FLOOR CLEANER AND STEAM CLEANING APPARATUS FOR A FLOOR CLEANER

BACKGROUND

The present disclosure relates to a floor cleaner, and more particularly to a floor cleaner with a cleaning apparatus such as a cleaning tray.

SUMMARY

In one embodiment, a cleaning apparatus for a floor cleaner is disclosed. The floor cleaner may have a base that is movable along a surface to be cleaned, an upright portion movable relative to the base between an inclined use position and an upright storage position, a supply tank configured to store cleaning fluid, a fluid distributer in fluid communication with the supply tank, a brushroll motor, and a brushroll rotatable relative to the base by the brushroll motor. The cleaning apparatus may comprise a tray configured to removably receive the base of the floor cleaner. The tray may include a brushroll-receiving portion configured to receive the brushroll of the floor cleaner. The cleaning apparatus may further comprise a reservoir configured to store liquid; a boiler in fluid communication with the reservoir, the boiler configured to convert the liquid into steam; and a steam opening configured to dispense the steam onto the brushroll to sanitize the brushroll.

In another embodiment, a combination of a floor cleaner and a cleaning apparatus for cleaning the floor cleaner is disclosed. The floor cleaner may include a base movable along a surface to be cleaned, an upright portion movable relative to the base between an inclined use position and an upright storage position, a supply tank configured to store cleaning fluid, a fluid distributer in fluid communication with the supply tank, a brushroll motor, and a brushroll rotatable relative to the base by the brushroll motor. The cleaning apparatus may include a tray that removably receives a portion of the base of the floor cleaner. The tray may include a brushroll-receiving portion to receive the brushroll of the floor cleaner. The cleaning apparatus may further include a reservoir configured to store liquid; a boiler in fluid communication with the reservoir, the boiler configured to convert the liquid into steam; and a steam opening configured to dispense the steam onto the brushroll to sanitize the brushroll.

In another embodiment, a method of cleaning a floor cleaner by using a cleaning apparatus having a tray is disclosed, the cleaning occurring when the floor cleaner is in a mounted position in the tray. The method may further include storing a supply of liquid in a reservoir on the cleaning apparatus, boiling the liquid to generate steam, and dispensing the steam through a steam opening in the cleaning apparatus to a brushroll of the floor cleaner to sanitize the brushroll.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a floor cleaner in a mounted position in a cleaning apparatus according to an embodiment.

FIG. 2 is an exploded view of the floor cleaner and the cleaning apparatus of FIG. 1.

FIG. 3 is an upper perspective view of the cleaning apparatus of FIG. 1.

FIG. 4 is a lower perspective view of the cleaning apparatus of FIG. 1.

FIG. 5 is a cross-section of the floor cleaner in the mounted position in the cleaning apparatus of FIG. 1 along the line A-A.

FIG. 6 is a cross-section of a floor cleaner in a mounted position in a cleaning apparatus according to another embodiment.

FIG. 7 is an upper perspective view of the cleaning apparatus of FIG. 1 showing a steam opening.

FIG. 8 is an upper perspective view of a cleaning apparatus according to another embodiment showing a plurality of steam openings.

FIG. 9 is an upper perspective view of a cleaning apparatus according to another embodiment showing a plurality of steam openings.

FIG. 10 is a plan view of a steam distributor for use with the cleaning apparatus of FIG. 1 according to an embodiment.

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and softwarebased devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components.

DETAILED DESCRIPTION

FIG. 1 illustrates a floor cleaner 10 positioned in a cleaning apparatus 28 that is formed as a cleaning tray in the illustrated embodiment. After a surface or floor cleaning operation of the floor cleaner 10, the floor cleaner can be placed in the cleaning apparatus 28 to clean a brushroll 26 (FIG. 2) of the floor cleaner 10 and/or other portions of the floor cleaner 10. The cleaning apparatus 28 includes a steam distributor configured to dispense steam onto the floor cleaner 10 to contribute to cleaning or sanitizing of the floor cleaner 10.

In the illustrated embodiment, the floor cleaner 10 includes a base 12 and an upright portion 14 pivotally coupled to the base 12. The floor cleaner 10 includes wheels 15 rotatably attached to the base 12 for moving the base 12 over a floor surface. With reference to FIGS. 1 and 5, the floor cleaner 10 includes at least one brushroll 26 that is rotatable with respect to the base 12 and that is arranged in the base 12. A brushroll motor 46 is disposed in the floor cleaner 10 operably connected to the brushroll 26 configured to rotate the brushroll 26, such as by a belt, a gear drive, or another brushroll drive. The upright portion 14 is movable and, more specifically, pivotal relative to the base 12 between an upright storage position (FIG. 1) in which the upright portion 14 is maintained in an upright position by the base 12 and an inclined use position in which the upright portion 14 is tilted rearwardly with respect to the upright storage position. In the illustrated embodiment, the floor cleaner 10 includes a supply tank 16, a recovery tank 18, and a suction motor 20. The supply tank 16 is configured to store a cleaning fluid such as water or a cleaning solution. The floor cleaner 10 is operable to dispense the cleaning fluid onto a surface to be cleaned through a fluid distributor 56. The fluid distributor 56 may include a pump 34 and/or a valve 38 operably connected to the supply tank 16 and configured to control the dispensation of the cleaning fluid from the supply tank 16 during operation. The fluid distributor 56 further includes a distribution nozzle 32 and/or an auxiliary fluid outlet 36 through which the cleaning fluid may be dispensed. The base 12 further includes a suction inlet 30 in fluid communication with the recovery tank 18 and the suction motor 20 operable to draw air and dispensed cleaning fluid into the suction inlet 30. The cleaning fluid is drawn from the surface to be cleaned through the suction inlet 30 and into the recovery tank 18 during operation of the floor cleaner. In one embodiment, the suction motor 20 also drives the brushroll 26 such that the brushroll motor 46 is the suction motor 20.

