Note: Descriptions are shown in the official language in which they were submitted.
ROBOTIC CLEANER
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation-in-part of U.S. Patent Application
No. 16/217,748,
filed December 12, 2018, which claims the benefit of U.S. Provisional Patent
Application No.
62/609,449 filed December 22, 2017, both of which are incorporated herein by
reference in their
entirety.
BACKGROUND
[0002] Autonomous or robotic floor cleaners can move without the assistance of
a user or
operator to clean a floor surface. For example, the floor cleaner can be
configured to sweep dirt
(including dust, hair, and other debris) into a collection bin carried on the
floor cleaner or to
sweep dirt using a cloth which collects the dirt. The floor cleaner can move
randomly about a
surface while cleaning the floor surface or use a mapping/navigation system
for guided navigation
about the surface. Some floor cleaners are further configured to apply and
extract liquid for deep
cleaning carpets, rugs, and other floor surfaces.
BRIEF SUMMARY
[0003] In one aspect, the disclosure relates to a floor cleaning robot. The
floor cleaning robot
includes an autonomously moveable housing, and a unitary assembly removably
mounted to the
autonomously moveable housing, the unitary assembly including a brush chamber,
a debris
receptacle, and a supply tank. The floor cleaning robot also includes a
brushroll located in the brush
chamber, at least one fluid distributor in fluid communication with the supply
tank, and a fluid
delivery pump configured to control a flow of the cleaning fluid to the at
least one fluid distributor.
[1]
Date Recue/Date Received 2020-06-10
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] In the drawings:
[0005] FIG. 1 is a schematic view of an exemplary autonomous floor cleaner
illustrating
functional systems in accordance with various aspects described herein.
[0006] FIG. 2 is a schematic view of the autonomous floor cleaner of FIG. 1
illustrating
additional functional systems in accordance with various aspects described
herein.
[0007] FIG. 3 is an isometric view of the autonomous floor cleaner of FIG. 1
in the form of a floor
cleaning robot in accordance with various aspects described herein.
[0008] FIG. 4 is an isometric view of the underside of the floor cleaning
robot of FIG. 3.
[0009] FIG. 5 is a side elevation cross-sectional view of the floor cleaning
robot of FIG. 3.
[0010] FIG. 6 is a schematic illustration of a dusting assembly of the
cleaning robot of FIG. 3.
[0011] FIG. 7 is an isometric view of the underside of the floor cleaning
robot of FIG. 3
illustrating a bumper assembly.
[0012] FIG. 8 is an isometric view of the floor cleaning robot of FIG. 3
illustrating a fluid spray
nozzle.
[0013] FIG. 9 is a cross-sectional view of a tank assembly in the floor
cleaning robot of FIG. 3.
[0014] FIG. 10 is a schematic illustration of a wheel assembly that can be
utilized in the floor
cleaning robot of FIG. 1.
[0015] FIG. 11 is a schematic illustration of another wheel assembly that can
be utilized in the floor
cleaning robot of FIG. 1.
[0016] FIG. 12 is an isometric view of another floor cleaning robot in
accordance with various
aspects described herein.
[0017] FIG. 13 is an isometric view of the floor cleaning robot of FIG. 12
illustrating a tank
assembly.
[2]
Date Recue/Date Received 2020-06-10
[0018] FIG. 14 is an isometric view of the tank assembly of FIG. 13
illustrating a fluid supply tank
and a debris receptacle.
[0019] FIG. 15 is an isometric view of the tank assembly of FIG. 14
illustrating a coupling
between the fluid supply tank and the debris receptacle.
[0020] FIG. 16 is a front isometric view of another floor cleaning robot in
accordance with
various aspects described herein.
[0021] FIG. 17 is a rear isometric view of the floor cleaning robot of FIG.
16.
[0022] FIG. 18 is a rear isometric view of the floor cleaning robot of FIG.
16, showing a tank
assembly in a partially removed state.
[0023] FIG. 19 is a close-up view of section XIX of FIG. 18.
[0024] FIG. 20 is a rear isometric view of the floor cleaning robot of FIG.
16, with the tank
assembly removed for clarity.
[0025] FIG. 21 is a cross-sectional view taken through line XXI-XXI of FIG.
16.
[0026] FIG. 22 is a close-up isometric cross-sectional view taken through line
XXI-XXI of
FIG. 16, showing a brush chamber of the floor cleaning robot FIG. 21.
[0027] FIG. 23 is an isometric view of an underside of the tank assembly of
the floor cleaning
robot of FIG. 16.
[0028] FIG. 24 is a side elevation view of the tank assembly of FIG. 23,
showing a lid is a
partially removed state.
[0029] FIG 25 is an isometric view of the tank assembly of FIG. 24.
[0030] FIG. 26 is an isometric view of a lower portion of the tank assembly of
FIG. 24, with
the lid removed.
[0031] FIG. 27 is a cross-sectional view taken through line XVII-XVII of FIG.
17.
[0032] FIG. 28 is an isometric view of another tank assembly that can be
utilized in the floor
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Date Recue/Date Received 2020-06-10
cleaning robot of FIG. 16.
[0033] FIG. 29 is an isometric view of another tank assembly that can be
utilized in the floor
cleaning robot of FIG. 16.
[0034] FIG. 30 is an isometric view of another tank assembly that can be
utilized in the floor
cleaning robot of FIG. 16.
DETAILED DESCRIPTION
[0035] The disclosure generally relates to autonomous floor cleaners for
cleaning floor surfaces,
including hardwood, tile and stone. More specifically, the disclosure relates
to devices, systems and
methods for sweeping and mopping with an autonomous floor cleaner.
[0036] FIGS. 1 and 2 illustrate a schematic view of an autonomous floor
cleaner, such as a floor
cleaning robot 10, also referred to herein as a robot 10. It is noted that the
robot 10 shown is but
one example of a floor cleaning robot configured to sweep as well as dust, mop
or otherwise
conduct a wet cleaning cycle of operation, and that other autonomous cleaners
requiring fluid
supply or fluid recovery are contemplated, including, but not limited to
autonomous floor cleaners
capable of delivering liquid, steam, mist, or vapor to the surface to be
cleaned.
[0037] The robot 10 can include components of various functional systems in an
autonomously
moveable unit. The robot 10 can include a main housing 12 (FIG. 3) adapted to
selectively mount
components of the systems to form a unitary movable device. A controller 20 is
operably coupled with
the various functional systems of the robot 10 for controlling the operation
of the robot 10. The
controller 20 can be a microcontroller unit (MCU) that contains at least one
central processing unit
(CPU).
