Patent Grant
11779176
Extraction cleaners are well-known surface cleaning apparatuses for deep cleaning carpets and other fabric surfaces, such as upholstery. Most extraction cleaners, or deep cleaners, comprise a fluid delivery system that delivers cleaning fluid to a surface to be cleaned and a fluid recovery system that extracts spent cleaning fluid and debris (which may include dirt, dust, stains, soil, hair, and other debris) from the surface. The fluid delivery system typically includes one or more fluid supply containers for storing a supply of cleaning fluid, a fluid distributor for applying the cleaning fluid to the surface to be cleaned, and a fluid supply conduit for delivering the cleaning fluid from the fluid supply container to the fluid distributor. An agitator can be provided for agitating the cleaning fluid on the surface. The fluid recovery system usually comprises a recovery container, a nozzle adjacent the surface to be cleaned and in fluid communication with the recovery container through a working air conduit, and a source of suction in fluid communication with the working air conduit to draw the cleaning fluid from the surface to be cleaned and through the nozzle and the working air conduit to the recovery container.
Many extraction cleaners for household use are uprights, and include a base and an upright body having a handle for directing the base across the surface to be cleaned. Some extraction cleaners have been provided as autonomous robots, which carry the systems on an autonomously-moveable unit.
An aspect of the present disclosure relates to a cleaning tray for an extraction cleaner having a fluid delivery system, a suction nozzle, a brush chamber, and an agitator, the cleaning tray including a tray body, a plurality of spray nozzles on the tray body, and a fluid delivery pathway supplying cleaning fluid to the plurality of spray nozzles, the fluid delivery pathway comprising an inlet configured to fluidly couple with the fluid delivery system of the extraction cleaner, wherein a portion of the fluid delivery pathway is one of formed in and mounted to the tray body.
In another aspect, the present disclosure relates to a self-cleaning cleaning system including an extraction cleaner apparatus comprising a fluid delivery system, a suction nozzle, a brush chamber, and an agitator, and a cleaning tray. The cleaning tray includes a tray body, a plurality of spray nozzles on the tray body, and a fluid delivery pathway supplying cleaning fluid to the plurality of spray nozzles, the fluid delivery pathway comprising an inlet configured to fluidly couple with the fluid delivery system of the extraction cleaner, wherein a portion of the fluid delivery pathway is one of formed in and mounted to the tray body. The extraction cleaner may be an upright or robot extraction cleaner.
In the drawings:
The disclosure generally relates to features and improvements for extraction cleaners for floor surfaces that have fluid delivery and recovery capabilities. In particular, the features and improvements relate to cleaning and maintaining such extraction cleaners.
The extraction cleaner 10 can include a fluid delivery system 12 for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned and a recovery system 14 for removing the spent cleaning fluid and debris from the surface to be cleaned and storing the spent cleaning fluid and debris.
The recovery system 14 can include a suction nozzle 16, a suction source 18 in fluid communication with the suction nozzle 16 for generating a working air stream, and a recovery container 20 for separating and collecting fluid and debris from the working airstream for later disposal. A separator 21 can be formed in a portion of the recovery container 20 for separating fluid and entrained debris from the working airstream.
The suction source 18 is provided in fluid communication with the recovery container 20. The suction source is illustrated herein as a motor/fan assembly 19 that can be electrically coupled to a power source 22, such as a battery or by a power cord plugged into a household electrical outlet. A suction power switch 24 between the motor/fan assembly 19 and the power source 22 can be selectively closed by the user, thereby activating the motor/fan assembly 19.
The suction nozzle 16 can be provided on a base or cleaning head adapted to move over the surface to be cleaned. An agitator 26 can be provided adjacent to the suction nozzle 16 for agitating the surface to be cleaned so that the debris is more easily ingested into the suction nozzle 16. 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.
The extraction cleaner 10 can also be provided with above-the-floor cleaning features. An accessory hose 28 can be selectively fluidly coupled to the motor/fan assembly 19 for above-the-floor cleaning using an above-the floor accessory tool 30 with its own suction inlet. A diverter assembly 32 can be selectively switched between on-the-floor and above-the floor cleaning by diverting fluid communication between either the suction nozzle 16 or the accessory hose 28 with the motor/fan assembly 19. The accessory hose 28 can also communicate with the fluid delivery system 12 to selectively deliver cleaning fluid.
The fluid delivery system 12 can include at least one fluid container 34 for storing a supply of fluid. The fluid can comprise one or more of any suitable cleaning fluids, including, but not limited to, water, compositions, concentrated detergent, diluted detergent, etc., and mixtures thereof. For example, the fluid can comprise a mixture of water and concentrated detergent.
The fluid delivery system 12 can further comprise a flow control system 36 for controlling the flow of fluid from the supply container 34 to at least one fluid distributor 38. In one configuration, the flow control system 36 can comprise a pump 40 which pressurizes the system 12 and a flow control valve 42 which controls the delivery of fluid to the distributor 38. An actuator 44 can be provided to actuate the flow control system 36 and dispense fluid to the distributor 38. The actuator 44 can be operably coupled to the valve 42 such that pressing the actuator 44 will open the valve 42. The valve 42 can be electrically actuated, such as by providing an electrical switch 46 between the valve 42 and the power source 22 that is selectively closed when the actuator 44 is pressed, thereby powering the valve 42 to move to an open position. In one example, the valve 42 can be a solenoid valve. The pump 40 can also be coupled with the power source 22. In one example, the pump 40 can be a centrifugal pump. In another example, the pump 40 can be a solenoid pump.
