the controller3308can be integrated with the HMI3030(FIG.33), or can be separate from both the HMI3030and SUI3032.

The battery3372can be located within a battery housing3374located on the upright body3012or base3014of the apparatus, which can protect and retain the battery3372on the apparatus3010. In the illustrated aspect, the battery housing3374is provided on the frame3018of the upright body3012. Optionally, the battery housing3374can be located below the supply tank3020and/or rearwardly of the recovery tank3022.

Referring toFIG.35, the surface cleaning apparatus3010can optionally be provided with a storage tray3380that can be used when storing the apparatus3010. The storage tray3380can be configured to receive the base3014of the apparatus3010in an upright, stored position. The storage tray3380can further be configured for further functionality beyond simple storage, such as for charging the apparatus3010and/or for self-cleaning of the apparatus3010.

Referring toFIG.36, the storage tray3380functions as a docking station for recharging the battery3372of the apparatus3010. The storage tray3380can optionally have at least one charging contact3382, and at least one corresponding charging contact3384can be provided on the apparatus3010, such as on the exterior of the battery housing3374. When operation has ceased, the apparatus3010can be locked upright and placed into the storage tray3380for recharging the battery3372. When the apparatus3010is removed from the storage tray3380, one or both of the charging contacts3382,3384can be shielded, as described in further detail below.

A charging unit3386is provided on the storage tray3380and includes the charging contacts3382. The charging unit3386can electrically couple with the battery3372when the base3014of the apparatus3010is docked with the storage tray3380. The charging unit3386can be electrically coupled to a power source including, but not limited to, a household outlet. In one example, a cord388can be coupled with the charging unit3386to connect the storage tray3380to the power source. The battery housing3374and the charging unit3386of the storage tray3380can possess complementary shapes, with the battery housing3374fitting against the charging unit3386to help support the apparatus3010on the storage tray3380. In the illustrated aspect, the battery housing3374can include a socket3390containing the charging contacts3384and the charging unit3386can be at least partially received by the socket3390when the apparatus3010is docked with the tray3380.

FIG.37is a rear perspective view of a lower portion of the upright body3012showing a cross-section through the charging contact3384of the battery3372. A contact casing3392can extend downwardly within the socket3390, and includes the charging contact3384, which is illustrated as DC connector or socket. The charging contact3384or socket can be normally covered, or closed, by a retractable charging contact cover3394, also referred to herein as battery-side cover.

The battery-side cover3394can be slidably mounted to or within the casing3392and can be biased to the normally covered position by a spring3396. When the battery-side cover3394is in the closed position, the battery-side cover3394shields the charging contact3384such that liquid cannot enter the charging contact3384or casing3392.

The battery-side cover3394can include a ramp3398against which a portion of the storage tray3380presses to move the cover3394to uncover the charging contact3384against the biasing force of the spring3396. It is noted that while a ramp3398is shown, the apparatus3010can include any suitable mating feature configurable to move the cover3394upon docking, such as a cam or a rack and pinion gear, for example. Alternatively, a linear actuator can be incorporated to move the cover3394to the open position upon docking.

Referring toFIG.38, the charging contact3382of the charging unit3386, which is illustrated as DC connector or plug, can be normally covered, or closed, by a retractable charging contact cover3400, also referred to herein as tray-side cover. A bracket3402can be provided in the charging unit to mount the charging contact or plug3382and the cover3400. The tray-side cover can be biased to the normally covered position by springs3404,3406, which bias the cover3400rearwardly and upwardly. When the tray-side cover3400is in the closed position, the tray-side cover3400shields the charging contact3382such that liquid cannot enter the charging contact3382or charging unit3386.

The tray-side cover3400can include a ramp3408against which a portion of the apparatus3010presses to move the cover3400to uncover the charging contact3382against the biasing force of the springs3404,3406. It is noted that while a ramp3408is shown, the apparatus3010can include any suitable mating feature configurable to move the cover3400upon docking, such as a cam or a rack and pinion gear, for example. Alternatively, a linear actuator can be incorporated to move the cover3400to the open position upon docking.

Docking the apparatus3010with the storage tray3380can automatically move the covers3394,3400to an uncovered or open position, an example of which is shown inFIGS.39-41, in which the charging contacts3382,3384can be coupled, i.e. by the socket3384receiving the plug382. In one aspect, in order to dock the apparatus3010within the storage tray3380for charging, the apparatus3010is lowered into the storage tray3380as shown inFIG.39and the casing3392pushes against the ramp3408on the tray-side cover3400, sliding the cover3400forwardly to expose the charging contact or plug3382. As the apparatus3010continues to be lowered onto the storage tray3380, the exposed plug3382presses against the ramp3398on the battery-side cover3394, as shown inFIG.40, sliding the cover3394laterally to expose the charging contact or socket3384. Continued lowering of the apparatus3010plugs the plug3382into the socket3384, as shown inFIG.41. The charging plug3382on the storage tray3380and socket3384on the apparatus3010become fully engaged, or electrically connected, when the apparatus3010is fully seated on the storage tray3380.