With continued reference to FIG. 1 and with reference to FIG. 2, the cleaning apparatus 28 is configured for the base 12 to be placed in the cleaning apparatus 28 for cleaning and/or storage of the floor cleaner 10. The cleaning apparatus 28 forms a tray 54 configured to receive cleaning fluid as well as to receive at least a portion of the base 12 of the floor cleaner 10 when the base 12 is placed in the cleaning apparatus 28. The cleaning apparatus 28 receives the floor cleaner 10 in a mounted position when the floor cleaner 10 or a portion of the floor cleaner 10 is operably connected to the cleaning apparatus 28 (for example, the base 12 or a portion of the base 12 is placed on or in the tray 54) for cleaning or storage or another operation.

With reference to FIG. 3, the cleaning apparatus 28 may further include wheel-receiving portions 58a, 58b that are spaced from one another and configured to receive the wheels 15 of the floor cleaner 10 when the floor cleaner 10 is in the cleaning apparatus 28. The wheel-receiving portions 58a, 58b may define a wheel-receiving axis A1 passing through a center, and in some embodiments a center of curvature, of the wheel-receiving portions 58a, 58b. The cleaning apparatus 28 includes a brushroll-receiving portion 62 configured to receive the brushroll 26 when the floor cleaner 10 is in the cleaning apparatus 28. The brushroll-receiving portion 62 includes a lower portion 66 configured to accommodate the brushroll 26 when the brushroll 26 is positioned in the tray 54. In the illustrated embodiment the lower portion 66 includes a concave portion configured to match the brushroll shape, such as a convex portion 122 of the brushroll 26 (described herein with reference to FIG. 5); however, the lower portion 66 may be a flat surface or any other shaped surface as desired. The brushroll-receiving portion 62 defines a longitudinal axis A2 of the brushroll-receiving portion 62 passing through a location of the brushroll 26 when the brushroll 26 is positioned in the tray 54. The brushroll-receiving portion 62 is positioned corresponding to the position of the brushroll 26 when the floor cleaner 10 is in the cleaning apparatus 28, which in the illustrated embodiment is on an opposite side of the cleaning apparatus 28 from the wheel-receiving portions 58a, 58b. In the illustrated embodiment, the longitudinal axis A2 of the brushroll-receiving portion 62 is parallel to or generally parallel to the wheel-receiving axis A1.

The cleaning apparatus includes a steam generator 68 including a reservoir 70 that provides liquid to a boiler 98 through the pump 94 or a valve. With continued reference to FIG. 3, the reservoir 70 is removably mounted in a reservoir-receiving portion 74 (FIG. 2) of the cleaning apparatus 28. The reservoir 70 is configured to store and selectively deliver a supply of liquid, such as water or other cleaning solution. The reservoir 70 includes a fill opening 78 and a discharge opening 82. The reservoir 70 may be removable from the cleaning apparatus 28, and more specifically from the tray 54, and even more specifically from the reservoir-receiving portion 74, for operations such as, for example, emptying, filling, cleaning, or replacing the reservoir 70. In some embodiments, the reservoir 70 is not removable from the cleaning apparatus 28 and is configured for a user to fill in-place. The cleaning apparatus 28 may include a wall system 86 at a border of the tray 54 to, among other things, collect liquid and inhibit liquid from leaving the tray 54 except in a controlled manner (for example, through a suction system of the floor cleaner 10 or through a drain, or by a user pouring the liquid out).

With reference to FIG. 4, the discharge opening 82 of the reservoir 70 is connected by a tubing system 90 to the pump 94 and the boiler 98. The pump 94 is operably positioned between the reservoir 70 and the boiler 98, configured to selectively deliver the liquid from the reservoir 70 to the boiler 98. In some embodiments, the pump 94 can be replaced by a valve and the liquid may be gravity-fed through the valve from the reservoir 70 to the boiler 98. The boiler 98 includes a heating element or other means for heating the liquid to convert the liquid into steam for delivery along the tubing system 90 to a steam distributor 162 (FIGS. 5-7), 174 (FIG. 8), 194 (FIG. 9) having a steam outlet formed by one or more steam openings 102 (FIGS. 5-7), 106 (FIG. 8), 110 (FIG. 9). The distributors 162, 174, 194 may function similarly to each other except for visible and/or noted differences, and the steam openings 102, 106, 110 may also function similarly to each other. Certain characteristics may be described with reference to one embodiment that are applicable to other embodiments. As used in the present Detailed Description and in the appended Claims, “steam” includes vapor from boiled liquid having a temperature higher than the boiling point of the liquid, as well as heated vapor lower than the boiling point of the liquid.

To facilitate applying steam to the brushroll 26, the illustrated steam distributor 162, 174, 194 is disposed along the brushroll-receiving portion 62 to deliver steam onto the brushroll 26 when the floor cleaner 10 is in the cleaning apparatus 28, and more specifically to distribute steam along the length of the brushroll 26. In some embodiments, one or a plurality of the steam openings 102, 106, 110 extend along or are positioned along a portion of the brushroll-receiving portion 62 and may extend along any proportion of the length of the brushroll 26. In some embodiments, one or a plurality of the steam openings 102, 106, 110 extend along, for example, at least 50% of a length of the brushroll 26 when the brushroll 26 is positioned in the brushroll-receiving portion 62. In some embodiments, one or a plurality of the steam openings 102, 106, 110 extend along at least 80% of a length of the brushroll 26 when the brushroll 26 is positioned in the brushroll-receiving portion 62, and in some embodiments, one or a plurality of the steam openings 102, 106, 110 extend along at least 90% of a length of the brushroll 26 when the brushroll 26 is positioned in the brushroll-receiving portion 62. The distribution of the steam openings 102, 106, 110 along, for example, 80%, 90%, or 100% of the brushroll 26 accordingly dispenses steam directly onto 80%, 90%, or 100% of the brushroll 26 to reduce the amount of lateral migration of the steam along the brushroll 26 to obtain cleaning efficacy along the entire length of the brushroll 26. The steam distributor 162 includes a plenum 114 for distributing the steam to the steam openings 102, 106, 110 along a length of the brushroll-receiving portion 62. While the steam distributor 162, 174, 194 is described herein with reference to the brushroll-receiving portion 62 and brushroll 26, it will be appreciated that the cleaning apparatus 28 may be configured to direct steam onto other components or portions of the floor cleaner 10 by positioning the steam distributor with reference to the other components or portions of the floor cleaner as desired, for example an underside surface of the base 12, the suction inlet 30, the wheels 15, a nozzle, a duct, or other components or portion of the floor cleaner as desired for the cleaning application.

