Surface Cleaning Apparatus Base Including Sound Reduction Passage

The present disclosure generally relates to a surface cleaning apparatus that includes a housing with a base, and more specifically, to a surface cleaning apparatus base that includes features to reduce sound.

Extraction cleaners can be used for cleaning various types of surfaces, including carpet, upholstery, and other surfaces. Many extraction cleaners include systems for storing and delivering cleaning fluid to a surface to be cleaned. Additionally, many extraction cleaners generate a vacuum effect to draw dispensed cleaning fluid and messes into the extraction cleaner for collection and disposal.

According to one aspect of the present disclosure, a surface cleaning apparatus includes a housing that defines an interior. The housing includes an enclosure and a plate body that supports the enclosure and defines an exhaust vent. A suction source is configured to draw a working airflow from a suction inlet through the interior and exhaust the working airflow through the exhaust vent. The plate body includes a ramp downstream of the exhaust vent that defines an exit airflow pathway away from the exhaust vent. The ramp includes a sidewall that defines a perimeter. A height of the sidewall varies from a proximal portion adjacent the exhaust vent toward a distal portion.

According to another aspect of the present disclosure, a surface cleaning apparatus includes a suction source in fluid communication with a suction inlet and configured to draw a working airflow through the suction inlet. A recovery system is in fluid communication with the suction source and the suction inlet. The recovery system is configured to separate entrained debris in the working airflow. The surface cleaning apparatus also includes a housing that defines an interior. The housing includes an enclosure and a base unit configured to support the enclosure. The base unit includes a support with a first side that opposes a second side. An exhaust vent is disposed at the first side and is in fluid communication with the suction source to exhaust the working airflow drawn through the suction source. A passage is downstream from the exhaust vent and extends from the first side toward the second side. The passage includes a deep portion adjacent the first side and a shallow portion adjacent the second side.

According to yet another aspect of the present disclosure, a surface cleaning apparatus includes a housing that defines an interior. The housing includes an enclosure and a base unit configured to support the enclosure. The base unit includes a support that defines an exhaust vent. A passage is in fluid communication with the exhaust vent and open to an exterior of the housing. The housing also includes a suction system that includes a suction source in fluid communication with a suction inlet and configured to draw a working airflow from the suction inlet through the suction source. The suction system is in fluid communication with the exhaust vent to exhaust the working airflow from the interior. The passage is disposed downstream of the exhaust vent and receives the working airflow exhausted from the exhaust vent.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a surface cleaning apparatus. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Referring to, reference numeralgenerally designates a cleaning apparatus. The cleaning apparatusincludes a housingthat defines an interior. The housingincludes an enclosure, a plate body, and a suction source. The plate bodysupports the enclosureand defines an exhaust vent. The suction sourceis configured to draw a working airflow A from a suction inletthrough the interiorand exhaust the working airflow through the exhaust vent. The plate bodyincludes a rampdownstream of the exhaust ventthat defines an exit airflow pathwayaway from the exhaust vent. In some aspects, the rampincludes a sidewallthat defines a perimeter. A height H of the sidewallcan vary from a proximal portionadjacent the exhaust venttoward a distal portion.

Referring to, the cleaning apparatusmay have a variety of configurations. For example, the cleaning apparatusmay be an extraction cleaner often used to clean rugs, carpeting, drapes, upholstered surfaces, hard surfaces, etc. In various aspects, the cleaning apparatusincludes a suction system, a liquid delivery system, and a recovery system. The liquid delivery systemand the suction systemmay be used for dispensing liquid and recovering fluid and debris material, respectively.

The liquid delivery systemincludes a supply tankfor holding and storing liquid such as a cleaning solution for use in a cleaning process. The liquid may also be water or combinations of cleaning solution(s) and water. For example, many household extraction cleaning tasks can be performed using water along with or in combination with a liquid cleaning solution that contains surfactants, stabilizers, fragrances, and/or other active and inactive ingredients.

The liquid delivery systemalso includes a pump, valves, and or similar features to direct the liquid out of the supply tankand, consequently, out of the cleaning apparatus. The cleaning apparatusmay optionally include a heaterto heat or warm liquid that is dispensed. The pumpis configured to direct the liquid from the supply tankand through a dispensing outletof the cleaning apparatusto be dispensed onto a surface to be cleaned.