[0038] A navigation/mapping system 30 can be provided in the robot 10 for
guiding the movement
of the robot 10 over the surface to be cleaned, generating and storing maps of
the surface to be
cleaned, and recording status or other environmental variable information. The
controller 20 can
[4]
Date Recue/Date Received 2020-06-10
receive input from the navigation/mapping system 30 or from a remote device
such as a smaitphone
(not shown) for directing the robot 10 over the surface to be cleaned. The
navigation/mapping system
30 can include a memory 31 that can store any data useful for navigation,
mapping or conducting a
cycle of operation, including, but not limited to, maps for navigation, inputs
from various sensors that
are used to guide the movement of the robot 10, etc. For example, wheel
encoders 32 can be placed
on the drive shafts of wheels coupled to the robot 10 and configured to
measure a distance traveled
by the robot 10. The distance measurement can be provided as input to the
controller 20.
[0039] In an autonomous mode of operation, the robot 10 can be configured to
travel in any
pattern useful for cleaning or sanitizing including boustrophedon or
alternating rows (that is, the
robot 10 travels from right-to-left and left-to-right on alternate rows),
spiral trajectories, etc.,
while cleaning the floor surface, using input from various sensors to change
direction or adjust its
course as needed to avoid obstacles. In a manual mode of operation, movement
of the robot 10
can be controlled using a mobile device such as a smartphone or tablet.
[0040] The robot 10 can also include at least the components of a sweeper 40
for removing debris
particles from the surface to be cleaned, a fluid delivery system 50 for
storing cleaning fluid and
delivering the cleaning fluid to the surface to be cleaned, a mopping or
dusting assembly 60 for
removing moistened dust and other debris from the surface to be cleaned, and a
drive system 70
for autonomously moving the robot 10 over the surface to be cleaned.
[0041] The sweeper 40 can also include at least one agitator for agitating the
surface to be cleaned.
The agitator can be in the form of a brushroll 41 mounted for rotation about a
substantially
horizontal axis, relative to the surface over which the robot 10 moves. A
drive assembly including
a separate, dedicated brush motor 42 can be provided within the robot 10 to
drive the brushroll 41.
Other agitators or brushrolls can also be provided, including one or more
stationary or non-moving
brushes, or one or more brushes that rotate about a substantially vertical
axis. In addition, a debris
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Date Recue/Date Received 2020-06-10
receptacle 44 (FIG. 4) such as a dustbin can be provided to collect dirt or
debris from the brushroll
41.
[0042] The fluid delivery system 50 can include a supply tank 51 for storing a
supply of cleaning
fluid and at least one fluid distributor 52 in fluid communication with the
supply tank 51 for depositing
a cleaning fluid onto the surface. The cleaning fluid can be a liquid such as
water or a cleaning solution
specifically formulated for hard or soft surface cleaning. The fluid
distributor 52 can be one or more
spray nozzles provided on the housing 12 with an orifice of sufficient size
such that debris does not
readily clog the nozzle. Alternatively, the fluid distributor 52 can be a
manifold having multiple
distributor outlets.
[0043] A pump 53 can be provided in the fluid pathway between the supply tank
51 and the at least
one fluid distributor 52 to control the flow of fluid to the at least one
fluid distributor 52. The pump
53 can be driven by a pump motor 54 to move liquid at any flowrate useful for
a cleaning cycle of
operation.
[0044] Various combinations of optional components can also be incorporated
into the fluid delivery
system 50, such as a heater 56 or one or more fluid control and mixing valves.
The heater 56 can be
configured, for example, to warm up the cleaning fluid before it is applied to
the surface. In one
embodiment, the heater 56 can be an in-line fluid heater between the supply
tank 51 and the distributor
52. In another example, the heater 56 can be a steam generating assembly. The
steam assembly is in
fluid communication with the supply tank 51 such that some or all the liquid
applied to the floor surface
is heated to vapor.
[0045] The dusting assembly 60 can be utilized to disperse the distributed
fluid on the floor
surface and remove moistened dust and other debris. The dusting assembly 60
can include at
least one pad 61 that can optionally be rotatable. For example, the at least
one pad 61 can be
driven to rotate about a vertical axis that intersects with the center of the
respective pad 61. A
[6]
Date Recue/Date Received 2020-06-10
drive assembly including at least one pad motor 62 can be provided as part of
the dusting
assembly 60. Each pad 61 can be optionally be detachable for purposes of
cleaning and
maintenance.
[0046] The drive system 70 can include drive wheels 71 for driving the robot
10 across a surface
to be cleaned. The drive wheels can be operated by a common wheel motor 72 or
individual wheel
motors coupled with the drive wheels by a transmission, which may include a
gear train assembly
or another suitable transmission. The drive system 70 can receive inputs from
the controller 20 for
driving the robot 10 across a floor, based on inputs from the
navigation/mapping system 30 for the
autonomous mode of operation or based on inputs from a smartphone for the
manual mode of
operation. The drive wheels 71 can be driven in a forward or reverse direction
to move the unit
forwardly or rearwardly. Furthermore, the drive wheels 71 can be operated
simultaneously at the same
rotational speed for linear motion or independently at different rotational
speeds to turn the robot 10 in
a desired direction.
[0047] The robot 10 can include any number of motors useful for performing
locomotion and
cleaning. In one example, five dedicated motors can be provided to rotate each
of two pads 61, the
brushroll 41, and each of two drive wheels 71. In another example, one shared
motor can rotate both
the pads 61, a second motor can rotate the brushroll 41, and a third and
fourth motor can rotate each
drive wheel 71. In still another example, one shared motor can rotate the pads
61 and the brushroll
41, and a second and third motor can rotate each drive wheel 71.
[0048] In addition, a brush motor driver 43, pump motor driver 55, pad motor
driver 63, and wheel
motor driver 73 can be provided for controlling the brush motor 42, pump motor
54, pad motors
62, and wheel motors 72, respectively. The motor drivers 43, 55, 63, 73 can
act as an interface
between the controller 20 and their respective motors 42, 54, 62, 72. The
motor drivers 43, 55, 63,
73 can also be an integrated circuit chip (IC). It is also contemplated that a
single wheel motor
[7]
Date Recue/Date Received 2020-06-10
driver 73 can control multiple wheel motors 72 simultaneously.
[0049] Turning to FIG. 2, the motor drivers 43, 55, 63, 73 (FIG. 1) can be
electrically coupled to
a battery management system 80 that includes a built-in rechargeable battery
or removable battery
pack 81. In one example, the battery pack 81 can include lithium ion
batteries. Charging contacts
for the battery pack 81 can be provided on an exterior surface of the robot
10. A docking station
(not shown) can be provided with corresponding charging contacts that can mate
to the charging
contacts on the exterior surface of the robot 10. The battery pack 81 can be
selectively removable
from the robot 10 such that it can be plugged into mains voltage via a DC
transformer for
replenishment of electrical power, i.e. charging. When inserted into the robot
10, the removable
battery pack 81 can be at least partially located outside the housing 12 (FIG.
