SURFACE CLEANING APPARATUS INCLUDING A REMOVABLE BRUSHROLL DRIVE TRAIN

Abstract

A surface cleaning apparatus (10) includes a cleaning head (12) including housing, a brushroll (22) mounted in the housing, a motor (54) mounted in the housing, and a drive train (52) removably coupled to the housing. The housing includes a sidewall. The motor includes a motor shaft. The drive train includes a panel (100) removably coupled to the housing, a first coupler (102) mounted on the panel such that the first coupler is rotatable relative to the panel, a second coupler (106) mounted on the panel such that the second coupler is rotatable relative to the panel; and a belt extending between the first coupler and the second coupler to transmit rotation between the first coupler and the second coupler. When the drive train is coupled to the housing rotation of the motor shaft is transmitted through the drive train to the brushroll.

Description

BACKGROUND

The present invention relates to a surface cleaning apparatus and a drive train for driving a brushroll of the surface cleaning apparatus.

SUMMARY

In one embodiment, a surface cleaning apparatus includes a body including a handle configured to be engaged by a user; and a cleaning head connected to the body. The cleaning head includes a housing, a brushroll mounted in the housing, a motor mounted in the housing, and a drive train removably coupled to the housing. The housing includes a bottom wall facing a surface to be cleaned, a top wall spaced above the bottom wall, and a sidewall extending between the bottom wall and the top wall. The brushroll is rotatable relative to the housing about a brushroll axis. The motor includes a motor shaft, and the motor is operable to rotate the motor shaft relative to the housing about a motor axis. The drive train includes a panel removably coupled to the housing, a first coupler mounted on the panel such that the first coupler is rotatable relative to the panel, a second coupler mounted on the panel such that the second coupler is rotatable relative to the panel; and a belt extending between the first coupler and the second coupler to transmit rotation between the first coupler and the second coupler. When the panel is removed from the housing, the first coupler, the second coupler, and the belt are carried with the panel. When the drive train is coupled to the housing, the first coupler is coupled to the motor shaft to rotate therewith, and the second coupler is coupled to the brushroll to rotate therewith, such that rotation of the motor shaft is transmitted through the drive train to the brushroll.

In another embodiment, a surface cleaning apparatus is disclosed including a body having a handle and a cleaning head connected to the body. The cleaning head includes a housing, a brushroll, a motor mounted in the housing, and a drive train removably coupled to the housing. The housing includes an opening. The housing defines a cavity that is accessible through the opening. The brushroll is mounted in the housing for rotation relative to the housing about a brushroll axis. An end of the brushroll is disposed in the cavity. The motor includes a motor shaft configured to rotate relative to the housing about a motor axis. The motor shaft has an end disposed in the cavity. When the drive train is in a coupled position the drive train drivingly connects the end of the motor shaft to the end of the brushroll. In the coupled position the drive train transmits rotation from the motor to the brushroll.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention 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 accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a perspective view of a surface cleaning device.

FIG. 2 illustrates a perspective view of a cleaning head of the surface cleaning device of FIG. 1.

FIG. 3 illustrates a cross sectional view of the cleaning head of FIG. 2.

FIG. 4 illustrates an exploded view of a drive train of the cleaning head of FIG. 2 with the drive train in an uncoupled position.

FIG. 5 illustrates a back perspective view of the exploded drive train of FIG. 3.

FIG. 6 illustrates a drive train of a cleaning head according to another embodiment with the drive train in an uncoupled state.

FIG. 7 illustrates an exploded view of the drive train shown in FIG. 6.

FIG. 8 illustrates a back perspective view of the exploded drive train of FIG. 7.

FIG. 9 illustrates a cross section view of the cleaning head of FIG. 6.

FIG. 10 illustrates a perspective view of another embodiment of a cleaning head.

FIG. 11 illustrates a perspective view of the cleaning head of FIG. 10 with a drive train in an uncoupled position.

FIG. 12 illustrates a front exploded view of the drive train of FIG. 11.

FIG. 13 illustrates a rear exploded view of the drive train of FIG. 11.

FIG. 14 illustrates a cross section view of the cleaning head of FIG. 10.

FIG. 15 illustrates a perspective view of the cleaning head of FIG. 10 with portions removed to illustrate a brushroll cavity with the brushroll removed.

DETAILED DESCRIPTION

FIG. 1 illustrates a surface cleaning apparatus or floor cleaner 10 with a cleaning head 12 movable over a surface to be cleaned and a body portion 14 pivotally mounted to the cleaning head 12. The body portion 14 includes a handle 18. In the illustrated embodiment, the body portion 14 is pivotal relative to the cleaning head 12 between an upright storage position (FIG. 1) and an inclined floor cleaning position.