With reference again to, the cleaning apparatusalso includes the suction systemto draw fluid into the cleaning apparatus. The suction systemcan draw in liquid or semi-liquid messes from the surface being cleaned, liquid dispensed via the liquid delivery system, and/or other debris materials. The suction systemalso includes the suction source, which is in fluid communication with the suction inletto generate a suction or vacuum effect at the suction inlet. Therefore, fluid and debris material can be drawn through the suction inletdownstream from the surface being cleaned and into a recovery tankof the recovery system. The suction sourcemay be in the form of a motor and impeller assembly(). In some implementations, the suction inletis provided at a distal end of a suction hoseand/or a tool that is in fluid communication with the suction sourceand with the recovery system. However, the suction inletmay be in the form of any suitable suction inlet for a cleaning apparatus, such as a suction inletthat is provided on the housingas opposed to the hoseor tool. The recovery systemis configured to separate entrained debris in the working airflow (e.g., liquids and/or debris materials) and collect the entrained debris or other material in the recovery tankfor storing therein. A user can periodically empty collected fluid and debris from the recovery tank(e.g., by removing the recovery tankfrom the housing).

Components of the cleaning apparatusare electrically coupled to a power source, such as a battery, or to a power cord plugged into a household electrical circuit. A power switchbetween the power sourceand the electrical components of the cleaning apparatuscan be selectively closed by a user to activate the electrical components. The power sourcemay be utilized for powering the cleaning apparatusand/or components coupled thereto, such as an accessory or tool.

Referring now to, the housingdefines the interior, which contains the suction source(e.g., the motor and impeller assembly), positioned therein. As illustrated, the motor and impeller assemblyis disposed in the interioratop a base unit. The base unitcan support the enclosureof the cleaning apparatus. In some aspects, the base unitincludes a support, which may be in the form of the plate bodyor base bottom. As illustrated, the working airflow A can be drawn by the suction sourcethrough the recovery tank, exit the recovery tankthrough an outlet pipeand to the motor and impeller assemblywhere the working airflow A can exit an air outlettoward the exhaust ventto, ultimately, be exhausted from the interiorof the housingof the cleaning apparatus. The air outletassociated with the motor and impeller assemblyis in fluid communication with the exhaust vent.

As illustrated in, the supportincludes a first sidethat opposes a second sidewith the exhaust ventdisposed at the first side. When the supportis assembled with the cleaning apparatus, the exhaust ventis positioned to be in fluid communication with the air outlet() of the suction systemfor exhausting the working airflow A from the interior. The supportincludes an exterior surface, that faces an exterior E of the housing, and an interior surface, that faces the interiorof the housing. A passagedefined by the base unitproduces a pathway for the working airflow A exiting the exhaust ventto travel away from the exhaust vent. The passageis disposed, or extends, downstream of the exhaust vent(e.g., extending from the first sidetoward the second side) and receives the working airflow A exhausted from the exhaust vent. The passagemay be at least partially disposed on the exterior surfaceof the supportsuch that the passage is open to the exterior E of the housing.

Turning to, the illustrative plate bodyincludes a ramp. The rampcan define at least a portion of the passage. In this way, the rampis downstream of the exhaust ventand forms the exit airflow pathwayin the passagethat directs the working airflow A away from the exhaust vent. The rampmay include the sidewall, which can define the perimeter, or outer limit, of the ramp. Again, the height of the sidewallcan vary from the proximal portionadjacent the exhaust venttoward a distal portion, which corresponds to the first sideto the second sideof the support, respectively. For example, the sidewallcan include a proximal portion height, H, and a distal portion height, H, the distal portion height being less than proximal portion height.

