CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to co-pending U.S. Provisional Patent Application No. 63/377,843, filed September 30, 2022, the entire content of which is incorporated herein by reference.

BACKGROUND

[0002] The present disclosure relates to surface cleaners, and more particularly, to airflow paths for surface cleaners.

SUMMARY

[0003] In one embodiment a surface cleaner is disclosed including a base configured to support the surface cleaner on a surface and a suction nozzle configured to collect liquid and debris from an area to be cleaned. A suction source housing extends from the base and includes an inlet in fluid communication with the suction nozzle, a first outlet, and a second outlet. The surface cleaner includes an exhaust having an exhaust outlet, a first duct in fluid communication with the first outlet of the suction source housing, and a second duct in fluid communication with the second outlet of the suction source housing. The first duct providing a first fluid flow pathway from the first outlet of the suction source housing to the exhaust outlet. The second duct providing a second fluid flow pathway from the second outlet of the suction source housing to the exhaust outlet. A suction source is disposed within the suction source housing and configured to generate an airflow along an airflow path from the suction nozzle to the exhaust outlet. A first portion of the airflow generated by the suction source flows through the first duct from the first outlet toward the exhaust outlet and a second portion of the airflow generated by the suction source flows through the second duct from the second outlet toward the exhaust outlet.

[0004] In another embodiment a surface cleaner is disclosed including a suction nozzle configured to collect liquid and debris from an area to be cleaned, a recovery pathway coupled to the suction nozzle, and a suction source housing. The suction source housing including an inlet in fluid communication with the recovery pathway and the suction nozzle, a first outlet, and a second outlet. An exhaust is coupled to the suction source housing and includes an exhaust outlet, a first duct in fluid communication with the first outlet, and a second duct in fluid communication with the second outlet. The first duct providing a first non-linear fluid flow pathway from the first outlet of the suction source housing to the exhaust outlet. The second duct providing a second non-linear fluid flow pathway from the second outlet of the suction source housing to the exhaust outlet. A suction source is disposed within the suction source housing and configured to generate an airflow along an airflow path from the suction nozzle to the exhaust outlet. The first duct has a first length. The second duct has a second length. The second length is less than the first length. A first portion of the airflow generated by the suction source flows through the first duct from the first outlet toward the exhaust outlet and a second portion of the airflow generated by the suction source flows through the second duct from the second outlet toward the exhaust outlet.

[0005] Other aspects of the present disclosure will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Fig. l is a perspective view of a surface cleaner according to one embodiment of the present disclosure.

[0007] Fig. 2 is an exploded perspective view of the surface cleaner of FIG. 1.

[0008] Fig. 3 is a side view of the surface cleaner of FIG. 1.

[0009] Fig. 4 is a cross-sectional view of the surface cleaner of FIG. 1, taken along section line 4 - 4 in FIG. 1.

[0010] Fig. 5 is a top perspective view of a base of the surface cleaner of FIG. 1.

[0011] Fig. 6 is a bottom perspective view of the base of FIG. 5.

[0012] Fig. V is a bottom view of the base of FIG. 5.

[0013] FIG. 8 is a side view of the base of FIG. 5. [0014] FTG. 9 is a perspective view of an exhaust bottom cover according to one embodiment of the present disclosure.

[0015] FIG. 10 is a plan view of the exhaust bottom cover of FIG. 9.

[0016] Before any embodiments of the present disclosure 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. Example embodiments of the present disclosure are capable of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

The present disclosure relates to a surface cleaner including a suction source, a suction nozzle disposed upstream of the suction source and in fluid communication with the suction source, and an exhaust disposed downstream of the suction source and in fluid communication with the suction source. The suction source generates an airflow through the suction nozzle to collect liquid and debris from an area to be cleaned. The exhaust is provided downstream of the suction source to direct clean air to the atmosphere (e.g., outside of the surface cleaner). As will be described in further detail herein, the exhaust includes multiple fluid flow pathways designed to reduce sound (e g., tonal noise) generated by the surface cleaner.

[0017] Figs. 1-4 illustrate a surface cleaner 10. The surface cleaner 10 is a wet surface cleaner in the illustrated embodiment, such as a spot cleaner, carpet or hard floor extractor, or the like, that delivers a liquid to a surface to be cleaned. In other embodiments, the surface cleaner 10 may include dry or wet-dry type surface cleaners including, vacuum cleaners, wet-dry vacuums, utility vacuums, handheld vacuum cleaners, upright vacuum cleaners, and the like.