Referring back toFIGS.35-37, during use, the apparatus3010can get very dirty, particularly in the brush chamber and extraction pathway, and can be difficult for the user to clean. The storage tray3380can function as a cleaning tray during a self-cleaning mode of the apparatus3010, which can be used to clean the brushroll3060and internal components of the fluid recovery pathway of apparatus3010. Self-cleaning using the storage tray3380can save the user considerable time and may lead to more frequent use of the apparatus3010. The storage tray3380can optionally be adapted to contain a liquid for the purposes of cleaning the interior parts of apparatus3010and/or receiving liquid that may leak from the supply tank3020while the apparatus10is not in active operation. When operation has ceased, the apparatus3010can be locked upright and placed into the storage tray3380for cleaning. The apparatus3010is prepared for self-cleaning by filling the storage tray3380to a predesignated fill level with a cleaning liquid, such as water. The user can select the self-cleaning mode via the input control3040(FIG.33).

In one example, during the self-cleaning mode, the vacuum motor3064and brush motor3096are activated, which draws cleaning liquid in the storage tray3380into the fluid recovery pathway. The self-cleaning mode can be configured to last for a predetermined amount of time or until the cleaning liquid in storage tray3380has been depleted. Example of self-cleaning cycles and storage trays are disclosed in U.S. patent application Ser. No. 15/994,040, filed May 31, 2018, now Published as US2018/0344112, which is incorporated herein by reference in its entirety.

The tray3380can physically support the entire apparatus3010. More specifically, the base3014can be seated in the tray3380. The tray3380can have a recessed portion in the form of a sump3410in register with at least one of the suction nozzle3054or brushroll3060. Optionally, the sump3410can sealingly receive the suction nozzle3054and brushroll3060, such as by sealingly receiving the brush chamber3104. The sump3410can fluidly isolate, or seal, the suction nozzle3054and fluid distributor (not shown) within the brush chamber3104to create a closed loop between the fluid delivery and fluid extraction systems of the apparatus3010. The sump3410can collect excess liquid for eventual extraction by the suction nozzle3054. This also serves to flush out a recovery pathway between the suction nozzle3054and the recovery tank3022.

FIG.42is a perspective view of the storage tray3380. The tray3380can include guide walls3412extending upwardly and configured to align the base3014(FIG.36) within the tray3380. A rear portion of the tray3380can include wheel holders3414for receiving the rear wheels3072of the apparatus3010. The wheel holders3414can be formed as a recess, or groove in the storage tray3380, and can be provided on opposite lateral sides of the charging unit3386.

Optionally the storage tray3380can include a removable accessory holder3416for storing one or more accessories for the apparatus3010. The accessory holder3416can be provided on an exterior side wall of the tray3380, and can be removably mounted to the tray3380. The tray380can optionally be provided with a mounting location on either lateral side of the tray3380to allow the user some flexibility in where the accessory holder3416is attached.FIG.42includes an accessory holder3416in phantom line showing one optional alternative mounting location. The mounting locations can include a retention latch, sliding lock, clamp, brace, or any other mechanism in which to secure accessory holder3416on the storage tray3380Alternatively, storage tray3380can be configured with a non-removable or integral accessory holder3416.

The illustrated accessory holder3416can removably receive one or more brushrolls3060and/or one of more filters3276for the purposes of storage and/or drying. Accessory holder3416can include one or more brushroll slots3418to securely receive brushrolls3060in a vertical fixed position for drying and storage. Brushroll slots3418can be fixed or adjustable and include clamps, rods, or molded receiving positions that can accommodate brushroll3060with or without the dowel3110inserted. Accessory holder3416can include at least one filter slot3420to securely receive filter3276in a vertical fixed position for drying and storage. Alternatively, accessory holder3416can store the brushrolls3060and filter3276in a variety of other positions.

FIG.43is a block diagram for the apparatus3010, showing a condition when the apparatus3010is docked with the storage tray3380for recharging. The apparatus3010includes a battery charging circuit3430that controls recharging of the battery3372. When the apparatus3010is docked with the storage tray3380the battery charging circuit3430is active and the battery3372is charged. In at least some aspects of the storage tray3380, the tray3380includes power cord388plugged into a household outlet, such as by a wall charger3432having, for example an operating power of 35 W. However, during a self-cleaning cycle during which the vacuum motor3064, pump3094, and brush motor3096are all energized, the required power draw can far exceed the operating power of the wall charger. In one example, the required power draw for the vacuum motor3064, pump3094, and brush motor3096can be 200-250 W. The apparatus3010can include a battery monitoring circuit3432for monitoring the status of the battery3372and individual battery cells contained therein. Feedback from the battery monitoring circuit3432is used by the controller3308to optimize the discharging and recharging process, as well as for displaying battery charge status on the SUI3032.