The rampincludes an upper surface, or ceiling, that connects with the sidewall. The upper surfaceis recessed from the exterior surfaceof the support, thereby defining a depth of the exit airflow pathwaythat corresponds to the height of the sidewall. As the height of the sidewallvaries, the upper surfacemay include a gradient, G (). As illustrated, the recess or passagethat surrounds the exhaust venthas a ramped cross-section shape (e.g., the gradient, G) that leads from the exhaust ventto an opposing edge (e.g., the distal portion) of the passage. Thus, the exhaust air can be directed by the ramp, which can lengthen and gradually release the exhaust air along the exit airflow pathwayfrom under the housing. The exit airflow pathwayin the passagecan include a first portionadjacent the exhaust ventand a second portion, opposite the first portion, where the first portionhas a depth greater than the second portion. Stated another way, the first portionof the exit airflow pathwaymay extend further toward the interiorof the housingthan the second portion, such that the first portioncorresponds to a deep portion adjacent the first sideof the supportand the second portioncorresponds to a shallow portion adjacent the second sideof the support. The first portion, or deep portion, may be adjacent the exhaust ventand the second portion, or shallow portion, may be adjacent the distal portionof the ramp. The rampdirects the working airflow A along a path of least resistance toward the distal portionof the ramp. Thus, the rampcan be in the form of a chute that conveys the working airflow A exiting the exhaust ventdownstream from the exhaust venttoward an edgeof the plate bodythat is opposite the exhaust vent. Advantageously, reducing the airflow energy at the exhaust ventarea reduces the airborne noise.

With reference now to, which is a cross-sectional view of the support, the gradient G defined by the upper surface() of the rampis more clearly illustrated. As illustrated, the passagecan be at least partially defined by the sidewallthat can include a sloped lower surfacealong at least a portion thereof. In one aspect, the lower surfaceof the passageis planar, but is not limited to such, as will be described in more detail with respect to. A slope α of the lower surfacemay include an inclination that extends from adjacent the exhaust venttoward the edgeof the plate bodythat is opposite the exhaust vent(e.g., from the first sideto the second side). In some examples, the slope α includes an angle θ in a range of 0.1° to 5° or more. It is also contemplated that, the slope α can include an angle θ in a range of approximately 0.5° to approximately 1°. Due to the angle θ of inclination of the slope α, the second sideof the supportcan be elevated from the surface to be cleaned, while the first sideof the supportmay be in direct contact with the surface to be cleaned. As such, the angle θ of the slope α can correspond to a magnitude of an amount of working airflow A that is exhausted from the passage. Further, the lower surface, which is adjacent the second size 76 of the support, can form an outlet areaof the exit airflow pathway.

With reference now to, the lower surfaceof the passageis shown. In some aspects, the lower surfaceincludes a depending edgefrom the sidewallof the ramp. Accordingly, the depending edgemay define the slope α. The depending edgecan form a perimeter edge of the passagethat at least partially extends along the perimeterof the ramp, and, therefore, the passage. As illustrated, the depending edgeforms a rib that projects or extends from the exterior surfaceof the supportor plate body. The sidewalland at least a portion of the depending edgecan block the shortest exhaust path, forcing the exhausted air to follow the gradient G of the ramp. In this way, at least a portion of the inclined depending edgethat can be elevated from the surface to be cleaned may define the outlet area.

Referring now to, the interior surfaceof the supportthat faces the interiorof the housingis shown. As can be seen, the interior surfacecan include a plurality of mounting features to facilitate attaching the supportto the enclosure. The mounting features can include bosses, which may extend about a circumference of the support. The bossesmay provide a pilot channelto insert screws therein. Stakesmay be included to provide support against abutting components of the enclosure. In some aspects, flexible tabsmay be provided to fasten the supportto the enclosure. However, it is within the scope of the disclosure for the supportto be mounted or otherwise attached to the enclosureusing any suitable fastener or mounting structure, such as screws, adhesives, etc.

