Cleaning Apparatus with Multi-Input Relief Valve Control

This application claims priority to U.S. Provisional Application No. 63/659,987, filed on Jun. 14, 2024, entitled, “CLEANING APPARATUS WITH MULTI-INPUT RELIEF VALVE CONTROL,” the disclosure of which is hereby incorporated herein by reference in its entirety.

The present disclosure generally relates to a cleaning apparatus, and more specifically, to a vacuum cleaning apparatus with multi-input pressure relief valve control.

Vacuum cleaners can draw dirt from a surface using a vacuum system. Vacuum cleaners often include bleed valves that open in response to pressure. Typically, the bleed valves open to allow air to flow into the vacuum cleaner when there is a clog in the vacuum cleaner that prevents sufficient airflow.

According to one aspect of the present disclosure, a cleaning apparatus includes a base configured to engage an underlying surface, a body assembly, and a tank assembly for collecting debris material from working air. A suction assembly is in fluid communication with a suction inlet. The suction assembly includes a suction source configured to generate a vacuum effect at the suction inlet. An airflow path for the working air is defined from the suction inlet, through the tank assembly, and the suction assembly. A sensor is configured to sense a condition of the cleaning apparatus to provide a sensed value. A relief valve is disposed along the airflow path. The relief valve is operable between an opened state to allow cooling air into the airflow path at a location separate from the suction inlet and a closed state. A controller is communicatively coupled with the relief valve and the sensor where the relief valve is configured to adjust to the opened state in response to an activation signal from the controller. The controller is configured to send the activation signal when a differential between the sensed value and a baseline level for the condition exceeds a predefined value for a predefined period of time.

According to another aspect of the present disclosure, a cleaning apparatus includes a base, a body assembly, a tank assembly, and a suction assembly. The suction assembly includes a suction source in fluid communication with a suction inlet via an airflow path defined from the suction inlet, through the tank assembly, and through the suction assembly. A relief valve is disposed along the airflow path upstream of the suction assembly. The relief valve is operable between a closed state and an opened state. A pressure sensor is configured to sense pressure in the airflow path. A controller is communicatively coupled with the relief valve and the pressure sensor. The controller is configured to adjust the relief valve to the opened state to allow cooling air into the airflow path at a location separate from the suction inlet when the airflow path is at an elevated vacuum pressure relative to a baseline pressure level for a predefined period of time.

According to yet another aspect of the present disclosure, a cleaning apparatus includes a base configured to engage an underlying surface, a body assembly, and a tank assembly for collecting debris material from working air. A suction assembly is in fluid communication with at least one suction inlet. The suction assembly includes a suction source configured to generate a vacuum effect at the at least one suction inlet. An airflow path for the working air is defined from at least one suction inlet, through the tank assembly, and through the suction assembly. A relief valve assembly is disposed along the airflow path. The relief valve assembly includes a relief valve operable between an opened state to allow cooling air into the airflow path at a location separate from at least one suction inlet and a closed state, and a timer operably coupled to the relief valve. The relief valve is configured to adjust to the opened state after a predefined period of time has elapsed upon a predefined vacuum pressure in the airflow path being reached.

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 cleaning apparatus with multi-input pressure relief valve control. 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.

With reference to, reference numeralgenerally designates a cleaning apparatus that includes a foot or basefor engaging an underlying surface and a body assemblyoperably coupled to the base. The cleaning apparatusalso includes a tank assemblyfor collecting debris materials, as well as a suction assembly. The suction assemblyis configured to generate a vacuum or suction effect at a suction inletto draw the debris materials and air into the cleaning apparatusand along an airflow paththrough the cleaning apparatusto be exhausted via an exhaust outlet. A relief valveis disposed along the airflow path. The relief valveis operable between an opened state where additional cooling air can be drawn into the airflow pathat a location separate from the suction inletand a closed state. The relief valveis configured to adjust to the opened state when a condition related to the cleaning apparatusis at a predefined difference relative to a baseline level for the condition for a predefined period of time.

