FLOOR CLEANER

Abstract

A floor cleaner including a recovery tank that receives a fluid and a suction airflow from a suction inlet and separates the suction airflow from the fluid. The recovery tank includes a top side, a bottom wall opposite the top side, a sidewall that extends from the bottom wall. The bottom wall and the sidewall at least partially define a storage volume of the recovery tank. The recovery tank further includes an inlet duct having an inlet aperture configured to direct the fluid from the inlet duct into the storage volume, and a baffle wall connected to the sidewall, the baffle wall facing toward the top side of the recovery tank. The inlet aperture is directed along an inlet direction toward the sidewall adjacent the baffle, and the inlet aperture is disposed above the baffle in a direction from the bottom wall to the top side.

Description

BACKGROUND

The present disclosure relates to floor cleaners and more particularly to floor cleaners that dispense a fluid onto a surface and recover and store the fluid in a recovery tank.

SUMMARY

In one embodiment the disclosure provides a floor cleaner including a supply tank configured to store a fluid, a fluid distributor in fluid communication with the supply tank, the fluid distributor operable to dispense the fluid from the floor cleaner. The floor clean further includes a suction inlet and a suction source in fluid communication with the suction inlet, the suction source operable to generate a suction airflow that is configured to draw the fluid through the suction inlet. A recovery tank is in fluid communication with the suction inlet and the suction source, the recovery tank configured to receive the fluid and the suction airflow from the suction inlet and separate the suction airflow from the fluid. The recovery tank including, a top side, a bottom wall opposite the top side, a sidewall that extends from the bottom wall and defines a perimeter of the recovery tank, the bottom wall and the sidewall at least partially define a storage volume of the recovery tank. The recovery tank further includes an inlet duct having an inlet aperture configured to direct the fluid from the inlet duct into the storage volume, and a baffle wall connected to the sidewall, the baffle wall facing toward the top side of the recovery tank. The inlet aperture is directed along an inlet direction toward the sidewall adjacent the baffle, and the inlet aperture is disposed above the baffle in a direction from the bottom wall to the top side.

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a floor cleaner according to one embodiment.

FIG. 2 is a partially exploded view of the floor cleaner of FIG. 1.

FIG. 3 is a cross-sectional view of a recovery tank of the floor cleaner of FIG. 1.

FIG. 4 is an alternative cross-sectional view of the recovery tank of the floor cleaner of FIG. 1 illustrating a float of the recovery tank in an open position.

FIG. 5 is an alternative cross-sectional view of the recovery tank of the floor cleaner of FIG. 1 illustrating the float of the recovery tank in a closed position.

FIG. 6 is an alternative cross-sectional view of the recovery tank of the floor cleaner of FIG. 1.

FIG. 7 is an alternative cross-sectional view of the recovery tank of the floor cleaner of FIG. 1.

FIG. 8 is an alternative cross-sectional view of the recovery tank of the floor cleaner of FIG. 1.

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

DETAILED DESCRIPTION

FIG. 1 illustrates a floor cleaner 10 configured to clean floors and surfaces other than floors. The floor cleaner 10 includes a supply tank 12 and a fluid distributor 14. The supply tank 12 stores a fluid, for example, a cleaning fluid that includes water, detergent, or a mixture of water and detergent. The fluid distributor 14 is in fluid communication with the supply tank 12 and is operable to dispense the fluid from the supply tank 12, directly or indirectly, onto a surface being cleaned. The floor cleaner 10 further includes a suction inlet 16 and a suction source 18 (FIG. 2). The suction source 18 is in fluid communication with the suction inlet 16. The suction source 18 includes a motor and a fan in one embodiment that are operable to generate a suction airflow through the suction inlet 16. The suction airflow draws the fluid from the surface being cleaned through the suction inlet 16. The illustrated floor cleaner 10 is a portable or handheld type floor cleaner. In other embodiments, the floor cleaner may include an upright style floor cleaner, including the floor cleaner disclosed in U.S. Patent Application Publication No. 2021/0330159, the entire contents of which are hereby incorporated by reference herein.

The floor cleaner 10 further includes a recovery tank 20. The recovery tank 20 is in fluid communication with the suction source 18 and the suction inlet 16. The recovery tank 20 receives the fluid and the suction airflow from the suction inlet 16 and the recovery tank 20 separates the fluid from the suction airflow. The fluid is stored in the recovery tank 20 and the suction airflow exits the recovery tank and travels to the suction source 18 and subsequently out of the cleaner thought an exhaust port 19. In the illustrated embodiments, the recovery tank 20 is removably mounted to a base, such as base 15 shown in FIG. 2. The base is configured to be supported by a floor 11 (FIG. 2) or other supporting surface. In another embodiment, the floor cleaner may include an upright style floor cleaner having a pivoting handle connected to the base, where the recovery tank is mounted to the base as shown in U.S. Patent Application Publication No. 2021/0330159.