Referring now to, another exemplary supportfor use with a cleaning apparatus, such as cleaning apparatus, is illustrated. The supportis substantially similar to the support. Therefore, like parts will be identified with like numerals, increasing by 100, unless otherwise noted. Further, description with respect to like parts applies to components of the supportas well. As illustrated, the lower surface, which may be the depending edge, defines groovestherein. The groovescan be spaced about at least a portion of the depending edge, thereby forming projectionstherebetween. The location of the groovesmay form the outlet areato facilitate venting of the working airflow A along the of the exit airflow pathwaytherethrough. Accordingly, the sidewalland depending edgecan block the shortest exhaust path, forcing the exhausted air to follow the gradient G of the ramptoward the grooves. In specific examples, the groovesare disposed adjacent the distal portionof the rampand a transverse wallof the ramp. In some aspects, the groovesand the projectionsinclude matching or coordinating shapes, which can be a result of evenly spacing the groovesabout the depending edge. However, it is within the scope of the disclosure for the groovesto be spaced such that the projectionsare larger or smaller than the grooves. It is contemplated that any number of grooves may be present and may have consistent or varying shapes. Additionally, the groovesmay be spaced at varying intervals. In some implementations, the groovesmay include a “V” shape. Additionally, spacing the groovesapart by approximately the width of a single groovemay result in the projectionshaving a same shape and length as the grooves. A distance D between two same locations (e.g., an apex) of the groovesmay be in a range of 1-3 mm. In specific examples, the distance D is approximately 2 mm. Further, a width of the depending edgecorresponds to the width of the groovesas the groovesare configured to facilitate movement of the working airflow A through the depending edge. Thus, the width of the groovescan correspond to a magnitude of an amount of working airflow A that is exhausted from the passage.

As illustrated in, the lower surfaceis a notched due to the presence of the groovesand the projections. In this way, the depending edgemay define crenulations. In one example, the projectionsare spaced along a majority of a portion of the depending edgethat extends from the transverse wall.

Referring now to, another exemplary supportfor use with the cleaning apparatusis illustrated. The supportis substantially similar to the supportand the support. Therefore, like parts will be identified with like numerals, increasing by 200 from the supportandfrom the support, unless otherwise noted. Further, description with respect to like parts applies components of the supportas well. As illustrated, the supportcombines aspects of the supportand the support. The supportincludes the groovesand projections. As shown in, the supportincludes the sloped lower surfacealong at least a portion of the sidewall, which may include the lower surface of the transverse wallof the ramp. In this way, the sloped lower surfaceand the groovesform the outlet areaof the of the exit airflow pathwayto exhaust the working airflow A therethrough. In some implementations, the projectionsdecrease in height from the first sidetoward the second side. In this way, the projections, or crenulations, may gradually flatten toward the edgeof the plate bodythat is opposite the exhaust vent. However, it is within the scope of the disclosure for the lower surfaceor depending edgeto include the angle θ of inclination where groovesinclude a same depth. In this example, the projectionsmay not decrease in height. In this example, the angle θ of the slope α in combination with the width of the groovescan correspond to a magnitude of an amount of working airflow A that is exhausted from the passage.

With reference now to, a graph that compares sound pressure levels that emanate from cleaning apparatuses that utilize one of the supportand the supportwith a control cleaning apparatus that does not utilize the supports,described herein is illustrated. Each design (control, cleaning apparatuses that utilize supports, cleaning apparatuses that utilize supports) was tested using the International Electro-technical Commission (IEC) 0E free field response standard and the Underwriters Laboratories (UL) standard on stationary cleaners in a semi-reverberant room. The tests were conducting using a same or similar test procedure, with the exception of using different input voltage settings. The IEC tests included input voltages of 230V and the UL tests included input voltages of 120V. Sound pressure can be defined as the difference between the actual instantaneous pressure due to sound and the atmospheric pressure. The y-axis indicates a weighted sound pressure level (SPL) to correspond to a response of the human ear to noise. The SPL was recorded in decibels and a weighting curve was applied (dBA). During the IEC test for each device, a total SPL was measured at various frequencies (Hz), as indicated on the x-axis.

Table 1, shown below, illustrates the results of the tests that were performed to compare sound pressure levels that emanated from cleaning apparatuses, such as cleaning apparatus, that utilize one of the supportand the supportagainst a control cleaning apparatus that does not utilize the supports,described herein. As can be seen from Table 1, use of either one of the supportand the supportresulted in a significant reduction in SPL. More specifically, on average, SPL was reduced in comparison to the control device by approximately 5 dBA.

Use of the present device provides a variety of advantages. By way of aspects of the supports,,, described herein, the cleaning apparatuscan include a recess that surrounds the exhaust ventto redirect and slow exhaust air after the airflow has exited through the exhaust vent, which reduces sound pressure level (SPL) emanating therefrom. In this way, the present disclosure can reduce SPL by restricting the air exhausted from the cleaning apparatusto the exit airflow pathway. The sound pressure level can pre reduced by approximately 2.6 dBA (from 77.8 to 75.2 dBA) or more. Reducing the airflow energy at the exhaust outlet area reduces the airborne noise.