The fluid distributor 38 can include at least one distributor outlet 48 for delivering fluid to the surface to be cleaned. The at least one distributor outlet 48 can be positioned to deliver fluid directly to the surface to be cleaned, or indirectly by delivering fluid onto the agitator 26. The at least one distributor outlet 48 can comprise any structure, such as a nozzle or spray tip; multiple outlets 48 can also be provided. As illustrated in
Optionally, a heater 50 can be provided for heating the cleaning fluid prior to delivering the cleaning fluid to the surface to be cleaned. In the example illustrated in
As another option, the fluid delivery system can be provided with an additional container 52 for storing a cleaning fluid. For example, the first container 34 can store water and the second container 52 can store a cleaning agent such as detergent. The containers 34, 52 can, for example, be defined by a supply tank and/or a collapsible bladder. In one configuration, the first container 34 can be a bladder that is provided within the recovery container 20. Alternatively, a single container can define multiple chambers for different fluids.
In the case where multiple containers 34, 52 are provided, the flow control system 36 can further be provided with a mixing system 54 for controlling the composition of the cleaning fluid that is delivered to the surface. The composition of the cleaning fluid can be determined by the ratio of cleaning fluids mixed together by the mixing system. As shown herein, the mixing system 54 includes a mixing manifold 56 that selectively receives fluid from one or both of the containers 34, 52. A mixing valve 58 is fluidly coupled with an outlet of the second container 52, whereby when mixing valve 58 is open, the second cleaning fluid will flow to the mixing manifold 56. By controlling the orifice of the mixing valve 58 or the time that the mixing valve 58 is open, the composition of the cleaning fluid that is delivered to the surface can be selected.
In yet another configuration of the fluid delivery system 12, the pump 40 can be eliminated and the flow control system 36 can comprise a gravity-feed system having a valve fluidly coupled with an outlet of the container(s) 34, 52, whereby when valve is open, fluid will flow under the force of gravity to the distributor 38. The valve can be mechanically actuated or electrically actuated, as described above.
The extraction cleaner 10 shown in
In operation, the extraction cleaner 10 is prepared for use by coupling the extraction cleaner 10 to the power source 22, and by filling the first container 34, and optionally the second container 52, with cleaning fluid. Cleaning fluid is selectively delivered to the surface to be cleaned via the fluid delivery system 12 by user-activation of the actuator 44, while the extraction cleaner 10 is moved back and forth over the surface. The agitator 26 can simultaneously agitate the cleaning fluid into the surface to be cleaned. During operation of the recovery system 14, the extraction cleaner 10 draws in fluid and debris-laden working air through the suction nozzle 16 or cleaning tool 30, depending on the position of the diverter assembly 32, and into the downstream recovery container 20 where the fluid debris is substantially separated from the working air. The airstream then passes through the motor/fan assembly 19 prior to being exhausted from the extraction cleaner 10. The recovery container 20 can be periodically emptied of collected fluid and debris.
For purposes of description related to the figures, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inner,” “outer,” and derivatives thereof shall relate to the extraction cleaner 100 as oriented in
The various systems and components schematically described for
The flexible hose conduit 118 can define an airflow pathway 126 and can carry the flexible fluid delivery conduit 120 within the airflow pathway 126. Alternatively, the fluid delivery conduit 120 can extend externally to the airflow pathway 126. The airflow pathway 126 is configured to be coupled with the recovery container 20, and the fluid delivery conduit 120, which defines a fluid delivery pathway 128, is configured to be coupled with the supply container 34.
The wand 122 includes a housing 130 with an airflow pathway 132 having an airflow connector 134 which fluidly couples with the airflow pathway 126 of the hose conduit 118, and a fluid delivery pathway 136 having a fluid connector 137 which fluidly couples with the fluid delivery pathway 128 of the delivery conduit 120. A valve 138 can be provided in the fluid delivery pathway 136 for controlling the flow of cleaning fluid to the fluid connector 137. The valve 138 can be controlled by the user via a valve actuator, such as a trigger 140 provided on the housing of the wand 122.
The extraction cleaner 100 can have an integrated self-cleaning cycle configured to be run when the extraction cleaner 100 is docked with the cleaning tray 142 as shown in
Referring to
The tray 142 can be configured to physically support a portion of the extraction cleaner 100 in engagement with the collection reservoir 164, and can include a forward support 166 for engaging the front of the suction nozzle 16 and a rearward support 168 which engages the bottom of the base housing 106 behind the brush chamber 144. The tray 142 can also be used when storing the extraction cleaner 100 after use or self-cleaning, and can catch any drips from the extraction cleaner 100.