Referring to FIG. 3, the recovery tank 20 includes a top side 22, a bottom side or wall 24, opposite the top side 22, and a sidewall 26 that extends up from the bottom wall 24. The sidewall 26 defines a perimeter of the recovery tank 20 and together the sidewall 26 and the bottom wall 24 define a storage volume of the recovery tank 20 for the fluid. A lid 28 is removably coupled to the sidewall 26 and the lid 28 defines the top side 22 of the recovery tank 20 in the illustrated embodiment. The lid may define a portion of the top side 22 in other embodiments. In the illustrated embodiment, the lid 28 movable relative to the sidewall 26 between a closed position and an open position for emptying the liquid retained in the storage volume.

Referring to FIGS. 3, 6, and 7 the recovery tank 20 further includes an inlet duct 30 that extends inside the recovery tank 20 from the bottom wall 24 toward the top side 22 of the recovery tank 20. The inlet duct 30 is in fluid communication with and downstream of the suction inlet 16. The inlet duct 30 includes an inlet aperture 32. The suction airflow and the fluid enter the inlet duct 30 through an opening 44 in the bottom wall 24 of the recovery tank 20 and exit the inlet duct 30 through the inlet aperture 32 of the recovery tank 20. The inlet aperture 32 directs the fluid and the suction airflow from the inlet duct 30 into the storage volume of the recovery tank 20. The inlet aperture 32 is adjacent to the storage volume and adjacent the lid 28 and the top side 22 of the recovery tank 20. The inlet aperture 32 faces or opens toward the sidewall 26 such that the suction airflow and the fluid drawn into the recovery tank 20 are directed toward the sidewall 26 as represented by the arrow 34 in FIG. 7. The arrow 34 is generally perpendicular to the sidewall 26.

With continued reference to FIG. 7, the inlet aperture 32 includes an inlet aperture axis 36. The inlet aperture 36 axis extends centrally through the inlet aperture 32 as shown in FIG. 7. The inlet aperture axis 32 is parallel to the arrow 34, which represents the discharge direction of the fluid and the suction airflow from the inlet aperture 32. The inlet aperture axis 36 extends through the sidewall 26 at a location 38 between the top side 22 of the recovery tank 20 and a baffle wall 40 of the recovery tank 20, which will be discussed in more detail below. An inlet duct axis 42 extends centrally through the inlet duct 30 along a length of the inlet duct 30 as shown in FIG. 7. The inlet duct axis 42 extends upwardly from the bottom wall 24 transverse to the inlet aperture axis 36. In the illustrated embodiment, the inlet duct axis 42 is perpendicular to the bottom wall 24 and perpendicular to the inlet aperture axis 36.

Referring to FIGS. 4 and 5, the recovery tank 20 further includes an outlet duct 46 that receives the suction airflow from the storage volume and directs the suction airflow toward the suction source 18. An outlet aperture 48 of the recovery tank 20 is in the outlet duct 46. The suction airflow travels from the storage volume into the outlet duct 46 through the outlet aperture 48. The outlet duct 46 extends from the bottom wall 24 of the recovery tank 20 toward the top side 22 of the recovery tank 20. The bottom wall 24 includes an opening 50 in fluid communication with the outlet duct 46 and the suction airflow exits the outlet duct 46 through the opening 50 and travels toward the suction source 18. In one embodiment, the outlet duct is disposed in the lid, such as shown in U.S. Patent Application Publication No. 2021/0330159.

With continued referenced to FIGS. 4 and 5, the recovery tank 20 further includes a float 52. The float 52 moves along the outlet duct 46 as the fluid fills the recovery tank storage volume from an open position (FIG. 4) when the recovery tank 20 is empty to a closed position (FIG. 5) when the recovery tank 20 is full of recovered fluid. The outlet duct 46 guides movement of the float 52 between the open and the closed positions. In the closed position (FIG. 5), the float 52 covers the outlet aperture 48, which inhibits suction airflow from traveling through the outlet aperture 48. Inhibiting suction airflow from traveling through the outlet aperture 48 also inhibits suction airflow from traveling through the suction inlet 16 and inhibits the floor cleaner 10 from drawing in or recovering additional fluid. Accordingly, the closed position of the float 52 defines a maximum fill level 54 of the storage volume of the recovery tank 20. The maximum fill level 54 is the maximum amount of fluid that can be drawn into and stored in the recovery tank 20 before the float 52 reaches the closed position covering the outlet aperture 48 inhibiting the floor cleaner 10 from drawing in additional fluid and suction airflow. The maximum fill level 54 is also measured as a distance 56 from the bottom wall 24 to the maximum fill level 54 as shown in FIG. 5.