The cleaning apparatus 28 includes cleaning apparatus control circuitry including a printed circuit board assembly (“PCBA”) 118 (FIG. 4). The PCBA 118 may be positioned on a bottom side of the cleaning apparatus 28 or other position, and the PCBA 118 may be positioned in a location configured to inhibit water ingress. The cleaning apparatus control circuitry is configured to control operation of the cleaning apparatus 28 including, among other things, an operation of any one or combinations of the boiler 98, the pump 94, and/or a valve to control liquid flow from the reservoir 70. In some embodiments, the PCBA includes a controller. In some embodiments, the PCBA 118 is configured to operably connect to control circuitry in the floor cleaner 10 to receive one or more signals from the floor cleaner 10 representative of characteristics of, attributes of, and/or inputs from the floor cleaner 10 and send one or more signals to the floor cleaner 10 representative of characteristics of, attributes of, and/or inputs from the cleaning apparatus 28. The PCBA 118 is configured to control the cleaning apparatus 28 and/or the floor cleaner 10 based at least in part on the one or more signals received from the floor cleaner 10.

In some embodiments, the cleaning apparatus control circuitry includes a controller. The controller is electrically and/or communicatively connected to a variety of modules or components of the cleaning apparatus 28. The controller includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller and/or the cleaning apparatus 28. The controller further includes an electronic processor (for example, a microprocessor or another suitable programmable device) and memory. The memory includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (ROM) and/or random-access memory (RAM). Various non-transitory computer readable media, for example, magnetic, optical, physical, or electronic memory may be used. The electronic processor is communicatively coupled to the memory and executes software instructions that are stored in the memory, or stored on another non-transitory computer readable medium such as another memory or a disc. The software may include one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller receives a signal(s) indicative of a characteristic(s) and controls the cleaning apparatus 28 accordingly (for example, by varying a control signal). Although the controller is described as one controller, the controller could also include multiple controllers configured to work together to achieve a desired level of control for the cleaning apparatus 28. As such, any control functions and processes described herein with respect to the controller could also be performed by two or more controllers functioning in a distributed manner.

The brushroll-receiving portion 62 is configured to receive the brushroll 26 when the floor cleaner 10 is in the cleaning apparatus 28. The brushroll 26 defines a longitudinal axis A3 of rotation, shown perpendicular to or generally perpendicular to the frame of reference as illustrated in FIGS. 5 and 6. The brushroll 26 has an outer perimeter 126, and in some embodiments, the brushroll 26 is shaped as a cylinder. The brushroll 26 has a radius R1 defined from the longitudinal axis A3 of the brushroll 26 to the outer perimeter 126 of the brushroll. In some embodiments, the longitudinal axis A3 of the brushroll 26 is parallel to and/or collinear with the longitudinal axis A2 of the brushroll-receiving portion 62. The brushroll 26 includes an operational material 130 (e.g., bristles, tufted fiber pile, microfiber, woven or non-woven fabric, sponge, etc.) positioned about the outer perimeter 126 of the brushroll 26.

In the embodiment illustrated in FIG. 5, the steam distributor 162 includes a first wall 134 and a second wall 138 located on the tray 54, and more specifically adjacent the brushroll-receiving portion 62 and forming a portion of the plenum 114. In the illustrated embodiment, when the brushroll 26 is in the cleaning apparatus 28, the steam opening 102 is disposed at a dimension from the longitudinal axis A3 of the brushroll 26 that is less than R1 such that the steam opening 102 interferes with the brushroll 26 to deflect the operational material 130, for example to deflect or separate fibers or bristles of the brushroll 26, and thereby dispense steam into the brushroll 26 when the brushroll 26 is received within the brushroll-receiving portion 62 (e.g., when the base 12 is in the cleaning apparatus 28). In the illustrated embodiment, the steam opening 102 is provided adjacent the intersection of the first and second walls 134, 138. In one cleaning mode, the brushroll 26 is configured to rotate as steam is delivered from the steam distributor 162.

In some embodiments, the steam openings 102, 106, 110 of the steam distributors 162 (FIG. 7), 174 (FIG. 8), 194 (FIG. 9) are positioned offset from the brushroll 26 to not contact the brushroll 26. In other embodiments, the steam openings 102, 106, 110 are positioned to engage the brushroll 26. With continued reference to FIG. 5, in the illustrated embodiment, a first distance D1 is radially defined between the longitudinal axis A3 of the brushroll 26 and the lower portion 66 when the brushroll 26 is received by the brushroll-receiving portion 62. A second distance D2 is radially defined between the longitudinal axis A3 of the brushroll 26 and/or between the longitudinal axis A2 of the brushroll-receiving portion 62 and the steam opening 102. For example, in the illustrated embodiment, the second distance D2 is radially defined between the longitudinal axis A3 of the brushroll 26 and the steam opening 102. The second distance D2 may be less than the first distance D1. In some embodiments, the second distance D2 is less than the radius R1 from the longitudinal axis A3 of the brushroll 26 to the steam opening 102 when the brushroll 26 is received in the brushroll-receiving portion 62, the steam opening 102 configured to deliver steam inside the outer perimeter 126 of the brushroll 26. In some embodiments, the second distance D2 is between 0.5 mm and 12 mm less than the radius R1. In some embodiments, the second distance D2 is between 1 mm and 8 mm less than the radius R1. In some embodiments, the second distance D2 is between 2 mm and 6 mm less than the radius R1. In other embodiments and in addition to or in place of the walls 134, 138, projections or ribs (not shown) may be located on the distributor 162 or tray 54 to interfere with the brushroll 26 to further clean, e.g. wipe, scrape, comb and/or separate bristles or fibers of the brushroll 26 when the brushroll 26 is in the cleaning apparatus 28 and is rotated. When the second distance D2 is less than R1, the brushroll 26 engages the distributor 162 when the brushroll 26 rotates. When the operational material 130 of the brushroll 26 includes bristles or fiber, interference with the distributor 26 or projections aids in separating the fibers as the brushroll 26 rotates and steam is distributed from the steam opening 102 (or, in other embodiments, from the steam opening 106 (FIG. 8) or the steam opening 110 (FIG. 9)), exposing more of the brushroll 26 to the steam and facilitating cleaning or sanitizing of the brushroll 26. Stated another way, in some embodiments the cleaning apparatus 28 is configured to engage the brushroll 26 and expose an internal portion of the brushroll 26 to the steam openings 102, 106, 110, wherein the internal portion of the brushroll 26 includes portions of the brushroll 26 disposed at a dimension less than R1 from the rotational axis A3.