The front portion of the base housing 106 of the extraction cleaner 100, which includes at least the suction nozzle 16 and the brush chamber 144, rests on top of the tray 142 in the illustrated example.
The hose receiver 148 includes a fluid connector coupler 170 in fluid communication with the manifold 150 that receives the fluid connector 137 of the hose 116. A trigger actuator 172 is associated with the fluid connector coupler 170, and is configured to depress the trigger 140 when the fluid connector 137 is received in the coupler 170. Receipt of the fluid connector 137 in the fluid connector coupler 170 thereby simultaneously places the fluid connector 137 in fluid communication with the manifold 150 and opens the valve 138 to open the fluid delivery pathway 128. The hose receiver 148 further includes an airflow connector coupler 174 that receives the airflow connector 134 of the hose 116 to support the hose 116 in a substantially upright position on the tray 142.
Alternatively,
In an alternate aspect of the present disclosure shown in
More specifically, a base of the extraction cleaner 100 can be seated in the tray 142. As illustrated in
Turning to
The recessed portion 188 can include a receiver 187 inset within a portion of the recessed portion 188. The receiver 187 can further be configured to receive a brush cleaning insert 190. The brush cleaning insert 190 can include any suitable form, including a rectangular base plate 192 having a plurality of projections 194 such as teeth, nubs or tines extending from the base plate 192 and configured to contact the agitator. In the illustrated example the projections 194 can engage the bristles of brushrolls 196 in the brush chamber 144. In addition, while several rows of the same type of projection 194 are illustrated it will be understood that any of combination or placement of projections 194 can be utilized on the brush cleaning insert 190.
In operation, the extraction cleaner 100 can be docked within the cleaning tray 142. The docking can include aligning at least one of the suction nozzle 16 or brush chamber 144 over the recessed portion 188 within the guide walls 189. The docking can also include aligning the wheels 108 within the wheel wells 198. Once docked, cleaning fluid from the supply container 34 (
Referring now to
The projections 194 are schematically illustrated as essentially rectangular nubs, and it should be understood that any desired geometric profile can be utilized for the projections 194, including flexible bristles, teeth, pointed/triangular projections, or the like, or combinations thereof. In addition, a rear wall of the tray 142 can optionally comprise a tool recess 199 for mounting additional cleaning tools or accessories. One such example is a nozzle cleanout tool 199T, more fully disclosed in U.S. Patent Application Publication No. 2016/0270620, published Sep. 22, 2016, which is incorporated herein by reference in its entirety.
The tray 142 shown in
The self-cleaning cycle may begin at 203 with at least one spraying phase in which cleaning solution from the supply container 34 is delivered to the specially-aimed spray nozzles 152 on the cleaning tray 142 that spray the brush chamber 144. Because the hose receiver 148 depresses the trigger 140 on the wand 122 of the accessory hose 116, the pressurized fluid flow through the conduits 154 is sprayed through the spray nozzles 152 to wash off debris and hair from inside the brush chamber 144, including the brushrolls 196. The self-cleaning cycle may use the same cleaning fluid normally used by the extraction cleaner 100 for surface cleaning, or may use a different detergent focused on cleaning the fluid recovery system 14 of the extraction cleaner 100.
The self-cleaning cycle may also include at least one extraction phase at 204 in which the suction source 18 is actuated to suction up the cleaning fluid via the suction nozzle 16. During the extraction phase, the cleaning fluid and debris from the collection reservoir 164 in the tray 142 is sucked through the suction nozzle 16 and the downstream fluid recovery path. The flushing action also cleans the entire fluid recovery path of the extraction cleaner 100, including the suction nozzle 16 and downstream conduits.
The extraction phase of the cleaning cycle can occur simultaneously with the spraying phase or after the spraying phase is complete. In yet another alternative, the extraction phase can initiate after a timed delay from the initiation of the spraying phase. The self-cleaning cycle can optionally repeat the spraying and extraction phases one or more times. For example, the self-cleaning cycle can be configured to repeat the spraying and extraction phases three times before the end of the cycle. The end of the self-cleaning cycle at 205 may be time-dependent, or may continue until the recovery container 20 is full or the supply container 34 is empty. During the spraying phase and/or the extraction phase, the brushrolls 196 can rotate to propel fluid within the brush chamber 144 and provide agitation that enhances the cleaning effect.
The self-cleaning system and method is described above with reference to an upright extraction cleaner, but are also generally applicable to other types of extraction cleaners. For example, the self-cleaning system and method can be applied to an autonomous a deep cleaning robot.
The deep cleaning robot 300 mounts the components of various functional systems of the extraction cleaner 10 in an autonomously moveable unit or housing, including components of a fluid delivery system 12 for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned, a fluid recovery system 14 for removing the cleaning fluid and debris from the surface to be cleaned and storing the recovered cleaning fluid and debris, a drive system 310 for autonomously moving the robot over the surface to be cleaned, and a navigation/mapping system 320 for guiding the movement of the robot 300 over the surface to be cleaned, generating and storing maps of the surface to be cleaned, and recording status or other environmental variable information. The robot 300 includes a main housing adapted to selectively mount components of the systems to form a unitary movable device.