The float 52 includes a first portion that includes a buoyant portion 60 that floats on the fluid in the recovery tank 20. The float 52 includes a second portion that includes a closure portion 62 that covers the outlet aperture 48 in the closed position of the float 52. The closure portion 62 is moved between the open and the closed positions by the buoyant portion 60. Gravity moves the buoyant portion 60 to the opened position of the float 52 and the rising fluid in the recovery tank 20 moves the float 52 toward the closed position. In the closed position of the float 52, the closure portion 62 extends above the baffle wall 40 (i.e., between the baffle wall 40 and the top side 22 of the recovery tank 20) and the buoyant portion 60 is at least partially below the baffle wall 40 (i.e., between the baffle wall 40 and the bottom wall 24 of the recovery tank 20).

Referring to FIGS. 6 and 7, the recovery tank 20 further includes the baffle wall 40 connected to the sidewall 26, adjacent the inlet aperture 32. The baffle wall 40 faces toward the top side 22 of the recovery tank 20. The illustrated baffle wall 40 is formed as part of the sidewall 26 such that the baffle wall 40 and the sidewall 26 are integrally formed as a single component. For example, the sidewall 26 and the baffle wall 40 can be molded together from plastic. In one embodiment, not shown, the baffle is a plate attached to the sidewall. The baffle wall 40 defines a baffle plane 64 in which the baffle walls 40 lies. The baffle wall 40 and baffle plane 64 are approximately parallel to the floor 11. In the illustrated embodiment, the baffle wall 40 and baffle plane 64 are approximately parallel to the bottom wall 24 and the inlet aperture axis 36. However, the illustrated baffle wall 40 is angled a few degrees relative to the floor 11 (i.e., not exactly parallel to the floor 11, but approximately parallel) such that the fluid flows from the baffle wall by gravity. Also, the illustrated baffle wall 40 and the baffle plane 64 are approximately perpendicular to the sidewall 26. However, an angle 66, as shown in FIG. 7, between the baffle wall 40 and the sidewall 26 is a few degrees greater than 90 degrees (i.e., not exactly perpendicular but approximately). In one embodiment, the angle 66 is in a range from 90 degrees to 120 degrees. In another embodiment, the angle 66 is in a range from 90 degrees to 100 degrees. Also, an angle 68 between the baffle plane 64 and a reference line F parallel to the floor 11 is sloped 1 to 5 degrees such that the fluid flows away from the sidewall 26. In one embodiment, the angle 68 is in a range from 0 degrees to 20 degrees. In another embodiment, the angle 68 is in a range from 0 degrees to 10 degrees. As used in the Detailed Description and appended Claims, “approximately parallel” means being parallel as well as being sloped to the angles described and “approximately perpendicular” means being perpendicular as well as being angled to the angles described. These angles allow liquid to drain or flow off the baffle wall 40 by gravity and into the collection volume of the recovery tank 20.

Referring to FIGS. 5 and 7, the baffle wall 40 is spaced a baffle height 70 measured from the bottom wall 24. The baffle height 70 is greater than the maximum fill level distance 56 by an excess distance 72. Therefore, the fluid entering the recovery tank 20 through the inlet aperture 32 engages the baffle wall 40 before engaging the surface of the fluid, inhibiting formation of foam in the recovery tank 20. In some embodiments, the baffle height 70 is greater than the maximum fill level distance 56 by at least 50 percent of the distance 56. That is, the excess distance 72 is at least 50 percent of the maximum fill level distance 56. In other embodiments, the baffle height 70 is greater than the maximum fill level distance 56 by at least 25 percent of the distance 56. That is, the excess distance 72 is at least 25 percent of the maximum fill level distance 56.

In some embodiments, the baffle height 70 is between about 2 mm to about 80 mm greater than the maximum fill level 54. In some embodiments, the baffle height 70 is between about 10 mm to about 60 mm greater than the maximum fill level 54, and may be between about 30 mm and 60 mm greater than the maximum fill level 54 in some embodiments.