Referring to, the cleaning apparatusmay have a variety of configurations. For example, the cleaning apparatusmay be a vacuum cleaner. The vacuum cleaner may be usable in an upright mode of operation, where the vacuum cleaner can be maneuvered along the underlying surface, such as a floor surface. The vacuum cleaner may also be a portable unit. In such examples, the vacuum cleaner may be hand-carried by a user. The portable vacuum cleaner may be smaller and lighter to allow the user to carry the portable vacuum cleaner. Further, the vacuum cleaner may be operable in the upright mode of operation and may include an attachable portable unit that can be removed and hand-carried by the user.

The cleaning apparatusincludes the suction assemblyconfigured to generate the vacuum effect at the suction inletto capture the debris materials from a surface being cleaned. Based on the configuration and use of the cleaning apparatus, the surface to be cleaned may be an underlying surface or another surface, which may be horizontal or vertical. The vacuum or suction effect generated by the suction assemblydraws the air, which may be referred to as working air, and the debris material into the cleaning apparatusand along the airflow path.

The air and debris materials are drawn into a tank, which may be referred to as a dirty tank, of the tank assembly. The captured debris materials are generally collected in the dirty tankfor later disposal. The captured debris material may be separated from the working air via a separator. The working air is configured to flow through the separator, while the debris material is generally too large to flow through the separatorand is retained in the dirty tank. The air is drawn out of the tank assemblyand directed through the suction assemblyto be exhausted from the cleaning apparatus.

As the air is directed through the suction assembly, the air is configured to reduce or prevent overheating of a suction sourceof the suction assembly. The suction sourcetypically generates heat when activated, which can affect the performance of the suction source. The air flowing through the suction assemblycan capture or direct the generated heat away from the suction sourceto be exhausted with the air. Accordingly, the suction sourcemay be considered a flow-through suction sourcewhere the air flowing through the suction assemblyprovides cooling to assist with reducing or preventing overheating of the suction source.

Referring still to, the cleaning apparatusincludes the relief valve, which may also be referred to as a bleed valve, disposed along and in fluid communication with the airflow path. The relief valveis operable between the opened state, which allows cooling air to be drawn into the cleaning apparatusat a location separate from the suction inlet, and the closed state, sealing the separate location and reducing or preventing the cooling air from entering the cleaning apparatusat the auxiliary or separate location.

Depending on the configuration of the cleaning apparatus, the relief valvecan be disposed anywhere along the airflow pathbetween the suction inletand the suction source. The relief valveis configured to adjust the opened state to provide the cooling air for cooling the suction sourcewhen airflow upstream of the relief valveis blocked or significantly reduced, such as from a clogged airflow path.

The relief valvedisclosed herein may be controlled based on multiple inputs or conditions to adjust when the relief valvemoves to the opened state. In other words, the cleaning apparatusmay have or include multi-input pressure relief control. The relief valvemay have different configurations based on how the relief valveis controlled. For example, as illustrated in, the relief valvemay be associated or operate with a time-based adjustment feature or timer, which affects when the relief valveis opened, as discussed further herein. Additionally or alternatively, as illustrated in, the relief valvemay be controlled via a controller. In such examples, the relief valveor electronic component coupled with the relief valvemay receive an activation or control signal from the controllerto move the relief valvebetween the opened and closed states in response to inputs received by the controller, as discussed further herein.

Components of the cleaning apparatusare electrically coupled with a power source, such as a battery or power cord plugged into a household electrical outlet. A power switchbetween the power sourceand the electrical components of the cleaning apparatuscan be selectively closed by the user to activate the electrical components. The power sourcemay be utilized for powering the cleaning apparatus, such as the suction source, the relief valve, or components coupled to the cleaning apparatus.

Referring again to, as well as, an exemplary cleaning apparatusis illustrated. The cleaning apparatusincludes the basefor engaging the underlying surface and the body assembly, which is generally operably coupled with the base. The baseand the body assemblymay be collectively referred to as a housing. The baseincludes a base housingand wheelsoperably coupled to the base housing. The baseis adapted to be moved relative to the surface being cleaned via the wheels.