3) or completely
enclosed in a compartment within the housing 12, in non-limiting examples and
depending upon
the implementation.
[0050] The controller 20 is further operably coupled with a user interface
(UI) 90 on the robot 10 for
receiving inputs from a user. The user interface 90 can be used to select an
operation cycle for the robot
or otherwise control the operation of the robot 10. The user interface 90 can
have a display 91, such
as an LED display, for providing visual notifications to the user. A display
driver 92 can be
provided for controlling the display 91, and acts as an interface between the
controller 20 and the
display 91. The display driver 92 may be an integrated circuit chip (IC). The
robot 10 can further
be provided with a speaker (not shown) for providing audible notifications to
the user. The robot
10 can further be provided with one or more cameras or stereo cameras (not
shown) for acquiring
visible notifications from the user. In this way, the user can communicate
instructions to the robot
10 by gestures. For example, the user can wave their hand in front of the
camera to instruct the
robot 10 to stop or move away. The user interface 90 can further have one or
more switches 93
that are actuated by the user to provide input to the controller 20 to control
the operation of various
[8]
Date Recue/Date Received 2020-06-10
components of the robot 10. A switch driver 94 can be provided for controlling
the switch 93, and
acts as an interface between the controller 20 and the switch 93.
[0051] The controller 20 can further be operably coupled with various sensors
for receiving input
about the environment and can use the sensor input to control the operation of
the robot 10. The
sensors can detect features of the surrounding environment of the robot 10
including, but not limited
to, walls, floors, chair legs, table legs, footstools, pets, consumers, and
other obstacles. The sensor
input can further be stored in the memory or used to develop maps for
navigation. Some exemplary
sensors are illustrated in FIG. 2, and described below. Although it is
understood that not all sensors
shown may be provided, additional sensors may be provided, and that all of the
possible sensors
can be provided in any combination.
[0052] The robot 10 can include a positioning or localization system 100. The
localization system
100 can include one or more sensors, including but not limited to the sensors
described above. In
one non-limiting example, the localization system 100 can include obstacle
sensors 101
determining the position of the robot 10, such as a stereo camera in a non-
limiting example, for
distance and position sensing. The obstacle sensors 101 can be mounted to the
housing 12 (FIG.
3) of the robot 10, such as in the front of the housing 12 to determine the
distance to obstacles in
front of the robot 10. Input from the obstacle sensors 101 can be used to slow
down or adjust the
course of the robot 10 when objects are detected.
[0053] Bump sensors 102 can also be provided in the localization system 100
for determining front
or side impacts to the robot 10. The bump sensors 102 may be integrated with
the housing 12, such as
with a bumper 14 (FIG. 3). Output signals from the bump sensors 102 provide
inputs to the controller
for selecting an obstacle avoidance algorithm.
[0054] The localization system 100 can further include a side wall sensor 103
(also known as a
wall following sensor) and a cliff sensor 104. The side wall sensor 103 or
cliff sensor 104 can be
[9]
Date Recue/Date Received 2020-06-10
optical, mechanical, or ultrasonic sensors, including reflective or time-of-
flight sensors. The side
wall sensor 103 can be located near the side of the housing 12 and can include
a side-facing optical
position sensor that provides distance feedback and controls the robot 10 so
that robot 10 can follow
near a wall without contacting the wall. The cliff sensors 104 can be bottom-
facing optical position
sensors that provide distance feedback and control the robot 10 so that the
robot 10 can avoid
excessive drops such as stairwells or ledges.
[0055] The localization system 100 can also include an inertial measurement
unit (IMU) 105 to
measure and report the robot's acceleration, angular rate, or magnetic field
surrounding the robot
10, using a combination of at least one accelerometer, gyroscope, and,
optionally, magnetometer or
compass. The inertial measurement unit 105 can be an integrated inertial
sensor located on the
controller 20 and can be a nine-axis gyroscope or accelerometer to sense
linear, rotational or
magnetic field acceleration. The IMU 105 can use acceleration input data to
calculate and
communicate change in velocity and pose to the controller for navigating the
robot 10 around the
surface to be cleaned.
[0056] The localization system 100 can further include one or more lift-up
sensors 106 which
detect when the robot 10 is lifted off the surface to be cleaned e.g. if a
user picks up the robot 10.
This information is provided as an input to the controller 20, which can halt
operation of the pump
motor 54, brush motor 42, pad motor 62, or wheel motors 73 in response to a
detected lift-up event.
The lift-up sensors 106 may also detect when the robot 10 is in contact with
the surface to be
cleaned, such as when the user places the robot 10 back on the ground. Upon
such input, the
controller 20 may resume operation of the pump motor 54, brush motor 42, pad
motor 62, or wheel
motors 73.
[0057] The robot 10 can optionally include one or more tank sensors 110 for
detecting a
characteristic or status of the supply tank 51 or the debris receptacle 44. In
one example, one or
[10]
Date Recue/Date Received 2020-06-10
more pressure sensors for detecting the weight of the supply tank 51 or the
debris receptacle 44
can be provided. In another example, one or more magnetic sensors for
detecting the presence of
the supply tank 51 or debris receptacle 44 can be provided. This information
is provided as an
input to the controller 20, which may prevent operation of the robot 10 until
the supply tank 51 is
filled, the debris receptacle 44 is emptied, or both are properly installed,
in non-limiting examples.
The controller 20 may also direct the display 91 to provide a notification to
the user that either or
both of the supply tank 51 and debris receptacle 44 is missing.
[0058] The robot 10 can further include one or more floor condition sensors
111 for detecting a
condition of the surface to be cleaned. For example, the robot 10 can be
provided with an IR dirt sensor,
a stain sensor, an odor sensor, or a wet mess sensor. The floor condition
sensors 111 provide input to
the controller that may direct operation of the robot 10 based on the
condition of the surface to be
cleaned, such as by selecting or modifying a cleaning cycle. Optionally, the
floor condition sensors
111 can also provide input for display on a smai iphone.