The floor cleaner 10 includes one or more tanks for storing liquid and is configured to distribute cleaning solution to the floor. In the illustrated embodiment, the floor cleaner 10 includes a supply tank 16 for providing water or other cleaning solution and a debris collector 20 for collecting dirt and debris collected from the surface being cleaned. In the illustrated embodiment, the debris collector 20 is a recovery tank 20 for use with a wet-type floor cleaner or extractor. In other embodiments, such as for a dry-type floor cleaner or vacuum cleaner, the debris collector 20 may be a cyclonic separator, a filter bag, or other collector container. Furthermore, in other embodiments, the floor cleaner 10 can be other types or styles of surface or floor cleaners, including a handheld vacuum, a canister style vacuum, stick vacuum, a portable wet spot cleaner, and other types of floor cleaners and the like.

With continued reference to FIG. 1, one embodiment of the floor cleaner 10 may have a fluid distribution system including the supply tank 16 that distributes solution from the supply tank 16 to the surface to be cleaned. The cleaning head 12 includes one or more brushrolls 22 (FIG. 3) disposed in the cleaning head 12 to engage the surface to be cleaned to agitate or scrub or polish the surface.

The illustrated floor cleaner 10 includes a recovery system including a suction nozzle 24, the recovery tank 20, and a suction source. In the illustrated embodiment, the suction nozzle 24 has a suction inlet 30 at least partially spanning the front portion of the cleaning head 12. The suction nozzle 24 is in fluid flow communication with the recovery tank 20 by way of an air duct 32 operatively coupled between the cleaning head 12 and the body portion 14. The suction source, housed in the body portion 14, draws debris laden air through the suction nozzle 24 and the air duct 32 of the cleaning head 12, through a separator in the recovery tank 20, to then exhaust the air to the atmosphere leaving separated debris in the recovery tank 20. In other embodiments, the suction source may be housed in a different portion of the floor cleaner 10, such as the cleaning head 12. During operation, the floor cleaner 10 may distribute cleaning solution from the supply tank 16 to the surface, while simultaneously or sequentially extracting and recovering the applied cleaning solution in a continuous operation.

In the illustrated embodiment, the recovery tank 20 is removably coupled to the body portion 14 to allow a user to remove the recovery tank 20 and empty the contents. In other embodiments, the recovery tank 20 may be operatively coupled to another portion of the floor cleaner 10, such as the cleaning head 12. In some embodiments, the floor cleaner 10 is not an extractor and does not include a fluid distribution system. For example, the floor cleaner may be embodied as an upright vacuum cleaner, a stick vacuum, a handheld vacuum, a portable wet spot cleaner, or any other cleaner configuration as discussed above.

As shown in FIG. 2, the cleaning head 12 includes a housing 40 with a top wall 42, a bottom wall 44, and at least one sidewall 46. The housing 40 is coupled to a pair of wheels 50 that support the cleaning head 12 for movement across the surface to be cleaned. The bottom wall 44 of the housing 40 is positioned to face the surface to be cleaned as the cleaning head 12 is moved. The top wall 42 is spaced above the bottom wall 44. In the illustrated embodiment, the housing 40 includes a pair of sidewalls 46 on opposite sides of the cleaning head 12 extending between the top wall 42 and the bottom wall 44. In other embodiments, the housing 40 may include other configurations with differing wall structures. The cleaning head 12 includes a drive train 52 removably coupled to the housing 40.

With reference to FIG. 3, the cleaning head 12 contains the brushroll 22 and a motor 54. The motor 54 is mounted in the housing 40 and includes a motor shaft 56. The motor 54 is operable to rotate the motor shaft 56 with respect to the housing 40 about a motor axis 58. The motor shaft 56 extends along the motor axis 58 between a first end 60 and a second end 62. The first end 60 is positioned in the cavity 48. A fan 64 may be coupled to the second end 62 of the motor shaft 56 to cool the motor 54 when it is running. The motor 54 may be an electric motor and may be supplied power by an onboard power source or by an external power source. The motor shaft 56 includes a motor coupler 66 mounted to the first end 60 of the motor shaft 56 to rotate with the motor shaft 56. The motor coupler 66 includes a shaped projection 68. The motor 54 is mounted in the housing 40 to rotate the brushroll 22.

The brushroll 22 is rotatably mounted in the housing 40 near a front of the housing 40 for rotation about a brushroll axis 70. The brushroll axis 70 is parallel to the motor axis 58 but is spaced from the motor axis 58. The bottom wall 44 includes an opening 72 and the brushroll 22 is supported in the housing 40 to partially extend through the opening 72 to contact the surface to be cleaned. The brushroll 22 includes a roller body 74 extending along the brushroll axis 70 between a first end 76 and a second end 78. The first end 76 and second end 78 of the roller body 74 are supported by end caps, or brackets 80 for rotation relative to the housing 40. The first end 76 of the brushroll 22 is positioned in the cavity 48. In some embodiments, rotation of the brushroll 22 agitates the surface to dislodge embedded dirt or debris. In some embodiments, the brushroll 22 sweeps or assists in moving dirt toward the suction inlet 30.