In various aspects, the basedefines, includes, or is coupled with at least one suction inlet, which may be referred to as a base suction nozzle. Movement of the baseis configured to move the base suction nozzlerelative to the surface being cleaned. The basemay also include an agitatoroperably coupled with the base housing. The agitatoris positioned proximate or adjacent to the base suction nozzleand is configured to agitate the surface being cleaned to disrupt the debris material. Disruption of the debris materials on the surface being cleaned may assist with capturing the debris material with the suction effect at the base suction nozzle. The agitatormay be configured as at least one brushroll, at least one horizontally rotating brushroll, at least one vertically rotating brushroll, at least one stationary brushroll, etc.

The baseincludes or defines a base conduitin fluid communication with the base suction nozzle. In the illustrated configuration, the base conduithas an inlet end disposed proximate to the agitatorand an outlet end operably coupled with the body assemblyto provide fluid communication between the base suction nozzleand the body assembly. In the illustrated configuration, the base conduitextends through and out of the base housingto provide a physical connection between the baseand the body assembly. Further, as illustrated, the base conduitextends generally horizontally in the baseand then curves to extend generally vertically to engage the body assembly. The base conduitis configured to guide the debris material and the working air through the baseand to or towards the body assemblyalong the airflow path.

The body assemblyis operably coupled with the basefor directing the baseacross the underlying surface. A couplingmay operably couple the body assemblywith the base. This couplingcan be a pivoting, single-axis coupling or a rotational, multi-axis coupling. In the illustrated configuration, the couplingis disposed proximate to the portion of the base conduitthat extends between the baseand the body assembly. The body assemblyis generally configured to be an upright body, extending vertically from proximate the base.

Referring still to, the body assemblyforms one or more portions of the airflow path. As illustrated, the body assemblyincludes a first airflow passageand a second airflow passageof the airflow path, which extend generally parallel to one another. The first airflow passageis illustrated as extending along a rear of the cleaning apparatuswith the second airflow passagedisposed forward of the first airflow passage, though other configurations are contemplated without departing from the teachings herein. The first airflow passageis in fluid communication with the base conduit. Accordingly, the air and debris material are configured to flow from the base conduitand into the first airflow passageof the body assembly.

The first airflow passagemay also be a receiving passage for a tube or wandof the cleaning apparatus. An inlet endof the wandis inserted into the first airflow passageand can be configured to lock into the body assembly. The wandmay also be removed from the first airflow passageto be used separately from the baseand/or with an accessory or tool. When the wandis removed from the first airflow passage, the suction sourceis no longer in fluid communication with the basedue to a disruption in the airflow path, and the suction sourceremains in fluid communication with the wand. The inlet endof the wandcan form one of the suction inlets, which may be referred to as a wand suction nozzle, that can be manually maneuvered relative to the cleaning apparatusand the surface being cleaned. This configuration may be advantageous for applying the suction effect at smaller areas or crevices.

When the wandis removed from the first airflow passage, the inlet endmay be coupled with the accessory or tool. The toolis configured to utilize features and functions of the cleaning apparatus, such as the suction assembly. In such examples, the suction assemblycan be used to generate the suction effect at a tool suction nozzle(i.e., one of the suction inlets). Similar to the wand, the toolcan be manually maneuvered by the user relative to the surface being cleaned. The use of the toolmay provide different functions and features to the cleaning apparatusfor different cleaning processes. For example, the toolmay be a dusting brush, a crevice tool, a wand extension, a pet hair tool, or any other toolthat can utilize a suction or vacuum effect. The toolcan maximize the user experience by allowing the user to utilize the tool, the wand, or the basefor collecting debris material. Additionally, in examples where the cleaning apparatusis a portable unit or includes the detachable portable unit, the wandand the toolcan provide the suction inletas the user carries the detachable unit separate from the base.

