CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 62/633,404, filed February 21, 2018, the entire contents of which are hereby incorporated by reference herein.

BACKGROUND

[0002] The present disclosure relates to a battery ejection system. More specifically, the present disclosure relates to a battery ejection system associated with a surface cleaner.

[0003] Vacuum cleaners, hard floor cleaners, wet extractors, and other surface cleaners may be battery powered. An autonomous vacuum cleaner, for example, is a vacuum cleaner that is configured to traverse and vacuum an area without requiring a user to operate. An autonomous vacuum cleaner may be powered using rechargeable batteries.

SUMMARY

[0004] In some embodiments, the present disclosure relates to a surface cleaner. The surface cleaner comprises a nozzle having an air inlet, a suction motor for generating a suction airflow at the air inlet, a body configured to support at least one of the suction motor and the nozzle, a battery pack removably received by the body, and a battery cover pivotally coupled to the body. The battery cover has a first portion disposed over the battery pack and having a second portion configured to engage the battery pack and at least partially eject the battery pack from the body when the battery cover pivots from a closed state to an opened state.

[0005] In other embodiments, the present disclosure relates to a battery ejection system. The battery ejection system comprises a housing configured to support an electronic circuit, a battery pack for powering the electronic circuit, the battery pack being removably received by the housing, and a battery cover pivotally coupled to the housing. The battery cover has a first portion disposed over the battery pack and having a second portion configured to engage the battery pack and at least partially eject the battery pack from the housing when the battery cover pivots from a closed state to an opened state.

[0006] Other features and advantages of the present disclosure will become apparent by consideration of the following description and the appended claims when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a perspective view of an autonomous vacuum cleaner engaged with a charging base in accordance with an embodiment of the present disclosure.

[0008] FIG. 2 is a perspective view of the autonomous vacuum cleaner of FIG. 1.

[0009] FIG. 3 is a plan view of the bottom of the autonomous vacuum cleaner of

FIG. 2.

[0010] FIG. 4 is a front perspective view of the autonomous vacuum cleaner of FIG. 2 with a portion of an outer housing removed to illustrate a nozzle, a conduit that includes an object detection sensor, and a portion of a separator assembly.

[0011] FIG. 5 is a perspective view of the rear of the autonomous vacuum cleaner of FIG. 2 with a battery cover in a closed state.

[0012] FIG. 6 is a perspective view of the autonomous vacuum cleaner of FIG. 5 with a portion of the outer housing removed to illustrate a portion of the separator assembly, a dust cup, and a suction motor assembly.

[0013] FIG. 7 is a right side elevational view of the autonomous vacuum cleaner of FIG. 2.

[0014] FIG. 8 is another perspective view of the rear of the autonomous vacuum cleaner of FIG. 2 with a battery cover in an open state and a battery pack ejected from a body of the autonomous vacuum cleaner. [0015] FIG. 9 is a perspective view of the autonomous vacuum cleaner of FIG. 8 with the battery pack removed.

[0016] FIG. 10 is a perspective view of the autonomous vacuum cleaner of FIG. 8 with the battery cover and the battery pack removed.

[0017] FIG. 11 is a rear top perspective view of the battery cover of the autonomous vacuum cleaner of FIG. 2.

[0018] FIG. 12 is a rear bottom perspective view of the battery cover of the autonomous vacuum cleaner of FIG. 2.

DETAILED DESCRIPTION

[0019] Before any embodiments are explained in detail, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. It should be understood that the description of specific embodiments is not intended to limit the disclosure from covering all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure as defined in the appended claims. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0020] Referring now to the figures, FIG. 1 illustrates an embodiment of a surface cleaner having a battery ejection system (as described below). The battery ejection system is illustrated for use with an autonomous vacuum cleaner 10, but may be applied to other floor cleaning or other appliances. The autonomous vacuum cleaner 10 can selectively engage a charging base 14. The charging base 14 (or base station 14 or charging station 14) can be coupled to a source of electricity (e.g., to a wall outlet by a cord, etc.). In response to the autonomous vacuum cleaner 10 engaging the charging base 14, the charging base 14 can supply electricity to the autonomous vacuum cleaner 10, and more specifically can supply electricity to recharge one or more batteries (not shown) that power the autonomous vacuum cleaner 10.