[0018] The surface cleaner 10 includes a base 14 that supports components of the surface cleaner 10 and a foot 18 coupled to the base 14 to support the surface cleaner 10 on a surface, such as a surface to be cleaned. In some embodiments, the foot 18 may be permanently coupled to the base 14 (e.g., integrally formed). In other embodiments, all or part of the foot 18 may be selectively removable from the base 14. The surface cleaner 10 includes a front side 22, a rear side 26 opposite the front side 22, and a horizontal longitudinal axis Al extending between the front side 22 and the rear side 26 (Fig. 3). A first lateral side 30 extends between the front side 22 and the rear side 26, and a second lateral side 34 extends between the front side 22 and the rear side 26 opposite the first lateral side 30. The surface cleaner further includes a top side 38 opposite the base 14, and a bottom side 40 opposite the top side 38 (e.g., adjacent the base 14). The horizontal longitudinal axis Al is spaced centrally between the first and second lateral sides 30, 34. A supply tank 42 for providing a cleaning liquid is coupled to the base 14, and a recovery tank 46 for receiving and storing debris and/or liquid that is collected during use of the surface cleaner 10 is coupled to the base 14. In the illustrated embodiment, the supply tank 42 is removably coupled to the base 14 proximate the rear side 26 and the recovery tank 46 is removably coupled to the base 14 proximate the front side 22. In other embodiments, the recovery tank 46 is disposed proximate the rear side 26 and the supply tank 42 is disposed proximate the front side 22. The surface cleaner 10 further includes a suction nozzle 50 (shown in Fig. 1 in a stowed position) in fluid communication with a suction source 52 (Fig. 3) and the recovery tank 46. In use, the suction source 52 generates a suction airflow (e.g., negative pressure airflow) through the suction nozzle 50 to draw debris and/or liquid through the suction nozzle 50 and into the recovery tank 46. In some embodiments, the surface cleaner 10 includes a cleaning tool 54 removably attached to the main body 12 or the base 14 when in a storage position, as illustrated in FIG. 1. The cleaning tool 54 may be an agitating brush, a static brush, a spot cleaning tool, or another type of accessory cleaning tool. The cleaning tool 54 may include the suction nozzle 50 and may include a liquid distributor in fluid communication with the supply tank 42 to distribute liquid to the surface to be cleaned. In the illustrated embodiment, the surface cleaner 10 is a cordless surface cleaner including a battery 58. The battery 58 is a rechargeable battery and provides power to the surface cleaner 10, including the suction source 52

[0019] With reference to FIGS. 4 and 5, the suction source 52 is disposed within a suction source housing 60 that is coupled to the base 14. The suction source housing 60 extends from an upper side 16 of the base 14, opposite the foot 18. In the illustrated embodiment, the suction source housing 60 includes a generally cylindrical lower housing 64 that is integrally formed with the base 14 (FIG. 5). The suction source housing 60 also includes an upper housing 68 that is selectively securable to the lower housing 64 to form a chamber 66 in which the suction source 52 is housed. As will be described in greater detail herein, the suction source housing 60 includes an inlet 72 through which the suction source 52 is in fluid communication with the recovery tank 46 and the suction nozzle 50 to provide a pathway for the suction airflow, and the suction source housing 60 includes a first outlet 76 and a second outlet 80 each in fluid communication with an exhaust 84 through which airflow is expelled from the surface cleaner 10 (FIG. 6). Therefore, the surface cleaner 10 includes an airflow path from the suction nozzle 50, through the recovery tank 46 and the suction source housing 60, and through the exhaust 84. While the illustrated embodiment includes the first outlet 76 and the second outlet 80, in other embodiments, a suction source housing can include a greater number of outlets.

[0020] With reference to FIG. 4, the suction source 52 of the illustrated embodiment includes an electric motor 88 and fan 92. The fan 92 is coupled to the electric motor 88 for co-rotation about a common rotational axis A2. In the illustrated embodiment, the rotational axis A2 is vertically oriented (e.g., transverse to the base 14). Furthermore, the suction source 52 is located such that the rotational axis A2 and the horizontal longitudinal axis Al intersect (FIGS. 4 and 7). Rotation of the fan 92 induces an airflow towards the fan 92 along the rotational axis A2. Once the air reaches the fan 92, the airflow is directed radially away from the fan 92 to be exhausted. Therefore, the fan 92 creates a negative pressure or suction airflow upstream of the fan 92 (e.g., the suction airflow through the suction nozzle 50) and a positive pressure or exhaust airflow downstream of the fan 92.

[0021] Referring now to FIGS. 5-7, the inlet 72 of the suction source housing 60 is aligned with the rotational axis A2. An inlet duct 96 (FIGS. 6 and 7) fluidly couples the recovery tank 46 and the inlet 72 to direct the airflow from the recovery tank 46 to the suction source 52. The inlet duct 96 is formed on a lower side 17 of the base 14. Therefore, the inlet 72 to the suction source housing 60 is an aperture extending through the base 14 to allow the airflow to pass from the lower side 17 of the base 14 to the suction source housing 60, located on the upper side 16 of the base 14. In the illustrated embodiment, the inlet duct 96 is formed by inlet duct walls 98 integrally formed with the base 14 and extending from the lower side 17 of the base 14 (FIG. 6). The inlet duct walls 98 define a non-linear path between the recovery tank 46 and the inlet 72.