In various aspects, the body assemblyincludes an accessory receiverfor supporting the accessory or toolthat can be used with the cleaning apparatus. The body assemblycan also include one or more cord supports for supporting and stowing the power cord. Further, the body assemblymay include a hose supportfor securing a portion of a hoseto the body assembly. Additional support features may be included on or supported by the body assembly.

Referring still to, as well as, the body assemblyalso includes a spine section. The spine sectionmay support various components and provide connections between components. The spine sectionat least partially defines or includes the second airflow passage, which fluidly couples the tank assemblywith the suction assembly. The spine sectiongenerally projects upwardly from the suction assembly. As illustrated, the spine sectionincludes an outer channel, and the relief valveextends through an openingin the outer channelof the spine section. Sides of the outer channelmay assist in retaining space between the relief valveand the tank assemblyto allow air to be drawn through the relief valve.

When the wandis positioned in the first airflow passage, the wandextends out of the body assembly. An outer or exposed end of the wandincludes a handlecoupled thereto. The handlecan be grasped by the user for maneuvering the cleaning apparatuswhen the wandis disposed in the first airflow passageand/or the wandseparately from the basewhen the wandis removed from the first airflow passage.

The outer, exposed end of the wandis coupled with the hose. The hosecan be retained in the hose supportto reduce movement of the hose. The hosecan also be released from the hose support, which may assist in the maneuverability of the wand. The hoseextends from the wandand to a connecting passagecoupled with the body assembly. Generally, the hoseincludes a hose connectorthat can be selectively coupled with the connecting passage. The connecting passageprovides fluid communication between the hoseand the tank assembly, and, consequently, between the hoseand the suction assembly.

Referring still to, the tank assemblyis selectively and operably coupled with the body assembly. The tank assemblymay be supported by or coupled with the spine sectionand/or the suction assembly. In certain aspects, at least a portion of the tank assemblycan extend into the outer channelof the spine section, which may assist in aligning and positioning the tank assemblyon the body assembly.

The tank assemblygenerally includes the dirty tankand a lid or cover. Additionally, the coveroften includes a carrying handle, which may be advantageous for removing and carrying the dirty tankfor disposing of the debris material. Additionally, in configurations where the cleaning apparatusis or includes a portable or detachable unit, the user may carry the portable unit via the carrying handle. The tank assemblymay also include a lower door, which may be advantageous for removing the collected debris materials from the dirty tank.

The tank assemblyincludes an inlet conduitthat mates or couples with the connecting passageof the body assemblyto receive the working air and debris material from the hose. The tank assemblymay include the separatorfor separating the debris materials from the working air. The separatorcan have a variety of configurations. For example, the separatormay have multiple filtration layers. In such examples, the separatormay include a pre-filter or coarse filter, such as a mesh screen, and a fine filter, which collectively facilitate separating the debris materials from the working air. The components of the separatormay define different shapes, such as cylindrical, conical, or frustoconical shapes. Further, the components of the separatormay provide different levels of filtration, such that different-sized debris material may flow through some components and not others. The separatoris configured to retain the captured debris material within the dirty tankwhile allowing the working air to flow through the separatorand out of the tank assembly. Various filters, media, cyclonic, and non-cyclonic separation processes may be used to separate the debris material from the working air without departing from the teachings herein.

The tank assemblyalso includes an outlet conduit. Generally, the outlet conduitis defined or included at an upper portion of the tank assembly, such as in the cover. This configuration allows the inlet conduitto be vertically lower than the outlet conduitto assist with the debris material being collected in the bottom of the dirty tankand the substantially debris-free working air flowing upward and out of the tank assembly. The outlet conduitis configured to mate or couple with an air inletof the body assembly. The air inletis generally at a top or upper end of the spine sectionand in fluid communication with the second airflow passage. Accordingly, the tank assemblyis configured to fluidly couple the hosewith the second airflow passageat the spine sectionof the body assembly.