[0021] Referring to FIGS. 2-3, the autonomous vacuum cleaner 10 is shown disengaged from the charging base 14. The autonomous vacuum cleaner 10 includes a body 12 having a perimeter P and a front end 18 that is opposite a back end 22. The autonomous vacuum cleaner 10 also includes a chassis 26 (or an undercarriage 26 or a frame 26) (shown in FIG. 3). An outer housing 30 (or outer shell 30) cooperates with the chassis 26 to encase one or more components of the autonomous vacuum cleaner 10. The chassis 26 and the outer housing 30 may cooperate to define the body 12.

[0022] With specific reference to FIG. 2, a front bump sensor 34 is positioned at the front end 18 of the autonomous vacuum cleaner 10 and is mounted to and at least partially along the perimeter P of the body 12. The front bump sensor 34 is provided at a leading edge of the autonomous vacuum cleaner 10 in a direction of forward travel 38. The direction of forward travel 38 generally extends from the back end 22 towards the front end 18. The autonomous vacuum cleaner 10 is also configured to operate in a direction opposite the direction of forward travel 38, or in reverse.

[0023] Referring now to FIG. 3, the autonomous vacuum cleaner 10 includes a drive assembly 48. The drive assembly 48 includes a pair of motorized drive wheels 50, 54. A first drive wheel 50 is positioned proximate a first side 42, while a second drive wheel 54 is positioned proximate a second side 46 of the autonomous vacuum cleaner 10. The drive wheels 50, 54 can operate (or rotate) independently of each other. As such, the drive wheels 50, 54 can rotate at the same speed, resulting in the direction of forward travel 38 being generally straight, or can rotate at different speeds to facilitate a turning movement of the autonomous vacuum cleaner 10. The autonomous vacuum cleaner 10 can also include one or more third wheels 62, which can be driven or non-driven (e.g., a caster wheel 62).

[0024] The drive assembly 48 is operably connected to a controller 110 (shown in FIG. 6) of the autonomous vacuum cleaner 10. The controller 110 can be provided in association with a printed circuit board 114. The controller 110 may be configured to map the area to be cleaned and to operate the plurality of drive wheels 50, 54 to move the autonomous vacuum cleaner 10 (or the associated chassis 26) along a cleaning surface S (shown in FIG. 7) within the area to be cleaned.

[0025] For example, the controller 110 may be in communication with an area sensing unit that is configured to map the area to be cleaned. In the embodiment illustrated in FIGS. 4 and 6, the area sensing unit can be a laser distance sensor 118. The laser distance sensor 118 includes a laser emitter (not shown) and a light sensor (not shown). The laser emitter emits a beam (or a light beam or emitted light), and the light sensor detects light from the beam that is reflected by an obstacle (or reflected light). The light sensor outputs a signal to the controller 110 corresponding to a distance to the obstacle. In one example, the laser distance sensor 118 and the controller 110 are configured to calculate a distance to the obstacle by triangulation using the angle of reflected light and the distance between the laser emitter and the light sensor. In other embodiments, other laser rangefinders may be used. The laser distance sensor 118 measures a distance to objects at points around the autonomous vacuum cleaner 10 as the cleaner operates such that the controller 110 can determine the bounds of the map of the area to be cleaned as the autonomous vacuum cleaner 10 moves about the area.

[0026] In addition, the autonomous vacuum cleaner 10 can include one or more odometry encoders (not shown) operably connected to the drive wheels 50, 54, and configured to determine a distance and an estimated direction the autonomous vacuum cleaner 10 travels based on rotation of one or both of the drive wheels 50, 54. The odometry data from the encoders can be combined with the laser distance sensor data from the laser distance sensor 118 by the controller 110 using Simultaneous Localization and Mapping (SLAM) algorithms, or other mapping techniques, to develop the map of the area to be cleaned (or mapped area). The controller 110 can also control the autonomous vacuum cleaner 10 within the mapped area based on where the autonomous vacuum cleaner 10 travels.