In the embodiment illustrated in FIGS. 3-5, the brushroll 22 includes an adapter 82 rotatably coupled to the end cap 80 at the first end 76 of the roller body 74. In the illustrated embodiment the roller body 74 includes a roller recess 84 in the first end 76. The adapter 82 includes a roller projection 86, a shaft 90 mounted to the roller projection 86, and a drive projection 88 mounted on the shaft 90. The roller projection 86, the shaft 90, and the drive projection 88 are connected together and rotatable as a unit. The adapter 82 is supported by the bracket 80 on the first end 76 of the roller body 74 to rotate with respect to the bracket 80 and the housing 40. Specifically, the shaft 90 of the adapter 82 is supported in an adapter bearing 92 mounted to the bracket 80. The bracket 80 is configured to support the brushroll 22 in the housing 40. The bracket 80 is non-rotatably connected to the housing 40 fixing the adapter bearing 92 relative to the housing 40 and positioning the shaft 90 for rotation. The roller projection 86 engages the roller recess 84 to couple the adapter 82 to the brushroll 22 for corotation with the roller body 74, such that rotation of the drive projection 88 rotates the roller body 74 relative to the bracket 80 and the housing 40. In one embodiment, the roller recess 84 is configured to receive the shaft 90 directly without the intervening roller projection 86.

The cleaning head 12 includes the drive train 52 to drivingly couple the motor 54 to the brushroll 22. With reference to FIGS. 3-5, the drive train 52 is removably coupled to the housing 40 to transmit rotation from the motor 54 to the brushroll 22. The drive train 52 is movable between a coupled position (FIG. 2) and an uncoupled position (FIG. 4). The drive train 52 includes a panel 100, a first coupler 102 rotatably supported on the panel 100 by a first bearing 104, a second coupler 106 rotatably supported on the panel 100 by a second bearing 108, and a belt 110 rotatably coupling the first coupler 102 and the second coupler 106.

The housing 40 includes a cavity 48 configured to operably receive the drive train 52 in the coupled position. In the illustrated embodiment, the cavity 48 is accessible through the sidewall 46. As best shown in FIG. 4, the sidewall 46 includes an opening 112 for receiving the drive train 52. The opening 112 allows access to the cavity 48 through the sidewall 46. The panel 100 is removably coupled to the sidewall 46 and in the illustrated embodiment is sized and shaped to correspond to the opening 112. As seen in FIG. 2, in the coupled position the drive train 52 is received by the opening 112 in the sidewall 46. In one embodiment, the panel 100 is supported so an outer surface 114 (FIG. 5) forms an external surface of the housing 240 and may be configured to form a continuous side profile as desired. When the drive train 52 is received in the opening 112, the panel 100 fills the opening 112, preventing access to the cavity 48 through the sidewall 46. In one embodiment, the panel 100 is covered by a decorative cover or door after the panel 100 is installed, the decorative cover forming the external surface of the housing 240. Referring to FIG. 4, the panel 100 forms a structure maintaining a predetermined dimension between the first coupler 102 and the second coupler 106. The illustrated panel 100 includes ribs and mounting geometry on an inner side 118 with a pair of posts 120. In the illustrated embodiment the posts 120 have a cross shaped cross section, however, in other embodiments other cross sections may be used.

Each of the first bearing 104 and the second bearing 108 may be formed as roller bearings. For example, each may include an inner ring 124 and an outer ring 126. The inner ring 124 may include an inner opening 128 that receives the corresponding post 120. The outer ring 126 rotates relative to the inner ring 124. The first bearing 104 and the second bearing 108 may be press fit on the pair of posts 120. Other bearing types may also be used.

As illustrated in FIGS. 4 and 5, the first coupler 102 is mounted on the panel 100 and is rotatable relative to the panel 100. The first coupler 102 includes a first bearing cavity 132, a first sprocket portion 134, and a first recess 136. The first bearing cavity 132 may receive the first bearing 104 and may include engaging features such that the first coupler 102 may be press fit onto the first bearing 104. The first sprocket portion 134 is configured to engage the belt 110 and may include engaging teeth or other engaging features. The first sprocket portion 134 may have a first diameter. The first recess 136 is sized and shaped to drivingly engage the shaped projection 68 of the motor coupler 66 to fix the motor coupler 66 for corotation with the first coupler 102. The first sprocket portion 134 may be integrally formed with or a portion of the first coupler 102 or otherwise assembled to rotate together.