[0059] An artificial barrier system 120 can also be provided for containing
the robot 10 within a
user-determined boundary. The artificial barrier system 120 can include an
artificial barrier
generator 121 that comprises a barrier housing with at least one signal
receiver for receiving a signal
from the robot 10 and at least one IR transmitter for emitting an encoded IR
beam towards a
predetermined direction for a predetermined period of time. The artificial
barrier generator 121 can
be battery-powered by rechargeable or non-rechargeable batteries or directly
plugged into mains
power. In one non-limiting example, the receiver can comprise a microphone
configured to sense a
predetermined threshold sound level, which corresponds with the sound level
emitted by the robot
when it is within a predetermined distance away from the artificial barrier
generator. Optionally,
the artificial barrier generator 121 can further comprise a plurality of IR
emitters near the base of
the barrier housing configured to emit a plurality of short field IR beams
around the base of the
[11]
Date Recue/Date Received 2020-06-10
barrier housing. The artificial barrier generator 121 can be configured to
selectively emit one or
more IR beams for a predetermined period of time, but only after the
microphone senses the
threshold sound level, which indicates the robot 10 is nearby. Thus, the
artificial barrier generator
121 can conserve power by emitting IR beams only when the robot 10 is near the
artificial barrier
generator 121.
[0060] The robot 10 can have a plurality of IR transceivers (also referred to
as "IR XCVRs") 123
around the perimeter of the robot 10 to sense the IR signals emitted from the
artificial barrier
generator 121 and output corresponding signals to the controller 20, which can
adjust drive wheel
control parameters to adjust the position of the robot 10 to avoid boundaries
established by the
artificial barrier encoded IR beam and the short field IR beams. Based on the
received IR signals,
the controller 20 prevents the robot 10 from crossing an artificial barrier
122 or colliding with the
barrier housing. The IR transceivers 123 can also be used to guide the robot
10 toward the docking
station, if provided.
[0061] In operation, sound (or light) emitted from the robot 10 greater than a
predetermined
threshold signal level is sensed by the microphone (or photodetector) and
triggers the artificial
barrier generator 121 to emit one or more encoded IR beams for a predetermined
period of time.
The IR transceivers 123 on the robot 10 sense the IR beams and output signals
to the controller 20,
which then manipulates the drive system 70 to adjust the position of the robot
10 to avoid the
barriers 122 established by the artificial barrier system 120 while continuing
to perform a cleaning
operation on the surface to be cleaned.
[0062] The robot 10 can operate in one of a set of modes. The modes can
include a wet mode, a
dry mode and a sanitization mode. During a wet mode of operation, liquid from
the supply tank 51
is applied to the floor surface and both the brushroll 41 and the pads 61 are
rotated. During a dry
mode of operation, the brushroll 41, the pads 61, or a combination thereof,
are rotated and no liquid
[12]
Date Recue/Date Received 2020-06-10
is applied to the floor surface. During a sanitizing mode of operation, liquid
from the supply tank
51 is applied to the floor surface and both the brushroll 41 and the pads 61
are rotated and the robot
can select a travel pattern such that the applied liquid remains on the
surface of the floor for a
predetermined length of time. The predetermined length of time can be any
duration that will result
in sanitizing floor surfaces including, but not limited to, two to five
minutes. However, sanitizing
can be effected with durations of less than two minutes and as low as fifteen
seconds.
[0063] It is also contemplated that the pump 53 (FIG. 1) can be driven
according to a pulse-width
modulation (PWM) signal 28. Pulse-width modulation is a method of
communication by
generating a pulsing signal. Pulse-width modulation can be utilized for
controlling the amplitude
of digital signals in order to control devices and applications requiring
power or electricity, such
as the pump motor 54. The PWM signal 28 can control an amount of power given
to the pump 53
by cycling the on-and-off phases of a digital signal at a predetermined
frequency and by varying
the width of an "on" phase. The width of the "on" phase is also known as duty
cycle, which is
expressed as the percentage of being "fully on" (100%). The pump 53 can
essentially receive a
steady power input with an average voltage value which is the result of the
duty cycle and can be
less than the maximum voltage capable of being delivered from the battery pack
81. The PWM
signal 28 can be transmitted from the controller 20 and configured to provide
a set flowrate of
deposited cleaning fluid. In one non-limiting example of operation, the PWM
signal 28 can
cyclically energize the pump 53 for a first predetermined time duration, such
as 40 milliseconds,
and then de-energize the pump for a second predetermined time duration, such
as 2 seconds, at a
rate of 50 Hz and a duty cycle of 40%. Higher flow rates can be achieved by,
for example,
increasing either of both of the duty cycle or frequency. In this manner, the
controller 20 can
provide for any suitable or customized flow rate, including a low flow rate,
from the pump 53
being powered from the battery pack 81.
[13]
Date Recue/Date Received 2020-06-10
[0064] FIG. 3 illustrates the exemplary robot 10 that can include the systems
and functions
described in FIGS 1-2. As shown, the robot 10 can include a D-shaped housing
12 with a first end
13 and a second end 15. The first end 13 defines a housing front 11 of the
robot 10 which is a
straightedge portion of the D-shaped housing 12, and can be formed by the
bumper 14. The second
end 15 can define a housing rear 16 which is a rounded portion of the D-shaped
housing 12. The
battery pack 81 and supply tank 51 can also be mounted to the housing 12 as
shown.
[0065] Forward motion of the robot 10 is illustrated with an arrow 17, and the
bumper 14 wraps
around the first end 13 of the robot 10 to provide a lateral portion 18 along
the D-shaped front region
of the robot 10. In the illustrated example, the bumper 14 includes a lower
crenellated structure 19
which is described in more detail below. During a collision with an obstacle,
the bumper 14 can shift
or translate to register a detection of an object.
[0066] The robot 10 is shown in a lower perspective in FIG. 4, where an
underside portion 21 of
the housing 12 is visible. The robot 10 can include the sweeper 40 with
brushroll 41, at least one
wheel assembly with a drive wheel 71, and the dusting assembly 60 which is
illustrated with two
circular pads 61. The brushroll 41 can be positioned within a brush chamber
22. The brushroll 41
and brush chamber 22 can be located proximate the first end 13, e.g. proximate
the straightedge
portion of the housing 12. Along the bottom surface of the robot 10 and with
respect to forward
motion of the robot 10, the sweeper 40 is mounted ahead of the pads 61 and
drive wheels 71 are
disposed therebetween. In addition, the debris receptacle 44 can be positioned
adjacent the
brushroll 41 and brush chamber 22. In the illustrated example, the debris
receptacle 44 is positioned
in line with the drive wheels 71, between the brush chamber 22 and pads 61.
[0067] The robot 10 can also include one or more casters 74 set behind the
brush chamber 22. The
casters 74 can include a wheel mounted on an axle, or an omnidirectional ball
for rolling in multiple
directions, in non-limiting examples. The one or more casters 74 can, in one
example, be utilized
[14]
Date Recue/Date Received 2020-06-10
to maintain a minimum spacing between the surface to be cleaned and the
underside portion 21 of
the robot 10.