With continued reference to FIG. 5, the plenum 114 includes plenum walls 142. One or more of the plenum walls 142 may be molded into the tray 54 or otherwise integrated into the tray 54. In some embodiments, the plenum walls 142 form a plenum unit 146 that is removable from the tray 54 for purposes that may include, for example, cleaning.

With reference to FIG. 6, an embodiment of a cleaning apparatus 28 as shown in FIG. 6 may be similar to the embodiment of the cleaning apparatus 28 shown in FIG. 5 and may include a cover portion 150 that is located on or adjacent to the first wall 134 or the second wall 138. The cover portion 150 is configured to shield at least a portion of the steam openings 102, 106, 110 to inhibit an ingress of fluid and/or debris into the steam openings 102, 106, 110. In some embodiments, the cover portion 150 may be configured to interfere with the brushroll 26. The cover portion 150 may curve in a direction over the steam opening 102, 106, 110.

With reference to FIG. 7, the steam distributor 162 includes the steam opening 102 positioned along the brushroll-receiving portion 62. The steam opening 102 may be dimensioned as a slot having a major dimension 154 and a minor dimension 158. The major dimension 154 and the minor dimension 158 may be different lengths as desired to achieve the desired cleaning application. The major dimension 154 extends along the brushroll 26 when the brushroll 26 is in the brushroll-receiving portion 62. In the illustrated embodiment, the steam opening 102 extends along a majority of the brushroll-receiving portion 62. The steam opening 102 may extend along various lengths of the brushroll-receiving portion 62 as disclosed herein. In one embodiment, the steam distributor 162 includes a longitudinal ridge 160 and the steam opening 102 extends along the longitudinal ridge 160. The steam opening 102 may be positioned on the distributor 162 and in communication with the plenum 114 such that steam can pass through the plenum 114 and pass through the steam opening 102. The distributor 162 may extend along the longitudinal axis A2 (FIG. 3) of the brushroll-receiving portion 62 positioned to direct steam toward the brushroll 26 when the floor cleaner 10 is in the mounted position.

With reference to FIG. 8, in another embodiment of the cleaning apparatus 28, a plurality of steam openings 106 extend along the steam distributor 174 and adjacent the brushroll-receiving portion 62. The steam distributor 174 includes a plurality of outwardly extending segments 178 disposed along the longitudinal axis A2 and/or longitudinal axis A3. At least one of the plurality of segments 178 includes at least one of the plurality of steam openings 106. In the illustrated embodiment, each of the plurality of segments 178 includes one steam opening 106. However, in other embodiments the segments 178 and the steam openings 106 are arranged as desired to achieve the desired cleaning application. Each steam opening 106 may be dimensioned as a port, ellipse, circle, and/or jet having a major dimension 166 and a minor dimension 170. The major dimension 166 may be positioned at a right angle to the minor dimension 170. In some embodiments, the major dimension 166 is the same as the minor dimension 170 (for example, when the steam opening 106 is a circle or a square). Each steam opening 106 may be any size or shape with a major dimension 166 and a minor dimension 170 that are sized as desired to achieve the desired cleaning application. In the embodiment of FIG. 8, the steam openings 106 are positioned on the outwardly extending projections or segments 178 along the distributor 174 in communication with the plenum 114 such that steam can pass through the plenum 114 and pass through the segments 178 to the steam openings 106. The distributor 174 may extend in a direction parallel to or generally parallel to the longitudinal axis A2 of the brushroll-receiving portion 62. The segments 178 may be provided in the brushroll-receiving portion 62 to engage the brushroll 26. In one embodiment, the segments 178 include an arcuate shape. In other embodiments, the segments 178 may be shaped as a cone or a truncated conc. In some embodiments, the cone-shaped segments 178 may point toward the longitudinal axis A2 of the brushroll-receiving portion 62. Each segment 178 has a width or thickness dimension along the longitudinal axis A2 that may be selected as desired to engage the brushroll 26. In some embodiments, the width dimension of the segments 178 may be narrow to form a comb shape (e.g., a shape that combs debris that may include hair from the brushroll 26) such as schematically illustrated in FIG. 10. The dimension D2 and the segment width or thickness dimension along the longitudinal axis A2 may be selected to provide desired steam delivery and reduce friction between the brushroll 26 operating material and the distributor 174 such that the brushroll motor 46 that rotates the brushroll 26 operates within its load capacity. In the illustrated embodiment, the distributor 174 includes a plurality of segments 178 that function similarly to the walls 134, 138 described herein to clean the brushroll 26 by interfering with the brushroll 26 when the brushroll 26 is placed in the brushroll-receiving portion 62 and rotated (that is, activated) and to dispense steam through the steam openings 106 into the brushroll 26.