The inlet aperture 32 includes a lower inlet surface 35. The lower inlet surface 35 is positioned a distance from the bottom wall 24 greater than the baffle height 70. Accordingly, the fluid and the suction airflow discharging from the inlet aperture 32 (arrow 34) travel above the baffle wall 40 to the sidewall 26. The fluid flows to and along the baffle wall 40 to the storage volume. For higher flow applications, more distance may be provided between the lower inlet surface 35 and the baffle wall 40 to allow space for the amount of fluid to flow along the baffle wall around the discharging flow from the inlet aperture 32.

As shown in FIG. 8, the baffle wall 40 approximately parallel to the floor 11 may be sloped in a direction transverse to the discharge direction 34 of the fluid and the suction airflow from the inlet aperture 32. In the illustrated embodiment, the baffle wall 40 and baffle plane 64 are sloped between lateral sides of the recovery tank 20. Orienting by the cross section of FIG. 8, the slope may direct fluid toward the left side as shown, or the right side (not shown), or sloped from a central portion 86 both toward the left side and the right side (not shown). In the illustrated embodiment, the slope directs the fluid in a direction away from the outlet aperture 48. An angle 82 (FIG. 8) between the baffle plane 64 and a reference line F parallel to the floor 11 is sloped 1 to 5 degrees such that the fluid flows away from the central portion 86 of the baffle wall 40. In one embodiment, the angle 82 is in a range from 0 degrees to 20 degrees. In another embodiment, the angle 82 is in a range from 0 degrees to 10 degrees.

In the embodiment illustrated in FIG. 7, the baffle wall 40 approximately parallel to the floor 11 slopes away from the sidewall 26 by angle 68 such that the fluid flows by gravity toward the storage volume. In another embodiment, at least a portion of the baffle wall slopes toward the sidewall by angle 68 (a negative angle 68) such that the fluid flows toward the sidewall 26. In one such embodiment, the angle 68 slopes toward the sidewall 26 in the central portion 86 (negative angle 68) adjacent the fluid and the suction airflow discharging from the inlet aperture 32 (arrow 34) and flows away from the sidewall 26 (positive angle 68) along at least one of a first edge portion 84 and a second edge portion 88 away from the fluid discharging from the inlet aperture 32.

The lid 28 may include a redirecting rib 78 (FIG. 7). In the illustrated embodiment, the redirecting rib 78 is positioned on an inner surface of the lid 28 extending toward the bottom wall 24. The fluid discharging from the inlet aperture 32 may splash toward the lid, and the continued airflow from the inlet aperture 32 can cause fluid to flow along the inner surface of the lid. The redirecting rib 78 is positioned to direct fluid flowing along the inner surface of the lid to flow (arrows 80 in FIG. 7) downward along the redirecting rib 78 and drip into the storage volume. The redirecting rib 78 is disposed along the lid between the baffle wall 40 and the outlet aperture 48 inhibiting the fluid flow toward the outlet aperture.

In operation, fluid and the suction airflow are drawn through the suction inlet 16 and are directed through the opening 44 in the bottom wall 24 of the recovery tank 20 and into the inlet duct 30. Referring to FIG. 7, the fluid and the suction airflow travel up the inlet duct 30 and exit the inlet duct 30 through the inlet aperture 32 of the recovery tank 20. The fluid and the suction airflow exit the inlet aperture 32 as represented by the arrow 34 in FIG. 7. A majority of the fluid travels in the direction of arrow 34 and onto the sidewall 26, after which the fluid flows to the baffle wall 40. Then, the fluid flows along the baffle wall 40 and down off of the baffle wall 40 as represented by the arrows 74 in FIG. 7. After flowing off of the baffle wall 40, fluid flows into the storage volume of the recovery tank and contacts a surface 76 of the fluid already in the recovery tank 20. The location of the baffle wall 40 minimizes the fluid that travels from the inlet aperture 32 onto the surface 76 without first settling along the baffle wall 40. Having the fluid first contact the baffle wall 40 before the surface 76 has been found to reduce the amount of foam in the recovery tank 20. Reducing the amount of foam can be desirable because foam may not have the density required to operate (e.g., lift or close) the float 52 and/or foam is susceptible to being drawn through the outlet aperture 48, which is undesirable.