[0068] In another example (not shown), a squeegee can optionally be provided
on the housing 12,
such as behind the pads 61. In such a case, the squeegee can be configured to
contact the surface
as the robot 10 moves across the surface to be cleaned. The squeegee can wipe
any remaining
residual liquid from the surface to be cleaned, thereby leaving a moisture and
streak-free finish on
the surface to be cleaned. In a dry application, the squeegee can prevent
loose debris from being
propelled by the brushroll 41 to the rear of the robot 10.
[0069] FIG. 5 is a side elevation cross-sectional view of the robot 10. The
supply tank 51 and debris
receptacle 44 can be separate components within the robot 10. Alternately, the
supply tank 51 and
debris receptacle 44 can be integrated into a single tank assembly.
[0070] The supply tank 51 can define at least one supply reservoir 51R to
store liquid for
application, via the pump 53 (FIG. 1), to a surface of a floor to be cleaned
by the dusting assembly
60. The debris receptacle 44 can define at least one receptacle reservoir 44R
and can include a
receptacle inlet 45 directly adjacent, and open to, the brush chamber 22. The
brush chamber 22 can
include a partition having a ramped front surface 24 provided at a bottom of
the receptacle inlet 45
to guide debris into the debris receptacle 44. In operation, dirt or debris
swept up by rotation of the
brushroll 41 can be moved by the brushroll 41 through the brush chamber 22,
including along the
ramped front surface 24, and propelled through the receptacle inlet 45 into
the debris receptacle 44.
[0071] Optionally, pad holders 64 can be utilized to mount the circular pads
61 to the housing 12. In
such a case, the pad holders 64 can include rotation plates and form the
bottom of the base of the
dusting assembly 60. The pad holders 64 can include a bottom cover through
which a motor shaft of
the pad motor 62 extends. The pad motor 62 rotates the motor shaft via a
suitable transmission, such
as a worm gear assembly that can rotate the pad holder 64 and, consequently,
the pad 61. The coupling
[15]
Date Recue/Date Received 2020-06-10
between the motor shaft and the rotatably driven pad holder 64 defines a
vertical axis of rotation for
the pad 61.
[0072] To remove the pads 61 for cleaning, the dusting assembly 60 can include
selectively removable
elements. In one non-limiting example, the selectively removable elements can
be the pads 61, and in
such a case a user or consumer can remove the pads 61 for cleaning or
replacement. In another non-
limiting example, the removable elements include detachable elements such as
the pad holder 64 which
couple the pads 61 to the pad motor 62. In such a case, a consumer can release
the removable elements
(e.g. the pad holders 64) through any suitable decoupling means and can then
remove the pads 61 from
the removable elements for cleaning or replacement. In one example, the
removable elements are
released from the robot 10 via an actuator 65 directly coupled to a mechanical
catch and latch assembly.
It is also contemplated that the pad holders 64 can also be rotatable along
with the pads 61 in the dusting
assembly 60.
[0073] Alternatively, or in addition to the selectively removable elements, a
cleaning station (not
shown) can be provided to aid in cleaning or replacing the pads 61 of the
dusting assembly 60. The
robot 10 can be placed on the cleaning station and can apply or assist in a
cleaning operation for the
pads 61. In one example, the cleaning station can include a surface provided
with a plurality of
bosses or nubs for agitating the bottom of the pads 61. The robot 10 can
activate a self-cleaning
mode where the pads 61 are rotated while in contact with the plurality of
bosses or nubs to produce
an agitation process that mechanically cleans the pads 61.
[0074] FIG. 6 illustrates additional details of the dusting assembly 60. The
robot 10 can optionally
include a pad-lifting assembly 66 that selectively and automatically lifts the
pads 61 off the floor
surface whenever the robot 10 comes to a complete stop. In the illustrated
example, the dusting
assembly 60 including the rotating pads 61 are coupled to a movable frame that
includes a spring
67 which is biased to provide vertical separation between the pads 61 and the
floor surface. A user
[16]
Date Recue/Date Received 2020-06-10
can initiate a cleaning cycle of operation, for example, by pressing a button
75 that activates a
microswitch 68 and displaces the dusting assembly 60 from a raised position,
with the pads 61 out
of contact with the floor surface, downwardly to a lowered position in which
the pads 61 contact
the floor surface. The dusting assembly 60 can be selectively retained in the
lowered position by a
catch 69 that is selectively movable by another actuator 65 such as a
solenoid. The robot 10 can
be configured to activate the actuator 65 to move the catch 69 and release the
dusting assembly 60
after a cleaning cycle of operation such that the spring 67 urges the dusting
assembly 60 to translate
back to the raised position. In this manner, the pads 61 can be out of contact
with the floor surface
while drying, thus preventing streaking and staining of the floor surface
directly beneath the pads
61.
[0075] In another example (not shown), the pad-lifting assembly 66 can include
a caster 74
coupled to an actuator, such as a solenoid, configured to affect a linear
motion that extends the
caster 74 downward from a first raised position to a second lowered position.
The caster 74 can
travel downward to contact the surface of the floor and at which point it
raises at least a rear portion
of the robot 10 until the pads 61 are no longer in contact with the floor
surface. In another example,
the robot 10 can selectively engage the pad-lifting assembly 66 to raise the
pads 61 off the floor
surface at the completion of a scheduled cleaning cycle of operation.
[0076] In still another example (not shown), the robot 10 can vary the speed
and direction of the
rotation of the pads 61. The robot 10 can select the speed and rotation
according to a cycle of
operation to aid or improve cleaning or locomotion of the robot 10. In one
example, the pads 61
can counter-rotate such that the front edge of each pad 61 is spinning away
from the fluid distributor
52 (FIG. 1) or spray nozzle 57 (FIG. 8). The rate of spinning can include any
rate useful for
performing a cleaning cycle of operation including, but not limited to a range
of rotations per
minute from 80 to 120. However, slower and faster rotations may be
advantageous for specialized
[17]
Date Recue/Date Received 2020-06-10
cleaning modes.
[0077] FIG. 7 illustrates the underside of the robot 10 with the bumper 14
shown in additional
detail. A lower portion of the bumper 14 can include a crenellated structure
19 of interleaved
merlons 25 and crenels 26. In other words, the lower portion of the bumper 14
has a series of
projecting lead-ins (merlons 25) that direct debris into the openings (crenels
26) disposed along
the lower leading edge of the bumper 14 between adjacent merlons 25. Such a
configuration allows
the robot 10 to detect surface transitions, such as from a hard surface to an
area rug or carpet,
through sensors on the forward bumper 14 while also allowing debris to pass
through the crenels
26. The merlons 25 can be formed of a substantially trapezoidal cross-section
where the shorter
base of the trapezoid forms the leading edge of the bumper 14 with respect to
the forward motion
of the robot 10. In this way, debris can be funneled along the legs of the
trapezoidal merlons 25 to
the sweeper 40 (e.g. the brushroll 41 and brush chamber 22) configured behind
the bumper 14. In
another example (not shown), the debris receptacle 44 can include a flapper to
prevent the collected
debris from inadvertently spilling out of the debris receptacle 44 during
removal or transport to a
waste container.