Referring toFIG.44, the block diagram shows a condition when the apparatus3010is docked with the storage tray3380in the self-cleaning mode. Depressing the self-cleaning mode input control3040disables or shuts off the battery charging circuit3430, and allows the apparatus3010to energize and be powered by the onboard battery3472. The apparatus3010then automatically cycles through the self-cleaning mode, and during this cycle the battery charging circuit3430remains disabled, i.e. the battery3372does not recharge during the self-cleaning mode. This operational behavior is beneficial because if the battery charging circuit3430is not disabled and power not supplied by the battery3472during the self-cleaning mode, a much higher capacity and more expensive wall charger is required to power the apparatus during the self-cleaning mode.

FIG.45depicts one aspect of the disclosure of a self-cleaning method3440for the apparatus3010using the storage tray3380. In use, a user at3442docks the apparatus3010with the storage tray3380. The docking may include parking the base3014on the cleaning tray3380and creating a sealed cleaning pathway between the brush chamber3104and the suction nozzle3054.

At step3444, the charging circuit3430is enabled when the apparatus3010is docked with the tray3380and the charging contacts3382,3384couple. When the charging circuit3430is enabled, the battery3372may begin being recharged.

At step3446, the self-cleaning cycle is initiated, with the user initiating the cycle by pressing the self-cleaning mode input control3040on the SUI3032. The self-cleaning cycle may be locked-out by the controller3308when the apparatus3010is not docked with the storage tray3380to prevent inadvertent initiation of the self-cleaning cycle.

At step3448, upon initiation of the self-cleaning cycle, such as upon the user pressing the self-cleaning mode input control3040, the charging circuit3430is disabled, i.e. the battery3372ceases to recharge.

Pressing the input control3040at step3446can energize one or more components of the apparatus3010that are powered by the onboard battery3472. The self-cleaning cycle may begin at step3450in which the pump3094is active to deliver cleaning solution from the supply tank3020to the distributor (not shown) that sprays the brushroll3060. During step3450, the brush motor3096can also activate to rotate the brushroll3060at while applying cleaning fluid to the brushroll3060to flush the brush chamber3104and cleaning lines, and wash debris from the brushroll3060. The self-cleaning cycle may use the same cleaning fluid normally used by the apparatus3010for surface cleaning, or may use a different detergent focused on cleaning the recovery system of the apparatus3010.

The vacuum motor can be actuated during or after step3450to extract the cleaning fluid via the suction nozzle3054. During extraction, the cleaning fluid and debris from the sump3410in the tray3380is sucked through the suction nozzle3054and the downstream fluid recovery path. The flushing action also cleans the entire fluid recovery path of the apparatus3010, including the suction nozzle3054and downstream conduits.

At step3452, the self-cleaning cycle ends. The end of the self-cleaning cycle can be time-dependent, or can continue until the recovery tank3022is full or the supply tank3020is empty. For a timed self-cleaning cycle, the pump3094, brush motor3096, and vacuum motor3064are energized and de-energized for predetermined periods of time. Optionally, the pump3094or brush motor3096can pulse on/off intermittently so that any debris is flushed off of the brushroll3060and extracted into the recovery tank3022. Optionally, the brushroll3060can be rotated at slower or faster speeds to facilitate more effective wetting, shedding of debris, and/or spin drying. Near the end of the cycle, the pump3094can de-energize to end fluid dispensing while the brush motor3096and vacuum motor3064can remain energized to continue extraction. This is to ensure that any liquid remaining in the sump3410, on the brushroll3060, or in the fluid recovery path is completely extracted into the recovery tank3022. After the end of the self-cleaning cycle, the changing circuit3430is enabled to continue to recharging the battery3472at step3454.

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 vacuum cleaner is illustrated herein as having all of these features does not mean that all of these features must be used in combination, but rather done so here for brevity of description. Furthermore, while the surface cleaning apparatus10shown herein has an upright configuration, the vacuum cleaner can be configured as a canister or portable unit. For example, in a canister arrangement, foot components such as the suction nozzle assembly580and brushroll can be provided on a cleaning head coupled with a canister unit. Still further, the vacuum cleaner can additionally have steam delivery capability. 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.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible with the scope of the foregoing disclosure and drawings without departing from the spirit of the invention which, is defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.