The second coupler 106 is mounted on the panel 100 and is rotatable relative to the panel 100. The second coupler 106 includes a second bearing cavity 140, a second sprocket portion 142, and a second recess 144. The second bearing cavity 140 may receive the second bearing 108 and may include engaging features such that the second coupler 106 may be press fit onto the second bearing 108. The second sprocket portion 142 is configured to engage the belt 110 and may include engaging teeth or other engaging features. The second sprocket portion 142 may have a second diameter. The second diameter is selected relative to the first diameter of the first sprocket portion 134 to control the rotational speed of the brushroll 22 relative to the rotational speed of the motor shaft 56 by the ratio of the first diameter to the second diameter. In the illustrated embodiment, the second diameter is larger than the first diameter to rotate the brushroll 22 at a slower speed than the speed of the motor shaft 56. The second recess 144 is sized shaped to drivingly engage the drive projection 88 of the brushroll 22. The drive projection 88 acts as a brushroll drive positioned in the cavity 48 to engage the second coupler 106 and to drive the brushroll 22. The second sprocket portion 142 may be integrally formed with or a portion of the second coupler 106 or otherwise assembled to rotate together.

The belt 110 is mounted between the first coupler 102 and the second coupler 106. The illustrated belt 110 is a timing or synchronous belt having a ridged inner surface 150. The belt 110 forms a loop that surrounds the first sprocket portion 134 and the second sprocket portion 142 so that the ridged inner surface 150 engages the engaging features of the first sprocket portion 134 and the second sprocket portion 142 to transmit rotation therebetween. However, other types of drive belt and corresponding sprockets may be used as desired for the application.

In the illustrated embodiment, the inner openings 128 of the first roller bearing and second roller bearing are press fit onto the pair of posts 120. The first coupler 102 is press fit onto the first roller bearing such that the first roller bearing is received in the first bearing cavity 132. The second coupler 106 is press fit onto the second roller bearing such that the second roller bearing is received in the second bearing cavity 140. The belt 110 is positioned to surround the first coupler 102 and the second coupler 106 to transmit rotation therebetween. Therefore, rotation of the first coupler 102 relative to the panel 100 results in rotation of the second coupler 106 relative to the panel 100. When the drive train 52 is in the uncoupled position, the first coupler 102, the second coupler 106, and the belt 110 are carried on the panel 100 and moved outside the cavity 48 as an assembly.

Once assembled, the drive train 52 can then be removably coupled to the housing 40. The drive train 52 can be positioned in the opening 112 in the sidewall 46. The illustrated panel 100 includes a pair of fastener openings 116 extending through the panel 100 and recessed from the outer surface 114. A pair of fasteners 154 can pass through the pair of openings 116 in the panel 100 and engage the housing 40 to secure the panel 100 relative to the sidewall 46. In the illustrated embodiment, the fasteners 154 are threaded screws that engage threaded mounting openings in the housing 40. In other embodiments, other fasteners may be used. Other attachment techniques may be used to hold the panel 100, such as interlocking features, one or more latches, or a combination of two or more selected from the group of fasteners, interlocking features, and latches as desired for the application.

In the illustrated embodiment, the motor coupler 66 is disposed at an axial end of the motor shaft 56 and the drive projection 88 is disposed at an axial end of the brushroll 22 and adaptor assembly. The drive train 52 installs to the coupled position by movement in an axial direction to engage the motor coupler 66 and the drive projection 88, the panel 100 and belt 110 transverse to the motor axis 58 and brushroll axis 70.

With reference back to FIG. 3, when the drive train 52 is in the coupled position, the first coupler 102, the second coupler 106, and the belt 110 are supported in the cavity 48. The first coupler 102 is coupled to the motor shaft 56 for corotation via the engagement between the first coupler 102 and the motor coupler 66. Specifically, the first recess 136 receives the shaped projection 68 of the motor coupler 66. The first coupler 102 rotates relative to the housing 40 about the motor axis 58 driven by the rotation of the motor shaft 56 and motor coupler 66. The second coupler 106 is coupled to the brushroll 22 for corotation via the engagement between the second coupler 106 and the adapter 82 of the brushroll 22. Specifically, the second recess 144 receives the drive projection 88 of the adapter 82 of the brushroll 22. The second coupler 106 rotates relative to the housing 40 about the brushroll axis 70 driven by rotation of the belt 110. In the illustrated embodiment the projections and recesses each have a generally star shaped profile, however, in other embodiments other profiles that prevent relative rotation between components may be used. Additionally, other methods of rotatably coupling the couplers other than using projections and recesses may also be used as would be apparent to a person of skill in the art.