[0022] With reference to FIG. 7, the suction source housing 60 includes the first outlet 76 and the second outlet 80 each in fluid communication with the exhaust 84. The exhaust 84 of the illustrated embodiment is disposed on the lower side 17 of the base 14. Therefore, the first and second outlets 76, 80 are apertures passing through the base 14 to allow the airflow that has been directed radially away from the fan 92 (e.g., on the upper side 16 of the base 14) to enter the exhaust 84 (e.g., the lower side 17 of the base 14) and ultimately be expelled to the atmosphere (e.g. outside of the surface cleaner 10). However, in other embodiments the exhaust 84 may be formed on the upper side 16 of the base 14. The first and second outlets 76, 80 are disposed closer to a perimeter of the suction source housing 60 than to the rotational axis A2. Therefore, the first and second outlets 76, 80 are located radially further from the rotational axis A2 than the inlet 72. Furthermore, the first outlet 76 is disposed on a first side of the horizontal longitudinal axis Al, and the second outlet 80 is disposed on a second side of the horizontal longitudinal axis Al. The second side of the horizontal longitudinal axis Al is opposite the first side. However, in the illustrated embodiment, the first and second outlets 76, 80 are not disposed directly opposite one another. Rather, the second outlet 80 is positioned closer to the rear side 26 of the surface cleaner 10 than the first outlet 76. In the illustrated embodiment, the first outlet 76 and the second outlet 80 are disposed an equal radial distance away from the rotational axis A2. Once the airflow is directed radially away from the fan 92, the suction source housing 60 directs the airflow downwards towards the base 14 and through the first and second outlets 76, 80 to enter the exhaust 84. In the illustrated embodiment, each outlet 76, 80 includes an outlet guide vane 100 positioned at an angle relative to vertical to assist in changing the direction of the airflow from downwards to horizontal as it enters the exhaust 84.

[0023] With reference to FIGS. 6 and 7, the exhaust 84 fluidly couples the suction source 52 to the atmosphere. More particularly, the exhaust 84 includes an exhaust outlet 104 disposed on the second side of the base 14 (e.g., the same side of the longitudinal axis Al as the second outlet 80 of the suction source housing 60). The exhaust outlet 104 is an aperture which provides a path for the airflow to exit the surface cleaner 10. Although not illustrated, the exhaust outlet 104 may include louvers or a grate which define a transition point between the surface cleaner 10 and the atmosphere. While the illustrated embodiment includes a single exhaust outlet 104, other embodiments may include a greater number of exhaust outlets 104. A first exhaust duct 108 fluidly couples the first outlet 76 of the suction source housing 60 to the exhaust outlet 104, and a second exhaust duct 112 fluidly couples the second outlet 80 of the suction source housing 60 to the exhaust outlet 104. The first exhaust duct 108 and the second exhaust duct 112 form parallel fluid flow pathways from the suction source housing 60 to the exhaust outlet 104. As used herein to describe the exhaust ducts, the term parallel does not mean geometrically parallel. Rather, parallel is defined as splitting the airflow into multiple portions that generally flow in a direction from the suctions source 52 toward the exhaust outlet 104. The exhaust 84 is formed on the lower side 17 of the base 14. The first exhaust duct 108 is formed by first exhaust duct walls 110 extending from the lower side 17 of the base 14, and the second exhaust duct 112 is formed by second exhaust duct walls 114 extending from the lower side 17 of the base 14 (FIGS. 6 and 8). The first and second exhaust ducts 108, 112 of the illustrated embodiment are integrally formed with the base 14.