A controller 350 is operably coupled with the various function systems of robot 300 for controlling its operation. The controller can be a microcontroller unit (MCU) that contains at least one central processing unit (CPU).
As described above, the fluid delivery system 12 can include a supply container 34 for storing a supply of cleaning fluid and a fluid distributor 38 in fluid communication with the supply container 34 for depositing a cleaning fluid onto the surface. The cleaning fluid can be a liquid such as water or a cleaning solution specifically formulated for carpet or hard surface cleaning. The fluid distributor 38 can be one or more spray nozzle 302 provided on the housing of the robot 300. Alternatively, the fluid distributor 38 can be a manifold having multiple outlets. A pump 40 driven by a pump motor 304 is provided in the fluid pathway between the supply container 34 and the distributor 38 to control the flow of fluid to the distributor 38. Various combinations of optional components can be incorporated into the fluid delivery system as is commonly known in the art, such as a heater for heating the cleaning fluid before it is applied to the surface or one more fluid control and mixing valves.
At least one agitator or brush 311 can be provided for agitating the surface to be cleaned onto which fluid has been dispensed. The brush can be a brushroll mounted for rotation about a substantially horizontal axis, relative to the surface over which the robot 300 moves. A drive assembly including a separate, dedicated brush motor 312 can be provided within the robot 300 to drive the brush 311. Alternatively, the brush 311 can be driven by the vacuum motor 313. Other aspects of the disclosure of agitators are also possible, including one or more stationary or non-moving brushes, or one or more brushes that rotate about a substantially vertical axis.
The fluid recovery system 14 (
While not shown, a squeegee can be provided on the housing 308, adjacent the suction nozzle 16, and is configured to contact the surface as the robot 300 moves across the surface to be cleaned. The squeegee wipes residual liquid from the surface to be cleaned so that it can be drawn into the fluid recovery pathway via the suction nozzle 16, thereby leaving a moisture and streak-free finish on the surface to be cleaned.
The drive system 310 can include drive wheels 314 for driving the robot 300 across a surface to be cleaned. The drive wheels 314 can be operated by a common drive motor 315 or individual drive motors coupled with the drive wheels 314 by a transmission, which may include a gear train assembly or another suitable transmission. The drive system 310 can receive inputs from the controller 350 for driving the robot 300 across a floor, based on inputs from the navigation/mapping system 320. The drive wheels 314 can be driven in a forward or reverse direction in order to move the robot 300 forwardly or rearwardly. Furthermore, the drive wheels 314 can be operated simultaneously or individually in order to turn the robot 300 in a desired direction.
The controller 350 can receive input from the navigation/mapping system 320 for directing the drive system 310 to move the robot 300 over the surface to be cleaned. The navigation/mapping system 320 can include a memory 322 that stores maps for navigation and inputs from various sensors, which is used to guide the movement of the robot 300. For example, wheel encoders 331 can be placed on the drive shafts of the wheel motors 315, and are configured to measure the distance traveled. This measurement can be provided as input to the controller 350.
Motor drivers 305 can be provided for controlling the pump motor 304, brush motor 312, vacuum motor 313, and wheel motors 317 and acts as an interface between the controller 350 and the motors 304, 312, 313, 317. The motor drivers 305 may be an integrated circuit chip (IC). For the wheel motors 317, one motor driver 305 can controller the motors 317 simultaneously.
The motor drivers 305 for the pump motor 304, brush motor 312, vacuum motor 313, and wheel motors 317 can be electrically coupled to a battery management system 360 which includes a rechargeable battery or battery pack 362. In one example, the battery pack 362 can include lithium ion batteries. Charging contacts for the battery pack 362 can be provided on the exterior of the housing 308. A docking station 301 for receiving the robot 300 for charging can be provided with corresponding charging contacts. In one example, the charging contacts provided on the robot 300 may be an electrical connector such as a DC jack.
The controller is further operably coupled with a user interface (UI) for receiving inputs from a user. The user interface 370 can be used to select an operation cycle for the robot 300 or otherwise control the operation of the robot 300. The user interface can have a display 372, such as an LED display, for providing visual notifications to the user. A display driver 374 can be provided for controlling the display 374, and acts as an interface between the controller 350 and the display 372. The display driver 374 may be an integrated circuit chip (IC). The robot 300 can further be provided with a speaker (not shown) for providing audible notifications to the user.
The user interface 370 can further have one or more switches 376 that are actuated by the user to provide input to the controller 350 to control the operation of various components of the robot 300. A switch driver 378 can be provided for controlling the switch 376, and acts as an interface between the controller 350 and the switch 376.
The controller 350 can further be operably coupled with various sensors for receiving input about the environment and can use the sensor input to control the operation of the robot 300. The sensor input can further be stored in the memory 322 and/or used to develop maps for navigation. Some exemplary sensors are illustrated in
The robot 300 can include a positioning or localization system 330 having one or more sensors determining the position of the robot 300 relative to objects, including the wheel encoders 331. The localization system can include one or more infrared (IR) obstacle sensors 332 for distance and position sensing. The obstacle sensors 332 are mounted to the housing of the autonomous robot 300, such as at the front of the robot 300 to determine the distance to obstacles in front of the robot 300. Input from the obstacle sensors 332 can be used to slow down and/or adjust the course of the robot 300 when objects are detected.