The second airflow passageextends between the outlet conduitand the suction assemblyto provide fluid communication therebetween. The suction assemblymay be included in the body assemblyor may be a separate component. In certain aspects, the suction assemblymay be supported on the baseand extend partially into the outer channelof the spine section. In examples where the cleaning apparatusis or includes the portable unit, the portable unit may generally include the suction assemblyand the tank assembly, which can be removed as a single unit from the baseand the body assembly.

The suction assemblyis in fluid communication with the suction inletfor generating the working airstream through the airflow path. When the suction assemblyis in fluid communication with the base suction nozzle, the airflow pathis defined: from the base suction nozzle, through the base conduit, through the first airflow passage, through the wand, through the hose, through the tank assembly, through the second airflow passage, and through the suction assemblyto be exhausted via the exhaust outlet. When the wandis removed from the first airflow passage, the airflow pathgenerated by the suction assemblyis defined: from the wand suction nozzleor the tool suction nozzle, through the wand, through the hose, through the tank assembly, through the second airflow passage, and through the suction assemblyto be exhausted via the exhaust outlet.

Referring still to, the suction assemblygenerally includes a ductfor guiding the working air from the second airflow passageand into a motor/fan housing. Further, the ductmay be configured to direct the air along or past the suction sourceto capture heat generated by the suction source. The motor/fan housinghouses the suction sourceand may be one integrated component or formed of several components coupled together. The suction sourcemay be or include a motorized fan assembly or vacuum motor. In various aspects, the suction may include an impeller assemblyoperably coupled with a motor, which drives the impeller assembly. A motor shroudmay be positioned about the motor.

Additionally, the motor/fan housingmay include an exhaust filterdisposed proximate to the exhaust outlet. The exhaust outletmay be a single openingor multiple openings. The working air is directed through the duct, around or through the suction sourceto capture heat, through the exhaust filter, and then exhausted from the cleaning apparatus.

The suction sourceis configured to generate the suction or vacuum effect at the suction inletand along the airflow pathto draw the debris materials into the tank assemblyand the working air through the suction assembly. In operation, a power button may be used to electrically couple the power source(see) with the suction assemblyto activate the suction sourceto generate the suction or vacuum effect. The user can move the suction inletrelative to the surface being cleaned to draw in the debris materials from the surface being cleaned into the cleaning apparatuswith the working air. As described herein, the debris materials are collected in the tank assemblyfor disposal and the working air flows through the suction assemblyto reduce or prevent overheating of the suction source.

Referring now to, the relief valveis disposed along the airflow pathto provide a secondary or separate location for air to flow into the airflow path, separate from the suction inlet(see), which may be referred to as cooling air. As illustrated, the relief valveis coupled with the spine sectionof the body assemblyto provide fluid communication with the second airflow passage. Accordingly, in the illustrated configuration of, the relief valveis disposed along the portion of the airflow pathbetween the tank assemblyand the suction assembly. However, it is contemplated that the relief valvemay be disposed anywhere along a negative portion of the airflow pathbetween the suction inletand the suction source. It may be advantageous to have the relief valveupstream of the suction sourceand downstream of the inlet endof the wandto be disposed along the airflow pathfor each of the suction nozzles,,(see) that can be used. Alternatively, multiple relief valvesmay be utilized without departing from the teachings herein.

The relief valveis configured to adjust to the opened state in response to at least one and often more than one condition or input. The configuration of the relief valvemay affect the conditions or inputs that can change the state of the relief valve. For example, as illustrated in, the relief valvemay be a mechanical valve. In additional or alternative examples, as illustrated in, the relief valvemay be an electronic or electric valve controllable via a signal from the controller.

Referring still to, an exemplary configuration of the relief valveis illustrated where the relief valveincludes an insertwhich extends through the openingof the cleaning apparatusand houses a valve bodyand a biasing member. Generally, the biasing memberis a coil spring positioned about the valve body. The biasing membermay be configured to bias the valve bodyto the closed state, which generally reduces or blocks the cleaning air from flowing through the opening. When the relief valveis in the opened state, the valve bodyis moved against the biasing force of the biasing member, which allows the cooling air to flow into the cleaning apparatusat the location of the relief valve(i.e., the auxiliary location separate from the suction inlet).