[0027] In addition, the controller 110 may receive signals from one or more obstacle detection sensors to identify objects (or obstacles) in the area to be cleaned (e.g., a chair, a sofa, an otoman, etc.). Obstacle detection sensors may include proximity sensors (e.g., infrared sensors, ultrasonic sensors, and tactile sensors), cliff sensors, bump sensors, or any other sensor that is configured to sense or detect an object as the autonomous vacuum cleaner travels. The controller 110 can then incorporate those objects into the map of the area to be cleaned. In the illustrated embodiment, the controller 110 may receive signals, for example, from the front bump sensor 34 to identify objects (or obstacles) in the area to be cleaned.

[0028] Referring back to FIGS. 2-4, the autonomous vacuum cleaner 10 includes a nozzle 66 (shown in FIG. 2) and optionally a brush roll 70 (shown in FIGS. 3-4) that is configured to rotate at least partially within the nozzle 66. The nozzle 66 is disposed interior of the perimeter P of the body 12 and may be carried by the chassis 26. The brush roll 70 extends through an air inlet 68, for example, an air inlet slot, of the nozzle 66 such that the brush roll 70 engages a portion of the cleaning surface S to facilitate dust collection. To facilitate rotation, the brush roll 70 is operably connected to a brush roll motor (not shown) by a belt (e.g., a geared belt, etc.) (not shown). With specific reference to FIG. 4, the nozzle 66 is fluidly connected to a dust separator assembly 74 by a conduit 78 for transporting dirty air (i.e., air containing dust) drawn into the nozzle 66 at the air inlet 68 to the separator assembly 74. In the illustrated embodiment, the separator assembly 74 is a cyclonic separator. In other embodiments, the separator assembly 74 can be any suitable separator assembly (e.g., a bag unit, a filter unit, any suitable non-cyclone separator, etc.).

[0029] With continued reference to FIG. 4, dust that exits the separator assembly 74 through a dust outlet 82 collects in a dust cup 86 (or a dust collection chamber 86 or a dirt cup 86 or a collection bin 86) (shown in FIG. 6). A portion of the outer housing 30 may form a removable cover 102 configured to cover the separator assembly 74 (or portion thereof) and the dust cup 86 (or portion thereof). With reference to FIG. 6, cleaned air exits through the separator assembly 74 by a clean air outlet 90, and travels to a suction motor assembly 94 and then is discharged through a vent 98 (shown in FIG. 5). More specifically, the suction motor assembly 94, which is in fluid communication with the nozzle 66 via the separator assembly 74, includes a suction motor 96 that rotates a fan or impeller to generate a suction airflow at the air inlet 68 for drawing dirty air through the suction nozzle 66 and into the separator assembly 74.

[0030] Referring to FIGS. 5 and 8-9, an energy storage system 106 (or a battery pack 106) is positioned in the autonomous vacuum cleaner 10 to store and provide electricity to operate the autonomous vacuum cleaner 10, including various components and associated electronic circuits thereof, such as the drive assembly 48, the suction motor 96, the controller 110 and the laser distance sensor 118. The energy storage system 106 can include a plurality of cells or battery cells (not shown). The illustrated energy storage system 106 can be recharged (e.g., in a remote charging station, at the charging base 14, etc.).

[0031] More specifically, the battery pack 106 is removably received by the body 12 of the autonomous vacuum cleaner 10 to facilitate charging or recharging in a remote charging station or replacement of the battery pack 106. The body 12 of the autonomous vacuum cleaner 10 may define a battery recess 120 at the back end 22 of the autonomous vacuum cleaner 10 for receiving the battery pack 106. Contacts 116 provided in the battery recess 120 can engage with corresponding contacts (not shown) on the battery pack 106 when the battery pack 106 is received in the battery recess 120 and is in a seated position. In one embodiment, the battery pack 106 may be received in the battery recess 120 such that it is disposed interior of the perimeter P of the body 12 in the seated position. In other embodiments, a portion of the battery pack 106 may be disposed exterior of the perimeter P of the body 12 when the battery pack 106 is in the seated position.