With continued reference to FIG. 8, a gap or divot 182 is formed between adjacent segments 178. Stated another way, each segment 178 is separated from an adjacent segment 178 by one of the divots 182. With analogous reference to FIG. 5, the second distance D2 may be similarly defined in the embodiment of FIG. 8 as a radial distance between the longitudinal axis A3 of the brushroll 26 and/or the longitudinal axis A2 of the brushroll-receiving portion 62 to one or more of the steam openings 106. In some embodiments, one or more of the divots 182 may be positioned a radial third distance from the longitudinal axis A2 of the brushroll-receiving portion 62, the third distance being measured to a rear wall 184 bounding the divots 182 and being greater than the second distance D2. In the illustrated embodiment, seventeen steam openings 106, seventeen segments 178, and sixteen divots 182 are provided. However, the number of steam openings 106 and segments 178 may be increased or decreased as desired to provide desired steam delivery to the brushroll 26 for the application.

With reference to FIG. 9, in another embodiment of the cleaning apparatus 28, the steam distributor 194 includes an outwardly extending longitudinal ridge 192 extending along at least a portion of the brushroll-receiving portion 62. A plurality of steam openings 110 extend along the distributor 194 and adjacent the brushroll-receiving portion 62. At least one of the plurality of steam openings 110 extend along the longitudinal ridge 192. In the illustrated embodiment, the plurality of steam openings 110 extend along the longitudinal ridge 192. However, in other embodiments the longitudinal ridge 192 and the steam openings 110 are arranged as desired to achieve the desired cleaning application. Each steam opening 110 may be dimensioned as a port, ellipse, circle, and/or jet having a major dimension 186 and a minor dimension 190. The major dimension 186 may be positioned at a right angle to the minor dimension 190. In some embodiments, the major dimension 186 may be the same as the minor dimension 190 (for example, when the steam opening 110 is a circle or a square). Each steam opening 110 may be any size or shape with a major dimension 186 and a minor dimension 190 that are sized as desired to achieve the desired cleaning application. In the embodiment of FIG. 9, the steam openings 110 are positioned on the outwardly extending longitudinal ridge 192 along the distributor 194 in communication with the plenum 114 such that steam can pass through the plenum 114 to the steam openings 110. In the illustrated embodiment, the longitudinal ridge 192 has a height 195 that is measured normal to a portion of the tray 54 from which the longitudinal ridge 192 extends and a length 196. The height 195 is selected to position the steam openings 110 at their desired positions relative to the brushroll and, in general, may be sized as desired. The distributor 194 may extend in a direction parallel to or generally parallel to the longitudinal axis A2 (FIG. 3) of the brushroll-receiving portion 62. In the illustrated embodiment, the steam openings 110 are equidistantly spaced apart, and further are equidistantly spaced apart on the distributor 194. In the illustrated embodiment, the distributor 194 functions similarly to the walls 134, 138 described herein to dispense steam into the brushroll 26 by interfering with the brushroll 26 when the brushroll 26 is placed in the brushroll-receiving portion 62 and rotated (that is, activated).

With continued reference to FIG. 9, and with analogous reference to FIG. 5, the second distance D2 may be similarly defined in the embodiment of FIG. 9 as a radial distance between the longitudinal axis A3 of the brushroll 26 and/or a radial distance between the longitudinal axis A2 of the brushroll-receiving portion 62 to one or more of the steam openings 110.

The floor cleaner 10 includes control circuitry 40 including a controller. The control circuitry 40 is configured to control operation of one or more components of the floor cleaner. The control circuitry 40 is operably connected to the brushroll motor 46, the suction motor 20, and the fluid distributor 56 and is configured to operate the floor cleaner 10 upon user actuation. With returning reference to FIG. 2, the brushroll 26 is driven by the brushroll motor 46, and the control circuitry 40 is connected to and operable to control the brushroll motor 46. The control circuitry 40 is operable in a brushroll-enabled condition when the floor cleaner 10 is in the inclined use position or other operational condition; a brushroll-disabled condition when the floor cleaner 10 is in the upright position or other storage condition and the floor cleaner 10 is not in the cleaning apparatus 28; and a brushroll-enabled condition when the floor cleaner 10 is in the mounted position. Thus, when the floor cleaner 10 is in the upright storage position, the brushroll 26 will not be activated unless the floor cleaner 10 is in the cleaning apparatus 28.

In some embodiments, the controller of the control circuitry 40 is electrically and/or communicatively connected to a variety of modules or components of the floor cleaner 10. The controller includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller and/or the floor cleaner 10. The controller further includes an electronic processor (for example, a microprocessor or another suitable programmable device) and memory. The memory includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (ROM), random access memory (RAM). Various non-transitory computer readable media, for example, magnetic, optical, physical, or electronic memory may be used. The electronic processor is communicatively coupled to the memory and executes software instructions that are stored in the memory, or stored on another non-transitory computer readable medium such as another memory or a disc. The software may include one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller receives a signal(s) indicative of a characteristic(s) and controls the floor cleaner 10 accordingly (for example, by varying a control signal). Although the controller is described as one controller, the controller could also include multiple controllers configured to work together to achieve a desired level of control for the floor cleaner 10. As such, any control functions and processes described herein with respect to the controller could also be performed by two or more controllers functioning in a distributed manner.

With reference to FIG. 2, in one embodiment, the control circuitry 40 includes two switches 42, 44. The first switch 42 indicates when the floor cleaner 10 is in the upright storage position. The second switch 44 indicates when the floor cleaner 10 is in the mounted position in the cleaning apparatus 28. The first switch 42 and second switch 44 may be mechanical or electrical switches, and may be activated by sensor input, by mechanical actuation, or other switching techniques. In some embodiments having a floor cleaner 10 without an upright storage position, the first switch 42 is omitted.