In certain aspects, the biasing membermay be calibrated such that a sufficient pressure difference between the airflow pathand a baseline pressure level, which is generally atmospheric pressure, can move the valve bodyagainst the biasing force. The relief valveis adjusted to the opened state, at least in part, due to the pressure difference between an internal vacuum pressure of the airflow pathand the baseline pressure. The pressure difference may be caused by the suction effect generated by the suction source. If there is insufficient air being drawn into the cleaning apparatusand the suction sourceis activated to generate the suction effect, a vacuum or negative pressure can be generated or increased in the airflow path. The vacuum pressure can be caused by closing the suction inletor a clog in the airflow path. The continued activation of the suction sourcewith reduced airflow to capture heat can increase a risk of overheating the suction source.

In more conventional systems, a bleed valve typically opens automatically when the pressure difference between internal and atmospheric pressures is reached. This can affect a sealed lift of the more conventional cleaning device. The sealed lift is generally a measurement (in inches of water or ″HO) of a maximum suction force when an inlet is blocked. A higher sealed lift value generally correlates to a cleaner being able to suction heavier or denser objects. However, bleed valves opening immediately upon the increase in the internal vacuum can significantly lower the available sealed lift at the inlet. In certain aspects, the suction or lift at the inlet can decrease up to between about 10% and about 20% compared to the maximum sealed lift when the bleed valve is opened.

In comparison, in the present cleaning apparatus, the sealed lift or the maximum suction/vacuum available to the user can be increased by controlling the relief valve. For example, the relief valvecan remain in the closed state as the pressure differential increases. In such circumstances, the internal vacuum pressure increases but the relief valveremains closed and is bypassed.

Referring again to, the relief valvemay be part of a relief valve assembly, which also includes the timing adjustment feature, which may also be referred to as the timer. The timercan adjust when the relief valveis opened. In other words, the timercan provide a time delay for adjusting the relief valveto the opened state. The relief valvecan then be adjusted based on at least two inputs: pressure and time.

With the relief valve assembly, the vacuum pressure of the cleaning apparatuscan change to create the predefined pressure differential compared to the baseline pressure. Instead of the relief valveautomatically opening, the vacuum pressure reaching a predefined value and/or the predefined pressure differential being reached can trigger or start a “countdown” for the predefined period of time. The predefined period of time may be set during a manufacturing process, calibrated, and/or adjusted or changed. The predefined period of time may be up to about 60 seconds, about 120 seconds, about 4 minutes, or any practicable amount of time.

The timermay have a variety of configurations such as a rotating timer, a feature that disengages the relief valveor the biasing memberafter the predefined period of time, etc. The relief valvemay remain in the closed state during the predefined period of time and, upon the predefined period of time elapsing, may then adjust to the opened state to allow the cooling air into the airflow path. The predefined period of time allows the maximum lift to be maintained for the user to use the maximum lift and then allows the cooling air to cool the suction assembly.

The timing aspect may be automatic, such that after the predefined period of time has elapsed, the relief valveis adjusted to the opened state. Additionally or alternatively, the relief valvemay be adjusted to the opened state if the pressure difference remains after the predefined period of time has elapsed. In this regard, when the vacuum pressure has reached the predefined pressure difference relative to the baseline pressure (i.e., a predefined vacuum pressure), the timing aspect may be initiated. The pressure may continue to be monitored such that if the pressure difference between the internal vacuum pressure and the baseline pressure is reduced when the time elapses, the relief valvemay remain in the closed state. This may be advantageous if the maximum lift causes the airflow pathto unclog or if the user temporarily seals the suction inletfor the cleaning process. In this configuration, if the pressure difference remains or has increased after the predefined time has elapsed, then the relief valvemay be adjusted to the opened state to cool the suction assembly.