During operation of the floor cleaner 10, power may be supplied to the motor 54 causing the motor 54 to rotate the motor shaft 56. Rotation of the motor shaft 56 is transmitted to the first coupler 102 through the engagement between the motor coupler 66 and the first coupler 102. Rotation is then transmitted by the belt 110 to the second coupler 106. The second coupler 106 transmits rotation to the brushroll 22 by engaging the drive projection 88 of the adapter 82. The adapter 82 transmits rotation to the roller body 74, which then rotates about the brushroll axis 70 to contact the surface to be cleaned.

FIGS. 6-9 illustrate another embodiment of a cleaning head 212. The cleaning head 212 includes features similar to the cleaning head 12, so only differences between the embodiments are discussed in detail. Like parts are represented with like reference numerals plus 200. As seen in FIG. 6, the cleaning head 212 includes a drive train 252 removably coupled to a housing 240 of the cleaning head 212. The drive train 252 is movable between a coupled position (FIG. 9) and an uncoupled position (FIG. 6).

As shown in FIGS. 7 and 8, the drive train 252 includes a first coupler 302 and a second coupler 306 rotatably supported on a panel 300 and rotatably coupled by a belt 310. The second coupler 306 includes an adapter 282, substantially similar to the adapter 82 of the brushroll 22 in cleaning head 12. The adapter 282 of the embodiment illustrated in FIGS. 7-8 is configured on the removable drive train 252 such that the roller projection 286 is a part of and removable with the drive train 252 instead of the brushroll 222.

The second coupler 306 includes a second bearing 308, a sprocket 360, an adapter bearing 362, a bearing cover 364, a bracket 280, a shaft 290, and a roller projection 286. The second coupler 306 is supported on the panel 300 by the second bearing 308. The panel 300 of the drive train 252 includes a single post 320. A first bearing 304 is mounted on the post 320 and rotatably supports the first coupler 302. The panel 300 also includes a panel bearing cavity 366 for receiving the second bearing 308. The second bearing 308 can be press fit into the panel bearing cavity 366. The sprocket 360 includes a second sprocket portion 342 and a second recess 344. The second sprocket portion 342 includes engaging features such as teeth to engage a ridged inner surface 350 of the belt 310. The bracket 280 is configured to support the brushroll 222 in the housing 240. The adapter 282, including the shaft 290 and the roller projection 286, is supported by the bracket 280 to rotate with respect to the bracket 280 and the housing 240. The shaft 290 is mounted in the adapter bearing 362 which is mounted to the bracket 280. The bracket 280 is configured to support the brushroll 222 in the housing 240. In the coupled position, the bracket 280 is non-rotatably connected to the housing 240 fixing the adapter bearing 362 relative to the housing 240 and positioning the shaft 290 for rotation. In the illustrated embodiment, in the coupled position, the bracket 280 is non-rotatably seated in a mounting cavity 370 in the housing 40. The bracket 280 includes an adapter bearing cavity 376. The adapter bearing cavity 376 is configured to receive the adapter bearing 362. The adapter bearing 362 may be press fit into the adapter bearing cavity 376 of the bracket 280.

The second coupler 306 includes the shaft 290 extending between a first end 378 and a second end 380. The first end 378 engages the roller projection 286 so that the shaft 290 does not rotate relative to the roller projection 286. The second end 380 engages the second bearing 308. The bracket 280, adapter bearing 362, and sprocket 360 are all mounted on the shaft 290 between the roller projection 286 and the second bearing 308.

FIG. 9 illustrates the drive train 252 assembled and in the coupled position. The second bearing 308 is press fit into the panel bearing cavity 366. The second end 380 of the shaft 290 is press fit into the second bearing 308. The second bearing 308 axially secures the shaft 290 to the panel 300 but allows for rotation of the shaft 290 relative to the panel 300. The sprocket 360 is mounted on the shaft 290 adjacent the second bearing 308. The sprocket 360 is secured so that rotation of the sprocket 360 results in rotation of the shaft 290. The adapter bearing 362 is received in the adapter bearing cavity 376. The bearing cover 364 is positioned over the adapter bearing cavity 376. The shaft 290 extends through the adapter bearing 362 and the bracket 280, allowing the shaft 290 to rotate relative to the bracket 280. The bracket 280 is received in the housing 240 in the mounting cavity 370 and is rotatably fixed relative to the housing 240. Finally, the roller projection 286 is mounted on the first end 378 of the shaft 290.

In operation, the motor 254 rotates the first coupler 302, which transmits rotation through the belt 310 to the second coupler 306. Specifically, the belt 310 engages the second sprocket portion 342 of the sprocket 360 to rotate the sprocket 360. The shaft 290 is mounted to rotate with the sprocket 360 and rotates within the bracket 280. The roller projection 286 is mounted on the end of the shaft 290 to rotate therewith. The roller projection 286 is received in the roller recess 284 of the brushroll 222, and rotation of the roller projection 286 by the belt 310 causes the brushroll 222 to rotate. The roller recess 284 acts as a brushroll drive positioned in the cavity 48 to engage the second coupler 306 and to drive the brushroll 22.