With continued reference to FIGS. 2 and 3, the second switch 44 may be positioned in the floor cleaner 10, for example, in the base 12, configured to be activated by an actuator 48 in the cleaning apparatus 28. The location of the second switch 44 and the location of the actuator 48 are selected such that the actuator 48 activates the second switch 44 when the floor cleaner 10 is in the mounted position, and the actuator 48 does not activate the second switch 44 when the floor cleaner 10 is not in the mounted position. The actuator 48 and second switch 44 may be positioned to ensure the floor cleaner 10 is in a desired position and alignment relative to features of the cleaning apparatus 28. The actuator 48 enables the brushroll 26 when the base 12 of the floor cleaner 10 is received in the tray 54 in that the actuator 48 is configured to activate the second switch 44 signaling to the control circuitry 40 that the floor cleaner is in the mounted position, and the control circuitry 40 puts the brushroll 26 in the brushroll-enabled condition. In one embodiment, the second switch 44 is a mechanically actuated switch (for example, a contact switch), and the actuator is a mechanical actuator 48 positioned in the cleaning apparatus 28 (shown, for example, in FIGS. 3, 7, 8, and 9). The mechanical actuator 48 in the cleaning apparatus 28 may be a rib, a pin, a protrusion, or other shape or feature positioned to actuate the second switch 44 in the floor cleaner 10 when the floor cleaner 10 is placed in the mounted position in the cleaning apparatus 28. In the example shown in FIG. 3, the mechanical actuator 48 is a protrusion extending upwardly positioned to engage the second switch 44 in the base 12. The second switch 44 may be adjacent an outer surface of the base 12 and positioned for direct engagement with the mechanical actuator 48. In one embodiment, the mechanical actuator 48 enters a recess or aperture in the base 12 to actuate the second switch 44. In one embodiment, the actuator 48 contacts a linkage or other intermediate member that actuates the second switch 44 in the floor cleaner 10 when the base 12 is placed in the cleaning apparatus 28.

In one embodiment, the second switch 44 is a magnetically activated switch (for example, a reed switch or a switch using a Hall Effect sensor), and the actuator is a magnet. In this embodiment, the reed switch is positioned in the floor cleaner 10 in a location corresponding to the location of the magnet in the cleaning apparatus 28 when the floor cleaner 10 is placed in the mounted position in the cleaning apparatus 28. In another embodiment, the second switch 44 includes a Hall Effect sensor and the actuator is a magnet positioned in the cleaning apparatus 28.

In one embodiment, the second switch 44 is a light activated switch (for example, a switch using a photodetector or photoresistor or a switch using a proximity sensor), and the actuator on the cleaning apparatus 28 is a light, a shape, a bar code, a reflector, or other feature sensed by the light activated switch when the floor cleaner 10 is placed in the mounted position in the cleaning apparatus 28. In other embodiments, the second switch 44 may be another type of proximity sensor configured to cooperate with the cleaning apparatus 28 to actuate the control circuit, such as a pressure sensor, ultrasonic sensor, or other proximity sensor.

In the illustrated embodiment the actuator 48 includes electrical contacts 60 (FIG. 3) and the second switch 44 is an electronic switch operatively connected to electrical contacts positioned to electrically connect with the actuator electrical contacts 60 when the floor cleaner 10 is in the mounted position, and the controller is configured to determine when the actuator 48 has connected to the second switch 44, for example by sensing a change in resistance or voltage across the second switch 44, or receiving a signal from the cleaning apparatus control circuitry, or other sensing technique.

With reference to FIGS. 1 and 2, the floor cleaner 10 and the cleaning apparatus 28 may be operated in a plurality of various cleaning modes. For example, in one cleaning mode the floor cleaner 10 operates a self-cleaning cycle while the steam generator 68 in the cleaning apparatus 28 is not operating. In another cleaning mode, the cleaning apparatus 28 operates a steam cleaning cycle while the floor cleaner 10 is not operating. In yet another cleaning mode, the cleaning apparatus 28 operates a steam cleaning cycle while the floor cleaner 10 operates portions of the floor cleaner 10 in cooperation with the steam cleaning cycle, for example, the brushroll motor 46.

The floor cleaner 10 may be operable in a cleaning mode having a self-cleaning cycle in which the controller is configured to control operation of one or more components of the floor cleaner 10 to clean one or more portions of the floor cleaner, for example the suction inlet 30 and the brushroll 26. The cleaning mode may be configured to operate when the floor cleaner 10 is in the mounted position in the cleaning apparatus 28. In one embodiment, the second switch 44 is configured to provide a signal to the controller when the second switch 44 is activated by the actuator 48 such that the control circuitry 40 senses the cleaning apparatus 28. In some embodiments, the second switch 44 enables the cleaning mode by the controller being configured to not operate the self-cleaning cycle of the cleaning mode unless the second switch 44 indicates that the floor cleaner 10 is in the mounted position. The controller is operatively connected to the fluid distributor 56 and may be configured to distribute solution from the supply tank 16 in response to activation of the second switch 44 by the cleaning apparatus 28 and initiation of the cleaning mode having the self-cleaning cycle. The controller is operatively connected to the suction motor 20 and configured to activate the suction motor 20 in response to activation of the second switch 44 by the cleaning apparatus 28 and initiation of a cleaning mode having a cleaning cycle.

For example, in one cleaning mode, when the floor cleaner 10 is in the cleaning apparatus 28, the controller receives a signal from second switch 44 indicating that the floor cleaner 10 is in the mounted position in the cleaning apparatus 28 enabling the cleaning mode. After actuation of the cleaning mode having a cleaning cycle, the controller operates the fluid distributor 54 to dispense cleaning fluid through the distribution nozzle 32 to the tray 54 of the cleaning apparatus 28. Subsequently, the controller activates the brushroll motor 46 to rotate the brushroll 26 in the cleaning fluid disposed in the tray 54. The controller further activates the suction motor 20 to extract the cleaning fluid from the brushroll 26 and the tray 54. In some embodiments the cleaning cycle of the cleaning mode is prevented when the floor cleaner 10 is not in the mounted position in the cleaning apparatus 28.