Bump sensors 333 can also be provided for determining front or side impacts to the robot 300. The bump sensors 333 may be integrated with a bumper on the housing 308 of the robot 300. Output signals from the bump sensors 333 provide inputs to the controller for selecting an obstacle avoidance algorithm.
In addition to the obstacle and bump sensors, the localization system 330 can include additional sensors, including a side wall sensor 334, one or more cliff sensors 335, and/or an accelerometer 336. The side wall sensor 334 can also be in the form of a wall following sensor located near the side of the robot 300, and can also include a side-facing optical position sensor that provides distance feedback and controls the robot 300 so that the robot 300 can follow near a wall without contacting the wall. The cliff sensors 335 can be bottom-facing optical position sensors that provide distance feedback and control the robot 300 so that the robot 300 can avoid excessive drops such as stairwells or ledges. In addition to optical sensors, the side wall sensors 334 and cliff sensors 335 can be mechanical or ultrasonic sensors.
The accelerometer 336 is an integrated inertial sensor located on the controller and can be a nine-axis gyroscope or accelerometer to sense linear, rotational and magnetic field acceleration. The accelerometer 336 can use acceleration input data to calculate and communicate change in velocity and pose to the controller for navigating the robot 300 around the surface to be cleaned.
The robot 300 can further include one or more lift-up sensors 337, which detect when the robot 300 is lifted off the surface to be cleaned, such as when the user picks up the robot 300. This information is provided as an input to the controller 350, which will halt operation of the pump motor 304, brush motor 312, vacuum motor 313, and/or wheel motors 317. The lift-up sensors 337 may also detect when the robot 300 is in contact with the surface to be cleaned, such as when the user places the robot 300 back on the ground; upon such input, the controller 350 may resume operation of the pump motor 304, brush motor 312, vacuum motor 313, and wheel motors 317.
While not shown, the robot 300 can optionally include one or more sensors for detecting the presence of the supply and recovery containers 34, 20. For example, one or more pressure sensors for detecting the weight of the supply container 34 and the recovery container 20 can be provided. This information is provided as an input to the controller 350, which may prevent operation of the robot 300 until the supply and recovery containers 34, 20 are properly installed. The controller 350 may also direct the display 372 to provide a notification to the user that the supply container 34 or recovery container 20 is missing.
The robot 300 can further include one or more floor condition sensors 338 for detecting a condition of the surface to be cleaned. For example, the robot 300 can be provided with an infrared dirt sensor, a stain sensor, an odor sensor, and/or a wet mess sensor. The floor condition sensors 338 provide input to the controller 350, which may direct operation of the robot 300 based on the condition of the surface to be cleaned, such as by selecting or modifying a cleaning cycle.
An artificial barrier system 340 can also be provided for containing the robot 300 within a user-determined boundary. The artificial barrier system 340 can include an artificial barrier generator 342 that comprises a housing with at least one sonic receiver for receiving a sonic signal from the robot 300 and at least one IR transmitter for emitting an encoded IR beam towards a predetermined direction for a predetermined period of time. The artificial barrier generator 342 can be battery-powered by rechargeable or non-rechargeable batteries. In one aspect of the disclosure, the sonic receiver can comprise a microphone configured to sense a predetermined threshold sound level, which corresponds with the sound level emitted by the robot 300 when it is within a predetermined distance away from the artificial barrier generator. Optionally, the artificial barrier generator 342 can further comprise a plurality of IR emitters near the base of the housing configured to emit a plurality of short field IR beams around the base of the artificial barrier generator housing. The artificial barrier generator 342 can be configured to selectively emit one or more IR beams for a predetermined period of time, but only after the microphone senses the threshold sound level, which indicates the robot 300 is nearby. Thus, the artificial barrier generator 342 is able to conserve power by emitting IR beams only when the robot 300 is in the vicinity of the artificial barrier generator.
The robot 300 can have a plurality of IR transceivers 344 around the perimeter of the robot 300 to sense the IR signals emitted from the artificial barrier generator 342 and output corresponding signals to the controller, which can adjust drive wheel control parameters to adjust the position of the robot 300 to avoid the boundaries established by the artificial barrier encoded IR beam and the short field IR beams. This prevents the robot 300 from crossing the artificial boundary and/or colliding with the artificial barrier generator housing. The IR transceivers 344 can also be used to guide the robot 300 toward the docking station 301.
In operation, sound emitted from the robot 300 greater than a predetermined threshold sound level is sensed by the microphone and triggers the artificial barrier generator 342 to emit one or more encoded IR beams as described previously for a predetermined period of time. The IR transceivers 344 on the robot 300 sense the IR beams and output signals to the controller 350, which then manipulates the drive system 310 to adjust the position of the robot 300 to avoid the border established by the artificial barrier system 340 while continuing to perform a cleaning operation on the surface to be cleaned.