As shown in FIG. 6, when the drive train 252 is in the uncoupled position, the roller projection 286 is carried with the panel 300 and the brushroll 222 remains with the housing 240. In the illustrated embodiment, the engagement of the roller projection 286 with the roller recess 284 of the brushroll 222 retains the brushroll 222 in the housing 240. As such, removal of the drive train 252 releases the brushroll 222 from the housing 240, but the brushroll 222 is not carried with the drive train 252.

FIGS. 10-15 illustrate another embodiment of a cleaning head 412. The cleaning head 412 includes features similar to the cleaning head 212, and like parts are represented with like reference numerals plus 200. Features of the cleaning heads 12 and 212 can be combined with features of the cleaning head 412 and vice versa. The cleaning head 412 includes a drive train 452 removably coupled to a housing 440 of the cleaning head 412. The drive train 452 is movable between a coupled position (FIG. 10) and an uncoupled position (FIG. 11).

As shown in FIGS. 12 and 13, the drive train 452 includes a first coupler 502 and a second coupler 506. The first coupler 502 includes a first recess 536 and a first sprocket portion 534 (FIG. 13). The first coupler 502 and second coupler 506 are rotatably supported on a panel 500 and rotatably coupled by a belt 510. The panel 500 is removably mounted to the housing 440 through fasteners 554 (FIG. 14) inserted through openings 516 in an outer surface 514 of the panel 500. In the illustrated embodiment, the outer surface 514 of the panel 500 is shaped to form the outer surface of the cleaning head 412. The first coupler 502 is coupled to a first shaft 584 mounted adjacent the first sprocket portion 534. The first shaft 584 is rotatably supported on the panel 500 by a first bearing 504. The first bearing 504 is mounted in a first bearing cavity 532, such as by press-fitting. In the illustrated embodiment, the first bearing cavity 532 is accessible through the outer surface 514 of the panel 500. An external bearing cover 592 is coupled to the panel 500 to enclose the first bearing cavity 532 and may further retain the first bearing 504 in the first bearing cavity 532. In the illustrated embodiment, the external bearing cover 592 is coupled to the panel 500 through a snap fit between the panel 500 and integral resilient snap projections. In other embodiments, the external bearing cover 592 may be coupled to the panel 500 in other ways, for example by using screws or other fasteners.

The second coupler 506 includes a sprocket 560, a second shaft 490, and an adapter 482. The adapter 482 includes a bracket 480 and a roller projection 486. The second shaft 490 includes a first end 578 coupled to the roller projection 486 of the adapter 482 and a second end 580 rotatably supported on the panel 500 by a second bearing 508. The panel 500 defines a bearing cavity 566 for receiving the second bearing 508 and the second end 580 of the second shaft 490. The sprocket 560 includes a second sprocket portion 542 which engages the belt 510 to rotatably couple the second coupler 506 to the first coupler 502. In the illustrated embodiment, a sprocket cover 596 is coupled to the sprocket 560 to retain the belt 510 on the second sprocket portion 542. The sprocket cover 596 is snap fit onto one side of the sprocket 560 and extends radially past the second sprocket portion 542. In other embodiments, the sprocket cover 596 may be coupled to the sprocket 560 in other ways or may not be needed. The sprocket 560 defines a second recess 544 that surrounds a portion of the bracket 480. The second shaft 490 extends through the bracket 480 for rotation by an adapter bearing 562 that is mounted in an adapter bearing cavity 576 in the bracket 480. An adapter bearing cover 564 is coupled to the bracket 480 to enclose the adapter bearing cavity 576 and may further retain the adapter bearing 562 therein. The bracket 480 includes flanges 598 configured to mount the bracket 480 to the panel 500. In some embodiments, the flanges 598 include openings that allow fasteners to pass therethrough and couple with corresponding features on the panel 500. In other embodiments other methods of coupling may be used.

As shown in FIG. 14, when the drive train 452 is in the coupled position, the drive train 452 is received in the cavity 448 such that a motor coupler 466 positioned on a first end 460 of a motor shaft 456 of a motor 454 engages the first coupler 502. The first shaft 584 is rotatable relative to the panel 500 and the housing 440. The second shaft 490 is similarly rotatable relative to the panel 500 and the housing 440. The bracket 480 is secured to the panel 500 and is prevented from rotating relative to the panel 500 or the housing 440. The sprocket 560 and the roller projection 486 are rotatable with the second shaft 490. The bracket 480 is received in a mounting cavity 570 (FIG. 11) of the housing 440 and supports the brushroll 422 for rotation in a brushroll cavity 600. The adapter 482, including the shaft 490 and the roller projection 486, is supported by the bracket 480 to rotate with respect to the bracket 480 and the housing 440. The shaft 490 is supported in the adapter bearing 562 that is mounted to the bracket 480. The bracket 480 is configured to support the brushroll 422 in the housing 440. In the coupled position, the bracket 480 is non-rotatably connected to the housing 440 fixing the adapter bearing 562 relative to the housing 440. Additionally, the bracket 480 provides additional support to the adapter bearing 562 and the brushroll 422 by extending between the panel 500 and the mounting cavity 570.