[0078] FIG. 8 is an isometric view of the robot 10 illustrating further
details of the fluid delivery
system 50. In the example shown, the distributor 52 includes a spray nozzle 57
fluidly coupled to
the supply tank 51 (FIG. 3) via the pump 53. The spray nozzle 57 can be
positioned between
adjacent pads 61 as shown. In one example, cleaning fluid dispensed from the
spray nozzle 57 can
be delivered directly to the floor surface, and the rotating pads 61 can
absorb and remove the
applied cleaning fluid from the floor surface, including during a wet mode of
operation of the robot
as described above.
[0079] A cross-sectional view of the debris receptacle 44 and supply tank 51
is shown in FIG. 9.
The supply tank 51 can further include a valve 58 with an outlet 59 that is
fluidly connected to a
[18]
Date Recue/Date Received 2020-06-10
downstream portion of the fluid delivery system, such as the spray nozzle 57
(FIG. 8). In one
example, the valve 58 can comprise a plunger valve removably mounted to an
open neck on bottom
of the supply tank 51. A mechanical closure 29, such as a threaded cap, can
secure the valve 58 to
the supply tank 51 and be easily removed for refilling the supply tank 51 when
necessary. In the
example shown, the supply tank 51 includes a single supply reservoir 51R for
water or a
combination of water and a cleaning formula. In another example (not shown),
the supply tank 51
can includes a first reservoir for storing water and a second reservoir for
storing a cleaning formula. It
is contemplated that the robot 10 can include multiple supply tanks, a single
supply tank with multiple
reservoirs or chambers therein, or the like, or combinations thereof for
storing cleaning fluid within the
robot 10.
[0080] FIG. 10 is a schematic illustration of a wheel assembly 76 of the robot
10 having parallel
linkages 77 and an extension spring 78. The wheel assembly 76 in the
illustrated example includes
one or more drive wheel subassemblies. A drive wheel subassembly includes at
least one drive
wheel 71 coupled to a wheel housing 79 via at least one linkage 77. The at
least one linkage 77 can
include any element useful for raising or lowering the wheel 71 with respect
to the wheel housing
79. The wheel housing 79 is coupled to the chassis or housing 12 of the robot
10. In addition, the
extension spring 78 can include a first end 83 coupled to the housing 12 or a
sensor thereon, such
as the lift-up sensor 106 (FIG. 2). A second end 84 of the extension spring 78
can couple to any
suitable portion of the robot 10, illustrated with an exemplary first position
85 on a housing of the
wheel motor 72, or an exemplary second position 86 directly on the at least
one linkage 77, in non-
limiting examples.
[0081] During locomotion of the robot 10, if the drive wheels 71 traverse an
obstacle such as a
threshold or power cord, the linkages 77 can rotate while the drive wheels 71
can partially rise into
the wheel housing 79, aided by the extension spring 78, such that the pads 61
remain in contact with
[19]
Date Recue/Date Received 2020-06-10
the floor surface. During locomotion of the robot 10, if the drive wheels 71
lose contact with the
floor surface, the drive wheels 71 can lower from the wheel housing 79 and
indicate that the robot
has been lifted from the floor surface.
[0082] FIG. 11 is a schematic illustration of another wheel assembly 76B
similar to the wheel
assembly 76. One difference is that the wheel assembly 76B includes a
compression spring 78B
biasing the drive wheels 71 downward toward the surface to be cleaned. Another
difference is that
the wheel assembly 76B can include non-parallel first and second linkages 77A,
77B coupling the
drive wheels 71 to the wheel housing 79. The non-parallel linkages 77A, 77B,
can, in one example,
be utilized in combination with the compression spring 78B to direct the drive
wheels 71 in a
customized direction or path of movement in the event of the robot 10
traversing an obstacle such
as a flooring threshold or power cord. The compression spring 78B can be
coupled at a first position
85B to the housing of the wheel motor 72, or directly to either of the non-
parallel linkages 77A. 77B
as illustrated with a second position 86B.
[0083] Referring now to FIG. 12, another autonomous floor cleaner, such as
another floor cleaning
robot 210 is illustrated that can include the various functions and system as
described in FIGS. 1-2.
The robot 210 is similar to the robot 10; therefore, like parts will be
identified with like numerals
increased by 200, with it being understood that the description of the like
parts of the robot 10
applies to the robot 210, except where noted.
[0084] The robot 210 can include the D-shaped main housing 212 adapted to
selectively mount
components of the systems to form a unitary movable device. One difference is
that the robot
210 can include a sweeper 240 without including a dusting assembly as
described above.
[0085] Another difference is that the robot 210 can be driven in an opposite
direction as
compared to the robot 10, where an arrow 217 illustrates a direction of motion
of the robot 10
during operation. More specifically, a first end 213 forming a straight-edge
portion of the D-
[20]
Date Recue/Date Received 2020-06-10
shaped housing 212 can define the housing rear 216, and a second end 215
forming a rounded
edge of the housing 212 can define the housing front 211.
[0086] Another difference is that the robot 210 can further include a unitary
or integrated tank
assembly 246. Turning to FIG. 13, the integrated tank assembly 246 can include
a supply tank 251
and debris receptacle 244. The tank assembly 246 is shown in a partially-
removed state from the
housing 212. It is contemplated that the tank assembly 246 can be selectively
removed by a
consumer such that both the supply tank 251 and the debris receptacle 244 are
removed together
in one action. For example, the tank assembly 246 can include a hook-and-catch
mechanism
wherein a hook 247 on the tank assembly 246 engages with a catch 248 on the
housing 212 of the
robot 210. A handle 249 can be provided on the tank assembly 246, wherein a
user can grasp the
handle 249 and rotate the tank assembly 246 to disengage the tank assembly 246
from the housing
212.
[0087] It is further contemplated that the tank assembly 246 can at least
partially define the brush
chamber 222. The brushroll is not shown in this view for clarity; however, any
suitable agitator
including one or more brushrolls can be provided. The brush chamber 222 can be
open to the debris
receptacle 244 as described above. In the illustrated example, the brushroll
(not shown) can be
located at the rear of the housing 212 when the robot 210 moves in the
direction indicated by the
arrow 217. Optionally, a bumper 214 can form the second end 215 of the housing
212.