The deep cleaning robot 300 can have an integrated self-cleaning mode or cycle configured to be run when the deep cleaning robot 300 is docked with the docking station as shown in
The docking station can include a recessed portion in the form of a sump 380 for collecting excess liquid and guiding it towards the suction nozzle 16 for eventual extraction. The sump 380 can be configured to align with the brush chamber 309 of the robot 300, and can include one or more spray nozzles 382 for spraying cleaning fluid into the brush chamber 309. The spray nozzles 382 can be in communication with a source of cleaning fluid stored on the docking station 301, or can be coupled with the fluid delivery system 12 of the robot 300 when docked and be supplied with fluid from the supply container 34.
The docking station 301 can include a ramp 384 which the robot 300 drives up to couple with charging contacts 364 for recharging the battery pack 362 (
Once docked, a self-cleaning cycle or mode of operation can be initiated at 402. Prior to initiation of the self-cleaning cycle, the robot 300 may send a confirmation signal to the docking station 301 indicating that the robot 300 has successfully docked, and it ready to commence self-cleaning. For example, an RF signal can be send from the robot 300 to the docking station 301, and back to the robot 300. Alternatively, a pulsed signal can be sent through the charging pathway between the charging contacts 364. As yet another alternative, an IR signal can be sent to the robot 300 to an IR receiver on the docking station 301.
The self-cleaning cycle can be manually initiated, with the user initiating the cycle by pressing a button on the user interface 370 (
Alternatively, the self-cleaning cycle can be automated so that the cleaning cycle is controlled by the controller 350 and automatically initiates once the deep cleaning robot 300 is docked in the docking station 301. For example, the self-cleaning cycle can be designed as a default setting configured to be run after each floor cleaning operation by the robot 300, after a predetermined amount of run time, or when the charge level of the battery 362 (
It is also noted that the self-cleaning cycle may be initiated before the robot 300 docks with the docking station 301, and that the movement of the robot 300 into the docking relationship shown in
Alternatively, the deep cleaning robot 300 can be provided with a sensor (not shown) for detecting when the fluid recovery system 14 and/or extraction pathway of the robot 300 is in need of cleaning, and input from the sensor can be provided to the controller 350 which implements the self-cleaning cycle.
The self-cleaning cycle may begin with at least one spraying phase at 403 in which cleaning solution is delivered to the at least one spray nozzle 382 in the sump 380 that sprays the brush chamber 309. During the spraying phase, the brush motor 312 (
The self-cleaning cycle may also include at least one extraction phase at 404 in which the suction source 18 (
The extraction phase of the cleaning cycle can occur simultaneously with the spraying phase or after the spraying phase is complete. In yet another alternative, the extraction phase can initiate after a timed delay from the initiation of the spraying phase. The self-cleaning cycle can optionally repeat the spraying and extraction phases one or more times. For example, the self-cleaning cycle can be configured to repeat the spraying and extraction phases three times before the end of the cycle. The end of the self-cleaning cycle at 405 may be time-dependent, or may continue until the recovery container 20 is full or the supply container 34 is empty. After the end of the self-cleaning cycle, the docked deep cleaning robot 300 can power off or continue to recharge the battery.
For a timed self-cleaning cycle, the pump 40, brush motor 312, and suction source 18 are energized and de-energized for predetermined periods of time. Optionally, the pump 40 or brush motor 312 can pulse on/off intermittently so that any debris is flushed off of the brush 311 and extracted into the recovery container 20. Optionally, the brush 311 can 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 pump 40 can de-energize to end the spraying phase while the brush motor 312 and suction source 18 can remain energized to continue the extraction phase. This is to ensure that any liquid remaining in the sump 380, on the brush 311, or in the fluid recovery path is completely extracted into the recovery container 20.
For purposes of description related to the figures, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inner,” “outer,” and derivatives thereof shall relate to the extraction cleaner 500 as oriented in
The upright assembly includes a main support section or frame supporting components of the fluid delivery system 12 and the recovery system 14, including, but not limited to, the recovery container 20 and the supply container 34. Additional details of the recovery container 20 for the extraction cleaner 500, which can include an air/liquid separator assembly (not shown) are disclosed in U.S. Patent Application Publication No. 2017/0071434, published Mar. 16, 2017, which is incorporated herein by reference in its entirety. The upright assembly 502 also has an elongated handle 512 extending upwardly from the frame that is provided with a hand grip 514 at one end that can be used for maneuvering the extraction cleaner 500 over a surface to be cleaned. Optionally, the hand grip 514 can include an actuator in the form of a trigger 515 for selective operation of one or more components of the extraction cleaner 500. The frame of the upright assembly can include container receivers for respectively receiving the recovery and supply containers 20, 34 for support on the upright assembly; additional details of the container receivers are disclosed in U.S. Patent Application Publication No. 2017/0071434, incorporated above. A motor housing 516 is formed at a lower end of the frame and contains the motor/fan assembly 19 (
The base assembly 504 includes a base housing 506 supporting components of the fluid delivery system 12 and the recovery system 14, including, but not limited to, the suction nozzle 16, the agitator 26, the pump 40, and at least one fluid distributor 38. Wheels 508 at least partially support the base housing 506 for movement over the surface to be cleaned. An additional agitator 26 in the form of stationary edge brushes 510 may also be provided on the base housing 506.