As seen in FIG. 15, the brushroll 422 can be removed from the brushroll cavity 600 while the drive train 452 is in the coupled position by uncoupling the brushroll 422 from the housing 440 at the brushroll end opposite the drive. The roller projection 486 and the bracket 480 partially extend into the brushroll cavity 600 to engage the brushroll 422.

In operation, when the brushroll 422 is installed, the motor 454 rotates the motor coupler 466 which engages and rotates the first coupler 502. The belt 510 transfers rotation from the first sprocket portion 534 of the first coupler 502 to the second sprocket portion 542 of the second coupler 506. The sprocket 560 rotates the second shaft 490 relative to the panel 500 and therefore the roller projection 486 rotates with respect to the housing 440. The roller projection 486 engages a recess 484 on the brushroll 422 and rotates the brushroll 422 about a brushroll axis 470.

The described embodiments offer several advantages. First, the drive train 52 is easily removable for maintenance such as replacement of the belt 110. Additionally, the drive train 52 forms a separate unit and can therefore be replaced or serviced independent from the rest of the cleaning head 12. Removal of the drive train 52 does not require removal of the motor 54 or brushroll 22 making the process simpler and faster.

While the removable drive train 52 has been described herein in relation to, an extractor carpet cleaning machine, the invention also finds application in relation to hard floor cleaners, sweepers, mops, vacuum cleaners, and other extractor or non-extractor floor cleaners and therefore should not be limited by the disclosed embodiments. For example, the floor cleaner 10 could be embodied as an upright vacuum with an upright portion and a base, with a removable drive train coupled to the base. The floor cleaner 10 could also be embodied as a stick vacuum, with the removable drive train coupled to the cleaning head attachment. Similarly, the floor cleaner described herein is illustrated as having a single brushroll. The floor cleaner could also be embodied with two brushrolls (or more), where the removable drive train drives one or both of the brushrolls. Other applications are possible and included in the scope of this disclosure.

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

Claims

1. A surface cleaning apparatus comprising: a body including a handle configured to be engaged by a user;a cleaning head connected to the body, the cleaning head including: a housing with a bottom wall facing a surface to be cleaned, a top wall spaced above the bottom wall, and a sidewall extending between the bottom wall and the top wall;a brushroll mounted in the housing such that the brushroll is rotatable relative to the housing about a brushroll axis;a motor mounted in the housing, the motor including a motor shaft and the motor operable to rotate the motor shaft relative to the housing about a motor axis; anda drive train removably coupled to the housing, the drive train including: a panel removably coupled to the housing;a first coupler mounted on the panel such that the first coupler is rotatable relative to the panel;a second coupler mounted on the panel such that the second coupler is rotatable relative to the panel; anda belt extending between the first coupler and the second coupler to transmit rotation between the first coupler and the second coupler;wherein when the panel is removed from the housing, the first coupler, the second coupler, and the belt are carried with the panel;wherein when the drive train is coupled to the housing, the first coupler is coupled to the motor shaft to rotate therewith, and the second coupler is coupled to the brushroll to rotate therewith, such that rotation of the motor shaft is transmitted through the drive train to the brushroll.

2. The surface cleaning apparatus of claim 1, wherein the motor axis and the brushroll axis are parallel and spaced from each other.

3. The surface cleaning apparatus according to claim 1, wherein the motor shaft includes a motor coupler engaging the first coupler to transmit rotation from the motor to the first coupler.

4. The surface cleaning apparatus of claim 3, wherein the motor coupler includes a projection, and the first coupler includes a recess shaped to receive the projection to fix the first coupler for corotation with the motor coupler.

5. The surface cleaning apparatus according to claim 1, wherein the bottom wall includes an opening and the brushroll is mounted to at least partially extend through the opening toward the surface to be cleaned.

6. The surface cleaning apparatus according to claim 1, wherein the brushroll includes a projection, and wherein the second coupler includes a recess shaped to receive the projection to fix the brushroll for corotation with the second coupler.

7. The surface cleaning apparatus according to claim 1, wherein the brushroll includes a roller body extending between a first end and a second end along the brushroll axis, and an adapter coupled to the first end of the roller body, the adapter including the projection.