The cleaning apparatus 28 is configured to at least partially surround the distribution nozzle 32, such that cleaning fluid from the distribution nozzle 32 contacts the cleaning apparatus 28 and is directed into the tray 54. The fluid distributor 56, shown schematically in FIG. 1, may include the auxiliary fluid outlet 36 in communication with the supply tank 16. The auxiliary fluid outlet 36 may be controlled by a valve 38 activated by the second switch 44. The auxiliary fluid outlet 36 may be configured to provide a flow rate greater than that provided by the pump 34 and distribution nozzle 32. The auxiliary fluid outlet 36 is positioned above the tray 54 when the base 12 is positioned on the cleaning apparatus 28 such that cleaning fluid from the supply tank 16 flows into the tray 54 when the valve 38 is actuated by the second switch 44.

In one embodiment, a cleaning cycle of a cleaning mode is initiated manually by the user operating the floor cleaner while the floor cleaner 10 is in the cleaning apparatus 28. For example, a cleaning cycle of a cleaning mode may be initiated when the user turns the floor cleaner 10 on by depressing, for example, a pushbutton 50, and then the user operates the floor cleaner 10 to dispense cleaning fluid into the tray 54 by activating a trigger 52, which in the illustrated embodiment is located on the handle of the floor cleaner 10, when the floor cleaner 10 is in the cleaning apparatus 28. The pushbutton 50, which is an on/off button in one example, activates the suction motor 20 and the brushroll motor 46, while the trigger 52 distributes cleaning fluid to the cleaning apparatus 28. The brushroll 26 rotates in the cleaning fluid collected in the tray to remove debris from the brushroll 26, whereupon the cleaning fluid and debris are sucked through the suction inlet 30 and through the recovery path to the recovery tank 18 of the floor cleaner 10.

In one embodiment, a cleaning cycle of a cleaning mode operates automatically after the cleaning cycle is initiated. An automated cleaning cycle is controlled by the control circuitry 40 including the floor cleaner controller. The controller is operatively connected to the fluid distributor 56, the suction motor 20, and the brushroll motor 46. The controller is further operably coupled with a user interface for receiving inputs from the user. In response to user activation or other activation, the controller is configured to activate an automated cleaning cycle of a cleaning mode when the floor cleaner 10 is in the cleaning apparatus 28. The controller operates the suction motor 20, the brushroll motor 46, and the fluid distributor 56 in the cleaning cycle.

A cleaning cycle may consist of a distribution phase and an extraction phase. During the distribution phase, cleaning fluid is distributed from the supply tank 16 through the fluid distributor 56, and into the tray 54 of the cleaning apparatus 28. During the extraction phase, the brushroll motor 46 is activated, allowing the brushroll 26 to rotate in the cleaning fluid in the cleaning apparatus 28 to remove dirt and debris. The suction motor 20 is also activated to extract the cleaning fluid, dirt, and debris through the suction inlet 30. The distribution phase and extraction phase may run simultaneously or may be staggered or sequential. In one embodiment, a cleaning cycle includes a distribution phase, an agitation phase, and an extraction phase. In this embodiment, cleaning fluid is distributed from the supply tank 16 into the tray 54 in the distribution phase. In the agitation phase, the brushroll motor 46 is activated, rotating the brushroll 26 in the cleaning fluid in the cleaning apparatus 28 to remove dirt and debris while the suction motor 20 is not activated. Then, the suction motor 20 is activated in the extraction phase. The distribution phase, agitation phase, and extraction phase may run simultaneously, or may be staggered or sequential. A cleaning cycle can optionally repeat the distribution phase and/or extraction phase and/or agitation phase if present one or more times. The length of each phase and quantity of cleaning fluid dispensed in a cleaning cycle may be time-dependent or may continue until the recovery tank 18 is full or the supply tank 16 is empty. In one embodiment, the controller operates the suction motor 20, the brushroll motor 46, and the fluid distributor 56 based on another control scheme, such as monitoring cleaning effectiveness by sensors.

In one embodiment of an automated cleaning cycle, a user activation is the user actuating a pushbutton 50 on the floor cleaner 10. In another embodiment, a user activation is placing the floor cleaner 10 into the cleaning apparatus 28. In yet another embodiment, a user activation is by an infrared, Wi-Fi, Bluetooth, or other signal sent from a remote device by user interaction with the device, such as a remote control, cell phone, or computer.

The cleaning apparatus 28 may be used to operate a steam cleaning cycle of a cleaning mode. During a steam cleaning cycle, which may be activated automatically or manually, the cleaning apparatus 28 generates steam and applies the steam to the floor cleaner 10 when the floor cleaner 10 is in the mounted position. In the illustrated embodiment, the cleaning apparatus 28 is configured to distribute steam onto the brushroll 26 to partially or entirely clean and/or sanitize the brushroll 26. More specifically, and in one embodiment of a steam cleaning cycle of a cleaning mode, when the floor cleaner 10 is in the mounted position, the brushroll 26 rotates while steam is dispensed onto and/or into the brushroll 26 through the steam openings 102, 106, 110. The flow rate of the steam through the steam distributor 162, 174, 194 and the rotational speed of the brushroll 26 are selected to provide a desired cleaning effect. The speed of the brushroll rotation may be less than 1 degree/second, or between 1 and 10 degrees per second, or any another rotational speed as desired to provide a dwell time for the steam to contact the brushroll 26. The flow rate of liquid through the steam generator 68 may be between 15 ml/min and 50 ml/min, or between 50 ml/min and 100 ml/min or any other flow rate of liquid as desired to provide a desired level of cleaning.