[0024] Further details of the first exhaust duct 108 will now be given with reference to FIG. 7. The first exhaust duct 108 defines a pathway for airflow between the first outlet 76 of the suction source housing 60 and the exhaust outlet 104. The first exhaust duct 108 therefore begins on a first side 140 of the base 14 and extends to a second side 144 of the base 14. The first side 140 of the base 14 and the second side 144 of the base 14 are separated by the horizontal longitudinal axis Al, as shown in FIG. 7. More particularly, the first exhaust duct 108 is routed from the first outlet 76 toward the rear side 26 of the surface cleaner 10 and curves around the rotational axis A2 of the suction source 52. In the illustrated embodiment, the first exhaust duct 108 curves around more that 50% of the rotational axis A2. By curving around the rotational axis A2, the first exhaust duct 108 passes onto the second side of the base 14. Tn the illustrated embodiment, the first exhaust duct 108 then curves towards the exhaust outlet 104. The curves direct the airflow in a non-linear path from the suction source housing 60 toward the exhaust outlet 104. A path through the first exhaust duct 108 is defined by a non-linear mathematical function. In the illustrated embodiment, the first exhaust duct 108 includes a guide vane 116 disposed within the curve that directs the duct 108 toward the exhaust outlet 104. The guide vane 116 is formed as a protrusion spaced between the first exhaust duct walls 1 lOand assists in directing the airflow around the curve. In other embodiments, the first exhaust duct 108 may include more or fewer guide vanes. For example, the first exhaust duct 108 may include a single guide vane within each curve, may include a guide vane within only the first curve, or may include multiple guide vanes within one or both of the above described curves. [0025] Further details of the second exhaust duct 1 12 will now be given with continued reference to FIG. 7. The second exhaust duct 112 defines a pathway for airflow between the second outlet 80 of the suction source housing 60 and the exhaust outlet 104. The second exhaust duct 112 therefore begins on the second side 144 of the base 14 and extends to the exhaust outlet 104, also positioned on the second side 144 of the base 14. In the illustrated embodiment, the second exhaust duct 112 includes a curve to direct airflow through the duct towards the exhaust outlet 104. In the illustrated embodiment, the second exhaust duct 112 does not curve around the rotational axis A2. However, in some embodiments, the second exhaust duct 112 may curve around the rotational axis A2. A path through the second exhaust duct 112 can be defined by a non-linear mathematical function that is different than that of the first exhaust duct 108. In the illustrated embodiment, neither the first exhaust duct 108 nor the second exhaust duct 112 are linear. However, in other embodiments, one or both of the first exhaust duct 108 and the second exhaust duct 112 may be linear. Due to the second exhaust duct 112 starting on the same side of the base 14 as the exhaust outlet 104, the second exhaust duct 112 of the illustrated embodiment has a length shorter than the first exhaust duct 108. The length is defined as the distance between the outlet 80 of the suction source housing 60 and the exhaust outlet 104 when following the path of the duct 112. The length of a duct may be measured in various ways including along a centerline evenly spaced between the walls of the duct, along an outer wall of the duct, along an inner wall of the duct, and as the shortest path through the duct. Other ways to measure the length of the duct may also be utilized; however, the same method for measurement must be applied to the first exhaust duct 108 and the second exhaust duct 112 in order to compare the respective lengths of the ducts 108, 112. The second exhaust duct 112 of the illustrated embodiment includes no guide vane. However, in other embodiments, one or more guide vanes may be included within the second exhaust duct 112 to assist in directing airflow through the duct 112.

[0026] All or part of the foot 18 may be removable from the base 14. With reference to FIGS. 9 and 10, the foot 18 of the illustrated embodiment includes a bottom cover 120 that is selectively securable to the base 14. The inlet duct 96 and the first and second exhaust ducts 108, 112 are formed by walls 98, 110, 114, respectively, extending from the lower side 17 of the base 14. However, the inlet duct 96 and the first and second exhaust ducts 108, 112 are not enclosed (FIG. 6). The bottom cover 120 is shaped to engage with the walls and enclose the inlet duct 96, the first exhaust duct 108, and the second exhaust duct 1 12 More particularly, the bottom cover 120 includes an inlet recess 124 for receiving the inlet duct walls 98, a first exhaust recess 128 for receiving the first exhaust duct walls 110, and a second exhaust recess 132 for receiving the second exhaust duct walls 114. Therefore, when coupled to the base 14, the bottom cover 120 forms a bottom wall of the first and second ducts 108, 112.

[0027] As described herein, the surface cleaner 10 includes a suction source 52 which generates an airflow along an airflow path through the surface cleaner 10. The airflow path begins at the suction nozzle 50, flows through the recovery tank 46, the inlet duct 96, into the suction source 52, and ultimately out of the surface cleaner 10 through the exhaust 84. A recovery pathway is defined as the portion of the airflow path upstream of the suction source 52. Downstream of the suction source 52, a first portion of the airflow flows through the first exhaust duct 108 and a second portion of the airflow flows through the second exhaust duct 112. In the illustrated embodiment, the first and second exhaust ducts 108, 112 merge prior to the airflow entering the exhaust outlet 104 through which the airflow is directed to the atmosphere. The first and second exhaust ducts 108, 112 are designed to create an out-of-phase destructive sound interference to decrease the noise generated during use of the surface cleaner 10.

[0028] While the exhaust 84 has been described as having first and second exhaust ducts 108, 112 that merge upstream of a single exhaust outlet 104. In other embodiments, an exhaust may include more than two ducts that provide pathways to one or more exhaust outlets. Furthermore, in other embodiments a suction source housing can utilize more than two outlets. For example, a suction source housing may include 3 outlets, each in communication with a duct (e.g., 3 ducts).

[0029] Although the present disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the present disclosure as described.

[0030] Various features and advantages of the present disclosure are set forth in the following claims.