An agitator housing 530 is provided beneath the suction nozzle 16 and defines an agitator or brush chamber 532 for the agitator 26. The agitator 26 of the illustrated aspect of the disclosure includes dual horizontally-rotating brushrolls 534 which are operatively coupled with the motor/fan assembly 19 (
The fluid distributor 38 includes at least one sprayer 550 positioned to dispense fluid onto the surface to be cleaned. The at least one sprayer 550 can dispense fluid directly onto the surface to be cleaned, such as by having an outlet of the sprayer 550 positioned in opposition to the surface, or indirectly onto the surface to be cleaned, such as by having an outlet of the sprayer 550 positioned to dispense into the brushrolls 534 (see
The at least one sprayer 550 of the fluid distributor 38 can be an elongated spray bar 554 or manifold provided with a plurality of distributor outlets 556 along its length. The spray bar 554 is trough-like, with an open top that receives fluid, which then flows along the length of the spray bar 554 and out through the distributor outlets 556. The distributor outlets 556 can be positioned to dispense cleaning fluid between the brushrolls 534, shown in
The nozzle flushing manifold 540 is mounted on the nozzle assembly 520, such as on the rear wall 524 of the nozzle assembly 520. The flushing manifold 540 includes one or a plurality of outlets 542 formed in the lower rear wall 524 to form a flow path from the manifold 540 into the suction pathway 526 of the suction nozzle 16. In one aspect of the disclosure, a plurality of outlets 542 are provided along the width of the suction nozzle 16. The outlets 542 spray directly into the suction pathway 526, and do not spray towards the surface to be cleaned.
A flow control mechanism or control valve 564 upstream from the manifold 540 can be fluidly connected to a pressurized supply line 566. The supply line 566 may be made up of one or more flexible and/or rigid sections, and may include a pump.
To flush the suction nozzle 16 and downstream working air path, a user selectively opens the control valve 564 and cleaning solution flows into the manifold 540 and is forced through the outlets 552, into the suction pathway of the suction nozzle 16. The cleaning solution rinses debris and flushes away odor from the working air path. The cleaning solution flows through the working air path and is collected in the recovery container 20.
The extraction cleaner 500 can also be provided with above-the-floor cleaning features. An accessory hose 570 can be selectively fluidly coupled to the motor/fan assembly 19 for above-the-floor cleaning using an above-the floor cleaning tool 572 with its own suction inlet. A diverter assembly can be selectively switched between on-the-floor and above-the floor cleaning by diverting fluid communication between either the suction nozzle 16 or the accessory hose 570 with the motor/fan assembly 19. The accessory hose 570 can also communicate with the fluid delivery system 12 to selectively deliver cleaning fluid.
The outlet of the supply container 34 is coupled to a receiver valve assembly 567 with two outlets to feed the pump and the fluid distributor, which is gravity-fed. The conduit 560 feeding the fluid distributor 38 includes a flow controller assembly 568, which in this aspect of the disclosure includes an adjustable valve that permits varied flow rate operation. The conduit extending from the outlet of the pump 40 branches into two separate conduits, one feeding the nozzle flushing manifold 540 and one feeding the accessory hose 570. When the accessory hose 570 is not installed and the control valve 564 is not open, the pump 40, which in this aspect of the disclosure is a centrifugal pump, operates in a “dead-head” condition, meaning the pump 40 continues to operate, but fluid is recirculated within the pump 40. Various combinations of optional components can be incorporated into the fluid delivery system 12 such as a heater, additional supply containers, and/or additional fluid control and mixing valves.
The extraction cleaner 500 can be provided with separate actuators for the fluid distributor and the nozzle flushing manifold, such that the fluid distribution and nozzle cleaning features can be individually activated. In the illustrated aspect of the disclosure, the actuator for the primary fluid distributor 38 comprises the trigger 515 (
The valve assembly 582 includes a valve body 584 that remains fixed in its location, a valve piston 586 that moves up and down a central axis 588 of the valve assembly 542, and a plunger 585 that moves up and down and rotates relative to the central axis of the valve assembly. The control pedal 575 acts as an interface between the operator and the valve assembly. A first spring 590 can bias the valve piston upwardly away from a bottom or end wall of the valve body, and a second spring 591 biases the control pedal 575 upwardly away from the valve housing.
The valve body 584 includes an inlet 592 in fluid communication with the pump 40 (
Referring to
The cam surfaces 602, 604, 606, 608 can include various cam profiles on the plunger 585, valve body 584, and valve piston 586. In one non-limiting aspect of the present disclosure, the cam interfaces are configured to rotate or index the plunger 585 a total of 60 degrees per cycle, each cycle comprising a downward and upward stroke of the plunger. The lower cam surface 604 of the plunger 585 is offset from the cam surface 608 on the valve piston 586 by 10 degrees and the remaining cam interfaces are configured such that on a downward stroke, the plunger 585 will rotate 20 degrees whereas on an upward stroke, the plunger 585 will rotate 40 degrees.