[0088] FIG. 14 illustrates the tank assembly 246 in isolation with the supply
tank 251 and debris
receptacle 244. The supply tank 251 can be positioned above the debris
receptacle 244. It is further
contemplated that the debris receptacle 244 can be selectively removable from
the supply tank 251.
Any suitable mechanism can be utilized, such as a second hook-and-catch
mechanism (not shown)
between the supply tank 251 and debris receptacle 244. A release button 295 or
other actuator can
optionally be provided for selective detachment of the debris receptacle 244
from the tank assembly
[21]
Date Recue/Date Received 2020-06-10
246.
[0089] FIG. 15 illustrates removal of the debris receptacle 244 from the
supply tank 251. The debris
receptacle 244 can be rotated downward and away from the supply tank 251 to
access the receptacle
reservoir 244R, such as for complete removal and cleanout of the receptacle
244. It can also be
appreciated that removal of the supply tank 251 and debris receptacle 244 in a
single integrated tank
assembly 246 can improve usability, wherein a consumer can remove the tank
assembly 246 in a
single action to fill the supply tank 251 with cleaning fluid and remove
debris from the receptacle
244.
[0090] Referring now to FIGS. 16-17, another autonomous floor cleaner, such as
another floor
cleaning robot 410 is illustrated that can include the various functions and
system as described in
FIGS. 1-2. The robot 410 is similar to the robot 10; therefore, like parts
will be identified with like
numerals increased by 400, with it being understood that the description of
the like parts of the
robot 10 applies to the robot 410, except where noted.
[0091] The robot 410 can include a D-shaped main housing 412 adapted to
selectively mount
components of the systems to form a unitary movable device. The D-shaped
housing 412 has a
first end 413 and a second end 415. The robot 410 can be driven in an opposite
direction as
compared to the robot 10, where an arrow 417 illustrates a direction of motion
of the robot 410
during operation. More specifically, a first end 413 forming a straight-edge
portion of the D-
shaped housing 412 can define the housing rear 416, and a second end 415
forming a rounded
edge of the housing 412 can define the housing front 411. Optionally, a bumper
(not shown)
can be provided at the second end 415.
[0092] Another difference is that the robot 410 can include a vacuum
collection or recovery
system for removing the liquid and debris from the floor surface, and storing
the recovered liquid
and debris in a debris receptacle 444 (or recovery tank). The details of one
embodiment of the
[22]
Date Recue/Date Received 2020-06-10
vacuum collection or recovery system for the robot 410 are described in more
detail below.
[0093] Another difference is that the robot 410 shown does not include a
mopping and dusting
assembly as described above, although in other embodiments the robot 410 can
be provided with
one or more vertically-rotating dusting pads as described above.
[0094] Another difference is that the robot 410 includes a unitary or
integrated tank assembly
446. The integrated tank assembly 446 can include at least a supply tank 451
and the debris
receptacle 444. It is further contemplated that the debris receptacle 444 can
be selectively
removable from the supply tank 451. A cover 427 defining a brush chamber 422
can be formed
with or otherwise coupled to the tank assembly 446, and can be removed from
the housing 412
along with the tank assembly 446 as one unit.
[0095] Referring to FIG. 18, it is contemplated that the tank assembly 446 can
be selectively
removed by a consumer such that the supply tank 451, the debris receptacle
444, and the brush
chamber 422 are removed together in one action. A handle 449 can be provided
on the tank
assembly 446, wherein a user can grasp the handle 449 and rotate the tank
assembly 446 to
disengage the tank assembly 446 from the housing 412. It is contemplated that
the handle 449 can
serve two purposes. First, when the tank assembly 446 is attached to the
housing 412, the handle
449 can be used to carry the entire robot 410. Second, when the tank assembly
446 is not attached
to the housing 412, the handle 449 can be used to carry the tank assembly 446.
[0096] The tank assembly 446 can be attached to the housing 412 using any
suitable mechanism.
In one exemplary embodiment, referring additionally to FIG. 19, the robot 410
can include a pivot
coupling for movement of the tank assembly 446 about axis A, shown herein as a
hook-and-catch
mechanism that allows the tank assembly 446 to be fully separated from the
housing 412. The
hook-and-catch mechanism can include a hook 447 on the tank assembly 446 that
engages with a
catch 448 on the housing 412 of the robot 410. Two hooks 447 can be provided
on opposing lateral
[23]
Date Recue/Date Received 2020-06-10
sides of a rear portion of the tank assembly 446, or on the cover 427, with
corresponding catches
448 provided on opposing lateral sides of the first end 313 or housing rear
416 of the housing 412.
Alternatively, the hooks 447 can be provided on the housing 412 and the
catches 448 can be
provided on the tank assembly 446.
[0097] In addition, a latch 433 can secure a portion of the tank assembly 446
to the housing 412.
Of course, in other embodiments of the robot 410, the tank assembly 446 can be
secured to the
housing 412 using just a hook-and-catch mechanism or just a latch mechanism.
The latch 433
includes a latch actuator, such as a latch button 434 that is depressed by the
user to release the tank
assembly 446. The latch 433 can be any suitable latch, catch, or other
mechanical fastener that
can join the tank assembly 446 and housing 412, while allowing for the regular
separation of the
tank assembly 446 from the housing 412, such as a spring-biased latch operable
via the latch button
434.
[0098] The tank assembly 446 is shown in a partially-removed state from the
housing 412 in FIG.
18. The tank assembly 446 can be removed from the housing 412 by pressing the
latch button 434
and rotating the tank assembly 446 as shown in FIG. 18, about an axis A
defined by the hook-and-
catch mechanism. Once the hooks 447 have cleared the catches 448, the tank
assembly 446 can
be lifted upwardly away from the housing 412. This process can be performed
with one hand.
Optionally, the handle 449 can be proximate to, i.e. lie close enough to, the
latch button 434 so
that the consumer can grip the handle 449 with one hand and actuate the latch
433 using the same
hand, e.g. press the latch button 434 with a finger or thumb of the same hand.
Having the tank
assembly 446 removable from the top side of the housing 412 also provides a
benefit for charging
or docking the robot 410 because the tank assembly 446 can be removed when the
robot 410 is
seated in the charging cradle or docking station.
[0099] Having the latch 433 on the housing 412 and the handle 449 on the tank
assembly 246 can
[24]
Date Recue/Date Received 2020-06-10
provide some further benefits to the tank removal process. The consumer must
provide opposing
forces to lift the tank assembly 446 upwardly while simultaneously pressing
downward on the
housing 412. This helps create a clean breakaway between the two assemblies
and keeps the
housing 412 in position during removal of the tank assembly 446. This can be
particularly helpful
if the robot 410 is in a charging cradle or at a docking station when the
consumer removes the
tank assembly 446. The tank assembly 446 can be removed without disturbing any
electrical
contact needed for charging the battery (not shown).