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

Claims

1. A floor cleaner comprising:

a supply tank configured to store a fluid;

a fluid distributor in fluid communication with the supply tank, the fluid distributor operable to dispense the fluid from the floor cleaner;

a suction inlet;

a suction source in fluid communication with the suction inlet, the suction source operable to generate a suction airflow that is configured to draw the fluid through the suction inlet; and

a recovery tank in fluid communication with the suction inlet and the suction source, the recovery tank configured to receive the fluid and the suction airflow from the suction inlet and separate the suction airflow from the fluid, the recovery tank including, a top side, a bottom wall opposite the top side, a sidewall that extends from the bottom wall and defines a perimeter of the recovery tank, the bottom wall and the sidewall at least partially define a storage volume of the recovery tank, an inlet duct having an inlet aperture configured to direct the fluid from the inlet duct into the storage volume, and a baffle wall connected to the sidewall, the baffle wall facing toward the top side of the recovery tank, wherein the inlet aperture is directed along an inlet direction toward the sidewall adjacent the baffle, and wherein the inlet aperture is disposed above the baffle in a direction from the bottom wall to the top side.

2. The floor cleaner of claim 1, wherein the sidewall includes the baffle wall such that the sidewall and the baffle wall are integrally formed as a single component.

3. The floor cleaner of claim 1, wherein the baffle wall is approximately parallel to the bottom wall.

4. The floor cleaner of claim 1, wherein the baffle wall slopes away from the sidewall.

5. The floor cleaner of claim 1, wherein the baffle wall slopes transverse to the inlet direction.

6. The floor cleaner of claim 1, wherein the baffle wall is below the inlet aperture and above the bottom wall such that the baffle wall is between the inlet aperture and the bottom wall.

7. The floor cleaner of claim 1, wherein the baffle wall is approximately perpendicular to the sidewall.

8. The floor cleaner of claim 1, wherein the inlet duct extends from the bottom wall toward the top side of the recovery tank.

9. The floor cleaner of claim 1, wherein the baffle wall is spaced a baffle height measured from the bottom wall, the baffle height is greater than a maximum fill level of the storage volume measured from the bottom wall.

10. The floor cleaner of claim 9, wherein the baffle height is greater than the maximum fill level of the storage volume measured from the bottom wall by at least 50% of the maximum fill level.

11. The floor cleaner of claim 9, wherein the baffle height is greater than the maximum fill level in a range from 2 millimeters to 80 millimeters.

12. The floor cleaner of claim 11, wherein the baffle height is greater than the maximum fill level in a range from 30 millimeters to 60 millimeters.

13. The floor cleaner of claim 1, further comprising an outlet duct including an outlet aperture configured to receive the suction airflow from the storage volume and direct the suction airflow toward the suction source.

14. The floor cleaner of claim 13, wherein the outlet duct extends inside the recovery tank from the bottom wall of the recovery tank toward the top side of the recovery tank.

15. The floor cleaner of claim 13, wherein the recovery tank includes a lid removably coupled to the sidewall, wherein the lid defines at least a portion of the top side of the recovery tank and wherein the outlet duct is disposed in the lid.

16. The floor cleaner of claim 13, wherein the recovery tank includes a lid removably coupled to the sidewall, wherein the lid includes a redirecting rib on an inner surface of the lid extending toward the bottom wall, disposed along the lid between the baffle wall and the outlet aperture.

17. The floor cleaner of claim 13, further comprising a float that closes the outlet aperture when the fluid reaches the maximum fill level.

18. The floor cleaner of claim 17, wherein the float moves along the outlet duct to close the outlet aperture.

19. The floor cleaner of claim 17, wherein the float includes a first portion and a second portion, wherein the first portion is at least partially below the baffle wall, between the baffle wall and the bottom wall, when the float is in the closed position, and the second portion extends above the baffle wall, between the baffle wall and the top side of the recovery tank, when the float is in the closed position.

20. The floor cleaner of claim 1, further comprising an inlet aperture axis that extends centrally through the inlet aperture, wherein the inlet aperture axis extends through the sidewall at a location between the top side of the recovery tank and the baffle wall.

21. The floor claim of claim 1, further comprising an inlet duct axis that extends centrally through the inlet duct along a length of the inlet duct, wherein the inlet duct axis extends through the bottom wall.

22. The floor cleaner of claim 21, further comprising an inlet aperture axis that extends centrally through the inlet aperture, wherein the inlet aperture axis extends through the sidewall at a location between the top side of the recovery tank and the baffle wall.

23. The floor cleaner of claim 22, wherein the inlet aperture axis is perpendicular to the inlet duct axis.

24. The floor cleaner of claim 1, wherein the recovery tank includes a lid removably coupled to the sidewall, wherein the lid defines at least a portion of the top side of the recovery tank and wherein the inlet aperture is adjacent the lid.

25. The floor cleaner of claim 1, wherein the baffle wall slopes in a direction away from the outlet aperture.