According to an aspect of the present disclosure, a surface cleaning apparatus includes a housing that defines an interior. The housing includes an enclosure and a plate body that supports the enclosure and defines an exhaust vent. A suction source is configured to draw a working airflow from a suction inlet through the interior and exhaust the working airflow through the exhaust vent. The plate body includes a ramp downstream of the exhaust vent that defines an exit airflow pathway away from the exhaust vent. The ramp includes a sidewall that defines a perimeter. A height of the sidewall varies from a proximal portion adjacent the exhaust vent toward a distal portion.

According to another aspect of the present disclosure, an exit airflow pathway defines a chute for a working airflow exiting an exhaust vent to travel from the exhaust vent toward an edge of a plate body opposite the exhaust vent.

According to another aspect of the present disclosure, an exit airflow pathway includes a deep portion adjacent the exhaust vent and a shallow portion adjacent the distal portion of the ramp.

According to still another aspect of the present disclosure, a surface cleaning apparatus includes a depending edge adjacent a sidewall that forms a rib projecting from an exterior surface of a plate body.

According to yet another aspect of the present disclosure, a depending edge defines a slope that extends adjacent from an exhaust vent toward an edge of a plate body opposite the exhaust vent.

According to another aspect of the present disclosure, a depending edge defines grooves therein.

According to another aspect of the present disclosure, grooves are spaced about a depending edge and form projections therebetween.

According to still another aspect of the present disclosure, grooves and projections include matching shapes.

According to another aspect of the present disclosure, projections decrease in height from an exhaust vent toward a distal portion.

According to yet another aspect of the present disclosure, grooves include a “V” shape.

According to another aspect of the present disclosure, an exit airflow pathway faces an exterior of a housing.

According to another aspect of the present disclosure, a surface cleaning apparatus includes a suction source in fluid communication with a suction inlet and configured to draw a working airflow through the suction inlet. A recovery system is in fluid communication with the suction source and the suction inlet. The recovery system is configured to separate entrained debris in the working airflow. The surface cleaning apparatus also includes a housing that defines an interior. The housing includes an enclosure and a base unit configured to support the enclosure. The base unit includes a support with a first side that opposes a second side. An exhaust vent is disposed at the first side and is in fluid communication with the suction source to exhaust the working airflow drawn through the suction source. A passage is downstream from the exhaust vent and extends from the first side toward the second side. The passage includes a deep portion adjacent the first side and a shallow portion adjacent the second side.

According to another aspect of the present disclosure, a passage defines a pathway for a working airflow exiting an exhaust vent to travel away from the exhaust vent.

According to another aspect of the present disclosure, a ramp defines at least a portion of a passage and the ramp includes a sidewall.

According to another aspect of the present disclosure, a ramp includes an upper surface that defines a gradient.

According to still another aspect of the present disclosure, a sidewall of a ramp defines a perimeter. A height of the sidewall varies from a first side to a second side of a support.

According to another aspect of the present disclosure, a sidewall of a ramp defines a depending edge that forms a rib that extends from an exterior surface of a support.

According to yet another aspect of the present disclosure, a depending edge defines a slope from a first side to a second side of a support. The slope includes an angle of inclination from approximately 0.5° to approximately 1° from the first side to the second side.

According to another aspect of the present disclosure, a surface cleaning apparatus includes a housing that defines an interior. The housing includes an enclosure and a base unit configured to support the enclosure. The base unit includes a support that defines an exhaust vent. A passage is in fluid communication with the exhaust vent and open to an exterior of the housing. The housing also includes a suction system that includes a suction source in fluid communication with a suction inlet and configured to draw a working airflow from the suction inlet through the suction source. The suction system is in fluid communication with the exhaust vent to exhaust the working airflow from the interior. The passage is disposed downstream of the exhaust vent and receives the working airflow exhausted from the exhaust vent.

According to still another aspect of the present disclosure, a perimeter edge of a passage defines a slope adjacent from an exhaust vent.