In some embodiments, the floor cleaner 10 and the cleaning apparatus 28 are configured to communicate when the floor cleaner 10 is in the mounted position. In the illustrated embodiment, the cleaning apparatus PCBA 118 is electrically connected to the actuator electrical contacts 60 and configured to send and receive signals through the electrical contacts 60 when the floor cleaner 10 is in electrical connection with the actuator 48 in the mounted position. In one embodiment, the floor cleaner controller is configured to instruct the cleaning apparatus control circuitry to operate the steam generator 68 in a steam cleaning cycle of a cleaning mode. In some examples, the cleaning apparatus control circuitry is configured to operate the steam generator 68 in a steam cleaning cycle of a cleaning mode. The steam cleaning cycle includes a distribution phase wherein liquid from the reservoir 70 is heated by the boiler 98 to make steam delivered through the steam distributor 162, 174, 194. In some embodiments, the steam cleaning cycle includes an agitation phase wherein the brushroll motor 46 in the floor cleaner 10 operates to rotate the brushroll 26. In one embodiment, the steam cleaning cycle includes an extraction phase wherein the suction motor 20 on the floor cleaner 10 operates to draw air and liquid into the suction inlet 30. The steam cleaning cycle may include various combinations of distribution, agitation, and extraction as described herein as desired.

In one embodiment, the cleaning apparatus control circuitry senses whether the floor cleaner 10 is in the mounted position, for example by sensing a change in resistance or voltage across the actuator electrical contacts 60, or receiving a signal from the floor cleaner control circuitry 40, or other sensing technique. In one embodiment, a third switch is provided on the cleaning apparatus 28 actuated by the floor cleaner 10 when the floor cleaner 10 is in the mounted position. In some embodiments, the cleaning apparatus control circuitry prevents operation of the steam generator 68 when the floor cleaner 10 is not in the mounted position.

A cleaning cycle and a steam cleaning cycle of a cleaning mode may be operable such that, in some embodiments, a cleaning cycle and a steam cleaning cycle may be operated individually, sequentially, or simultaneously. In other words, in an embodiment, a first cleaning cycle of a cleaning mode, in which the cleaning apparatus 28 does not dispense steam, may be operated prior to operating a steam cleaning cycle of the cleaning mode, in which the cleaning apparatus 28 dispenses steam onto and/or into the brushroll 26. In another embodiment, a single cleaning cycle of a cleaning mode may run that combines steam dispensation with a cleaning cycle. A user may actuate a single switch to activate both a cleaning cycle and a steam cleaning cycle of a cleaning mode, or in some embodiments, a user may actuate separate switches to activate a cleaning cycle and a steam cleaning cycle of a cleaning mode individually or sequentially.

The floor cleaner 10 may be cleaned in one embodiment by a method of cleaning a floor cleaner 10 using a cleaning apparatus 28 having an actuator 48 by receiving the floor cleaner 10 in the mounted position in the cleaning apparatus 28. The method includes sensing the presence of the cleaning apparatus 28 by a control circuitry 40 in the floor cleaner 10 that is activated by the actuator 48. Stated another way, the method may include activating the control circuitry 40 in the floor cleaner 10 by the cleaning apparatus actuator 48. The method further comprises activating a cleaning mode that distributes cleaning fluid from a supply tank 16 into the cleaning apparatus 28. A cleaning mode may further comprise activating the suction motor 20 to extract cleaning fluid from the cleaning apparatus 28. In a further embodiment, the brushroll 26 may be activated in a cleaning mode when the floor cleaner 10 is in the mounted position. In one embodiment, the control circuitry 40 may be configured to prevent the activation of a cleaning mode if the cleaning apparatus 28 is not sensed or if the floor cleaner 10 is not in the upright position. The method may further comprise, in a cleaning mode, distributing cleaning fluid from the supply tank 16 into the tray 54 via the fluid distributor 56, the supply tank 16 being on the floor cleaner 10. The method may be such that the floor cleaner 10 includes a suction motor 20, the method further comprising extracting the cleaning fluid from the tray 54 and into the recovery tank 18 on the floor cleaner 10 by activating the suction motor 20. The method may be such that the step of activating a cleaning mode includes activating a cleaning mode in response to a user activation. The method may further comprise activating the brushroll 26 while the steam is being dispensed.

The floor cleaner 10 may be cleaned in one embodiment by a method of steam cleaning a floor cleaner 10 using a cleaning apparatus 28 having an actuator 48 by receiving the floor cleaner 10 in the mounted position in the cleaning apparatus 28. The method includes sensing the presence of the cleaning apparatus 28 by a control circuitry 40 in the floor cleaner 10 that is activated by the actuator 48. Stated another way, the method may include activating the control circuitry 40 in the floor cleaner 10 by the actuator 48. The method may further include dispensing steam onto the brushroll 26 while the brushroll 26 is positioned in the cleaning apparatus 28. The method may further comprise storing a supply of liquid in the reservoir 70 on the cleaning apparatus 28. The method may further comprise boiling the liquid to generate steam. The method may further comprise dispensing the steam through a steam opening 102, 106, 110 in the cleaning apparatus 28 to the brushroll 26 of the floor cleaner 10. The method may further comprise pumping the liquid from the reservoir 70 to the boiler 98 for boiling the liquid. The method may further comprise sensing that a portion of the base 12 of the floor cleaner 10 is received by the cleaning apparatus 28, and the sensing may be performed by the cleaning apparatus control circuitry or the control circuitry 40 in the floor cleaner 10. The method may further comprise, when the control circuitry 40 senses that the portion of the base 12 of the floor cleaner 10 is received by the cleaning apparatus 28, activating a cleaning mode. The method may further comprise preventing activation of a cleaning mode if the control circuitry 40 does not sense that the portion of the base 12 of the floor cleaner 10 is received by the cleaning apparatus 28. The method may be such that the step of activating a cleaning mode includes activating a cleaning mode in response to a user activation. The method may further comprise activating the brushroll 26 while the steam is being dispensed.

Various features and advantages of the disclosure are set forth in the following claims.

FLOOR CLEANER AND STEAM CLEANING APPARATUS FOR A FLOOR CLEANER

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