In operation, when the user or operator presses downward on the control pedal 575, the lower cam surface 604 on the plunger 585 will engage the cam surface 608 of the valve piston 586. As the downward motion continues, the upper cam surface 602 on the plunger 585 will clear the fixed cam surface 606 on the valve body 584. The interface between the plunger 585 and valve piston 586 will cause the plunger 585 to rotate. In the illustrated aspect of the present disclosure the plunger 585 rotates 20 degrees in a counterclockwise direction on the downward plunger stroke. When the pedal 575 is released, the spring force will cause the plunger 585 and valve piston 586 to move upward, however, the plunger 585 will be fixed in a lower position due to the interface between the upper cam surface 602 of the plunger 585 and the valve body 584. The valve piston 586 will not be able to return to its “seated” position, causing the valve 582 to stay open, as shown in
When the valve 582 is open, a continuous spray of fluid will be provided by the nozzle flushing manifold 540 until the pedal 575 is pushed again. A mechanism can be provided for automatically turning off the spray from the nozzle flushing manifold 540 in case the pedal 575 is left in the “on” position. For example, a timer-controlled valve can be provided in the fluid pathway between the push-push valve 582 and the nozzle flushing manifold 540 which is configured to close after a predetermined amount of time.
Aspects of the present disclosure provide for a self-cleaning method for an extraction cleaner having a fluid supply container and a fluid distributor. The method includes docking an extraction cleaner in a cleaning tray having a recessed portion configured to sealingly receive a suction nozzle and an agitator of the extraction cleaner. The cleaning tray can also include an insert configured to engage the agitator. The method further includes rotating the agitator such that engagement with the insert scrapes debris from the agitator. Cleaning fluid can be distributed from the fluid supply container into the recessed portion via the fluid distributor, and the cleaning fluid can also be suctioned from the recessed portion into the extraction cleaner.
Optionally, the method can include rotating the agitator during either or both of the distributing cleaning fluid or suctioning cleaning fluid. Optionally, the method can include sensing via a controller when the docking is completed. In such a case, the cleaning fluid distribution can be performed automatically when the controller senses the docking is completed. Optionally, the method can include distributing cleaning fluid through a sealed cleaning pathway between a brush chamber and the suction nozzle of the extraction cleaner via the recessed portion.
There are several advantages of the present disclosure arising from the various features of the apparatus described herein. For example, aspects of the disclosure described above provide improved systems and methods for cleaning extraction cleaners. Extraction cleaners can get very dirty and can be difficult for the user to clean. The self-cleaning systems and method disclosed herein save the user considerable time, and may lead to more frequent use of the extraction cleaner.
Another advantage arising from the various features of the apparatus described herein is that the aspects of the disclosure described above provide a cleaning tray for an upright extraction cleaner. In particular, the brush chamber, brushrolls, and/or suction nozzle of an upright extraction cleaner can be cleaned by the cleaning tray. This can reduce the need for the user to manually remove the brushroll or suction nozzle for cleaning. The cleaning tray can take advantage of the fluid supply system of the extraction cleaner, which conventionally distributes cleaning fluid onto the surface to be cleaned, to spray cleaning fluid into the brush chamber to clean the brushroll automatically and without direct user inaction.
Yet another advantage arising from the various features of the apparatus described herein is that robotic extraction cleaners can be cleaned using a self-cleaning docking station. Prior robotic cleaners in need of cleaning have required the user to manually remove the brush, and rinse parts in the sink. Aspects of the present disclosure provide a docking station that can clean the brush chamber, brushroll, and/or suction nozzle of the robot when docked with the docking station according to an automatic cleaning cycle.
Yet another advantage arising from the various features of the apparatus described herein is that a nozzle flushing manifold can be provided for an extraction cleaner having a suction nozzle. The flushing manifold is mounted on the nozzle assembly and can take advantage of the fluid supply system of the extraction cleaner, which conventionally distributes cleaning fluid onto the surface to be cleaned, to spray cleaning fluid into the suction pathway to clean the suction nozzle automatically and without direct user inaction.
To the extent not already described, the features and structures of the various aspects of the present disclosure of the extraction cleaners, systems, and methods may be used in combination with each other as desired. That one feature may not be illustrated in all of the embodiments is not meant to be construed that it cannot be, but is done for brevity of description. Furthermore, while the extraction cleaners shown herein are upright or robot cleaners, features of the disclosure may alternatively be applied to canister-type, stick-type, handheld, or portable extraction cleaners. Still further, while the extraction cleaners shown herein deliver liquid cleaning fluid to the surface to be cleaned, aspects of the disclosure may also be incorporated into other extraction cleaning apparatus, such as extraction cleaning apparatus with steam delivery instead of or in addition to liquid delivery. Thus, the various features of the embodiments disclosed herein may be mixed and matched 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.
This application is a continuation of U.S. patent application Ser. No. 15/994,040, filed May 31, 2018, which claims the benefit of U.S. Provisional Patent Application No. 62/514,095, filed Jun. 2, 2017, both of which are incorporated herein by reference in their entirety.
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| Number | Date | Country | |
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| Number | Date | Country | |
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| Child | 17880824 | US |