8. The surface cleaning apparatus according to claim 1, wherein the roller body includes a roller recess positioned at the first end, and the adapter engages the roller recess such that the adapter is supported for rotation about the brushroll axis.

9. The surface cleaning apparatus according to claim 1, wherein the adapter is supported by a bracket for rotation about the brushroll axis, and wherein the bracket is non-rotatably connected to the housing.

10. The surface cleaning apparatus according to claim 9, wherein the bracket is removable with the drive train.

11. The surface cleaning apparatus according to claim 10, wherein the bracket extends between the housing and the panel when the drive train is coupled to the housing.

12. The surface cleaning apparatus according to claim 1, wherein the second coupler includes a projection and the brushroll includes a recess shaped to receive the projection to fix the brushroll for corotation with the second coupler.

13. The surface cleaning apparatus according to claim 1, wherein the sidewall defines an opening, wherein the drive train is removably positioned in the opening such that the panel forms an external surface of the sidewall.

14. The surface cleaning apparatus according to claim 1, wherein the panel includes an opening, and the drive train is removably secured to the housing by a fastener extending through the opening such that the panel is fixed relative to the housing.

15. The surface cleaning apparatus according to claim 1, wherein the first coupler rotates relative to the housing about the motor axis.

16. The surface cleaning apparatus according to claim 1, wherein the second coupler rotates relative to the housing about the brushroll axis.

17. The surface cleaning apparatus according to claim 1, wherein when the drive train is removed from the housing, the brushroll and the motor remain within the housing.

18. A surface cleaning apparatus comprising: a body having a handle; anda cleaning head connected to the body, the cleaning head including: a housing including an opening and defining a cavity that is accessible through the opening;a brushroll mounted in the housing for rotation relative to the housing about a brushroll axis, the brushroll having an end disposed in the cavity;a motor mounted in the housing, the motor including a motor shaft configured to rotate relative to the housing about a motor axis, the motor shaft having an end disposed in the cavity; anda drive train removably coupled to the housing, such that when the drive train is in a coupled position the drive train drivingly connects the end of the motor shaft to the end of the brushroll;wherein in the coupled position the drive train transmits rotation from the motor to the brushroll.

19. The surface cleaning apparatus of claim 18, wherein the drive train includes: a panel removably coupled to the housing;a first coupler mounted on the panel for rotation relative to the panel, the first coupler releasably connectable to the motor;a second coupler mounted on the panel for rotation relative to the panel, the second coupler releasably connectable to the brushroll; anda belt mounted between the first coupler and the second coupler, wherein the belt transmits rotation between the first coupler and the second coupler.

20. The surface cleaning apparatus according to claim 18, wherein when the drive train is in the coupled position, the first coupler, the second coupler, and the belt are positioned within the cavity, and when the drive train is in an uncoupled position, the first coupler the second coupler, and the belt are carried with the panel outside the cavity as an assembly.

21. The surface cleaning apparatus according to claim 18, wherein when the drive train is in the coupled position the first coupler is rotatable about the motor axis and engages the motor shaft to rotate therewith.

22. The surface cleaning apparatus of according to claim 18, wherein when the drive train is in the coupled position the second coupler is rotatable about the brushroll axis and engages the brushroll to rotate therewith.

23. The surface cleaning apparatus according to claim 18, wherein the motor shaft includes a motor coupler disposed in the cavity, and wherein the brushroll includes a brushroll drive disposed in the cavity, and wherein in the coupled position the first coupler is configured to engage the motor coupler and the second coupler is configured to engage the brushroll drive.

24. The surface cleaning apparatus of claim 23, wherein the brushroll drive includes a roller recess.

25. The surface cleaning apparatus of claim 23, wherein the motor coupler includes a shaped projection.

26. The surface cleaning apparatus of claim 23, wherein the brushroll drive includes a drive projection.

27. The surface cleaning apparatus according to claim 18, wherein brushroll includes a brushroll drive disposed in the cavity and the drive train includes an adapter configured to engage the brushroll drive and the second coupler to transfer rotation from the second coupler to the brushroll drive.

28. The surface cleaning apparatus of claim 27, wherein the adapter is removable with the drive train.

29. The surface cleaning apparatus of claim 27, wherein the adapter includes a bracket and a shaft, and the shaft is supported for rotation about the brushroll axis.

30. The surface cleaning apparatus of claim 29, wherein when the drive train is in the coupled position the bracket is non-rotatably connected to the housing and the bracket extends between the panel and the housing.

31. The surface cleaning apparatus according to claim 18, wherein when the drive train is in the coupled position the drive train is received in the opening and prevents access to the cavity through the wall, and when the drive train is in an uncoupled position the cavity is accessible through the opening in the wall.