[0032] A battery cover 122 is pivotally coupled to the body 12 for releasably securing and removing the battery pack 106 from its seated position in the battery recess 120. The battery cover 122, the body 12 and the battery pack 106 together may form a battery ejection system. The battery cover 122 may be pivotally coupled to the body 12 at a distal end 124 of the battery cover 122. For example, the battery cover 122 may form a hinge joint 130 with the body 12 at the distal end 124 of the battery cover 122. [0033] With reference to FIGS. 9-11, the hinge joint 130 may include a hinge pin 132 that is oriented perpendicular to a longitudinal axis of the battery cover 122 and extends through a pair of oppositely facing flanges l26a and l26b integrally formed at the distal end 124 of the battery cover 122. Opposite ends of the hinge pin 132 are received in a pair of socket openings 134 (only one shown) formed concentrically therewith in the lateral sidewalls of the battery recess 120 such that the hinge joint 130 defines a pivot axis P perpendicular to a longitudinal axis of the battery cover 122.

[0034] Referring now to FIGS. 8-9 and 11, the battery cover 122 includes a first portion 140 configured to be disposed over the battery pack 106 when the battery pack 106 is received in the battery recess 120. The battery cover 122 also includes a second portion 142 for engaging the battery pack 106. The second portion 142 can be made separately or formed integrally with the first portion 140. The second portion 142 may include one or more actuating members, for example, a pair of actuating members l44a and l44b, formed at the distal end 124 of the battery cover 122. The actuating members l44a and l44b may extend downwardly from the battery cover 122 proximal a distal end 108 (shown in FIG. 8) of the battery pack 106 when the battery pack 106 is received in the battery recess 120. For example, in the illustrated embodiment, the actuating members l44a and l44b may be arranged generally perpendicular to the first portion 140 of the battery cover 122 and may extend downwardly from the flanges l26a and l26b at the distal end 124 of the battery cover 122. The actuating members l44a and l44b can rotate to engage and eject the battery pack 106 when the battery cover 122 pivots at the hinge joint 130 from a closed to an opened state, as described in more detail below.

[0035] The battery cover 122 may also include a user interface such as a lifting lip 146 formed at a proximal end 128 of the battery cover 122 that is opposite the distal end 124. The lifting lip 146 is configured to allow a user to lift the proximal end 128 of the battery cover 122 so as to rotate the battery cover 122 about the hinge joint 130. For example, the lifting lip 146 can be a downwardly curved end portion of the first portion 140 at the proximal end 128 of the battery cover 122. Alternatively or additionally, the user interface of the battery cover may include a handle or grip portion or a battery cover shape configured for grasping by a user for operating the battery cover.

[0036] Referring back to FIGS. 5 and 8-9, the battery cover 122 may pivot between a closed state (as shown in FIG. 5) and an opened state (as shown in FIG. 8). More specifically, in the closed state, the battery cover 122 may be disposed above and/or covering at least a portion of the battery pack 106, which is received in the battery recess 120 in the seated position. When the battery cover 122 pivots from the closed state to the open state, the actuating members l44a and l44b of the second portion 142 rotate toward the battery pack 106 about the pivot axis P in a

counterclockwise direction (when viewed from the interior of the battery recess 120) with the battery cover 122 and engage the battery pack 106, thereby exerting an ejection force on the battery pack 106 in an ejection direction facing away from the body 12. More specifically, the ejection force can act in a direction opposite the direction of insertion (described below) for the battery pack 106. The ejection force exerted by the rotating actuating members l44a and l44b causes the battery pack 106 to move out of its seated position in the battery recess 120 and/or to be ejected or partially ejected from the contacts 116 so as to be at least partially ejected from the body 12. Once the battery cover 122 has pivoted to the open state and the battery pack 106 is at least partially from the body 12, a user may grasp and remove the battery pack 106 entirely out of the battery recess 120.

[0037] When the battery cover 122 is in its open state, the battery pack 106 can be inserted in the body 12 by sliding the battery pack 106 into the battery recess 120 in an insertion direction facing toward the body 12. The battery pack 106 may be inserted into the battery recess 120 until it engages the actuating members l44a and l44b of the second portion 142 of the battery cover 122. Continued insertion of the battery pack 106 will cause the actuating members l44a and l44b to rotate downwardly about the pivot axis P in a clockwise direction (when viewed from the interior of the battery recess 120), thereby forcing the battery cover 122 to pivot about the pivot axis P into its closed state. [0038] Referring to FIGS. 9-12, in order to limit the range of rotation of the battery cover 122 relative to the body 12, the battery cover 122 may include a guide pin 150 provided on an exterior, lateral surface of at least one actuating member l44a and l44b. The guide pin is received in a guide slot 152 formed in a lateral sidewall of the battery recess 120. The guide slot 152 is arc-shaped and is formed such that the guide pin 150 follows the guide slot 152 when the battery cover 122 pivots between the open state and closed state. The ends of the guide slot 152 can constrain rotation of the battery cover 122 so as to define limits in the arc of rotation of the battery cover 122 corresponding to the open state and the closed state of the battery cover 122. As a result, the battery cover 122 may rotate within a certain angle range when the guide pin 150 is received in the guide slot 152, for example an angle range between 30 and 110 degrees. In one embodiment the angle range is between 45 and 60 degrees. In another embodiment, the angle range is between 60 and 90. In yet another embodiment, the angle range is about 45 degrees.

[0039] In addition, with reference to Fig. 12, the battery cover 122 optionally may include a latch assembly 160 mounted at the proximal end 128 of the battery cover 122 to releasably secure the battery cover 122 in the closed state. In the illustrated embodiment, the latch assembly 160 includes a pair of spring-loaded sliding latches l62a and l62b movably mounted on the interior of the lifting lip 146. The sliding latches l62a and l62b are arranged to be oppositely facing when viewed along a direction perpendicular to a longitudinal axis of the battery cover 122. At least one latch spring (not shown) is disposed between the sliding latches l62a and l62b to normally extend them away from each other. Each of the sliding latches l62a and l62b has a catch 164 (only one shown) formed at an outer end thereof opposite an inner end facing the other sliding latch. Each catch 164 protrudes away from the battery cover 122 when the sliding latches l62a and l62b are normally extended away from each other. Further, when the battery cover 122 is in the closed state, the protruding catches 164 are received in corresponding latch openings 166 (shown in Fig. 10) formed in the lateral sidewalls of the battery recess 120. In operation, a user may grasp the sliding latches l62a and l62b and manually push them together, thereby withdrawing the catches 164 from the latch openings 166 and releasing the battery cover 122 so that it can pivot from its closed state to its open state. In other embodiments, other latch mechanisms may be used for retaining the battery cover in the closed state as desired. Alternatively or additionally, a spring may be provided, for example a torsion spring about the pivot axis P providing a force pressing the battery cover toward either its open state or its closed state as desired. In one embodiment, a spring is provided pressing the battery cover toward its closed state.

[0040] In one embodiment, the latch assembly 160 may include one or more inwardly facing ramped surfaces 166. A user may push down on the battery cover 122 once the battery pack 106 is received in the battery recess 120 to bring the ramped surfaces 166 of the latch assembly 160 into engagement with the proximal end 109 of the battery pack 106. The ramped surfaces 166 can cooperate with the battery pack 106 and act as a cam element to ensure the battery pack 106 is urged into the seated position when the battery cover 122 is rotated into its closed state.

[0041] Thus, the present disclosure provides, among other things, a battery ejection system suitable for use with a surface cleaner, such as an autonomous vacuum cleaner. However, a person skilled in the art will recognize from the previous description that the battery ejection system described herein may be used in association with other powered systems and devices and is not limited in its application to surface cleaners. Various features and advantages of the present disclosure are set forth in the following claims.