[00100] The tank assembly 446 combines the supply tank 451, debris
receptacle 444, and
brush chamber 422 in one unitary assembly or module. These parts of the robot
410 are serviced
most frequently, and providing them in a single unit allows the consumer to
easily remove them.
After a cleaning operation, the debris receptacle 444 is emptied and rinsed
along with the brush
chamber 422 since these two parts make up the recovery pathway for liquid and
debris. The supply
tank 451 will also most likely need to be refilled after each operation.
[00101] As shown in FIG. 20, removing the tank assembly 446 from the
housing 412 will
expose the brushroll 441 and allows the consumer to easily access the
brushroll 441. With the
tank assembly 446 removed, the consumer can remove the brushroll 441 by
lifting one end of the
brushroll upwardly, as indicated by arrow B in FIG. 20. The consumer can then
carry the brushroll
441, optionally along with the tank assembly 446, to a sink for service. The
brushroll 441 can be
rinsed after a cleaning operation; optionally, the user can manually remove
hair and other debris
as well.
[00102] After servicing, the user can easily reassemble the brushroll 441
and the tank
assembly 446 back on the housing 412, optionally after allowing one or both to
dry, to prepare
the robot 410 for its next cleaning operation. As noted above, while servicing
or allowing the
serviced components to dry, the housing 412 can be docked and charging.
[25]
Date Recue/Date Received 2020-06-10
[00103] Still referring to FIG. 20, in addition to the supply tank 451,
the fluid delivery system
can include at least one fluid distributor 452 in fluid communication with the
supply tank 451 for
depositing a cleaning fluid onto the surface. The fluid distributor 452 shown
is a manifold having
multiple distributor outlets. Other configuration for the fluid distributor
452 are possible. The fluid
distributor 452 can optionally be arranged forwardly of the brush chamber 422
to distribute
liquid in front of the brushroll 441, with reference to the front and rear
portions 411, 416 of the
robot 410.
[00104] A pump 453 is provided in the fluid pathway between the supply
tank 451 and the
fluid distributor 452, and is coupled to an inlet of the fluid distributor 452
by a first conduit 435. A
second conduit 436 couples the pump 453 to a valve receiver 437 on the housing
412 for fluidly
coupling with the supply tank 451 when the tank assembly 446 is seated within
the housing 12. As
discussed above, the pump 453 can be driven according to a pulse-width
modulation (PWM) signal
28 (FIG. 1).
[00105] The recovery system can include a recovery pathway through the
robot 410 having
an air inlet and an air outlet, the debris receptacle 444 for receiving
recovered liquid and debris
for later disposal, and a suction source 438 in fluid communication with the
brush chamber 422
and the debris receptacle 444 for generating a working airstream through the
recovery pathway.
The suction source 438 can include a vacuum motor located fluidly upstream of
the air outlet, and
can define a portion of the recovery pathway. Optionally, a pre-motor filter
and/or a post-motor
filter (not shown) can be provided in the recovery pathway as well. The
recovery pathway can
further include various conduits, ducts, or tubes for fluid communication
between the various
components of the vacuum collection system.
[00106] The suction source 438 can be positioned downstream of the debris
receptacle
444 in the recovery pathway. The suction source 438 can include a motor air
inlet port 439 for
[26]
Date Recue/Date Received 2020-06-10
coupling the debris receptacle 444 with the suction source 438. In other
embodiments, the suction
source 438 may be located fluidly upstream of the debris receptacle 444.
[00107] FIG. 21 is a side elevation cross-sectional view of the robot 410.
The supply tank
451 can define at least one supply reservoir 451R to store liquid for
application, via the pump
453, to a surface of a floor to be cleaned. The debris receptacle 444 can
define at least one
receptacle reservoir 444R and can include a separator 487 for separating
liquid and debris from
the working airstream.
[00108] The recovery system of the robot 410 can include a dirty inlet
defined by a suction
conduit 489. The dirty inlet or suction conduit 489 can be any type of suction
inlet suitable for
the purposes described herein, including the collection of debris and liquid
from the brushroll
441. In the illustrated embodiment, the dirty inlet or suction conduit 489
comprises an
elongated duct extending from a brush chamber 422 that receives the brushroll
441, and
fluidly couples the brush chamber 422 with the separator 487. The suction
conduit 489 pulls
debris and excess liquid from the brushroll 441. The brush chamber 422 helps
define the air
flow that goes through the suction conduit 489 and into the debris receptacle
444. The suction
conduit 489 can extend to or be integrally formed with the separator 487.
[00109] The debris receptacle 444 can be positioned behind the supply tank
451, relative
to the direction of forward travel 417 of the robot 410. The brush chamber 422
is located
proximate the first end 413, e.g. proximate the straightedge portion of the
housing 412 defining
the housing rear 416.
[00110] In addition to the drive wheels 471 and caster 474, the robot 410
can also include
one or more additional wheels 482 proximate to the first end 413 of the
housing 412. The
additional wheels 482 can, in one example, be utilized to maintain a minimum
spacing between
the surface to be cleaned and the underside of the housing rear 416. The
caster 374 can be
[27]
Date Recue/Date Received 2020-06-10
disposed proximate to the second end 415 of the housing 412 to maintain a
minimum spacing
between the surface to be cleaned and the underside of the housing front 11.
[00111] FIG. 22 is a cross-sectional view taken through the brush chamber
422. The brush
chamber 422 substantially surrounds the front, back, and top sides of the
brushroll 441 and is
defined by the cover 427. The brush chamber 422 is open at the bottom side of
brushroll 441 for
engagement of the brushroll 411 with the surface to be cleaned. In the
illustrated embodiment,
the cover 427 extends over the housing 412 so that the housing 412 is not
exposed to the brushroll
441, and is in particular not exposed to ingested debris and liquid. This
prevents debris from
collecting on the housing 412. Rather, debris not ingested into the debris
receptacle 444 instead
can collect on the cover 427 and in the suction conduit 489 extending to
debris receptacle 444.
Since these portions are removable along with the tank assembly 446, all dirt
collected by the
robot 410 will be able to be cleaned out at the sink or other waste
receptacle. In other words, all
surfaces of the robot 410 forming the recovery pathway are removable and
easily cleanable.
[00112] In some embodiments, the brush chamber 422 includes a scraper 496
that removes
liquid and debris from the brushroll 441 and keeps it in the brush chamber 422
so that it can be
removed by the suction conduit 489. The scraper 496 can be mounted to or
otherwise provided
within the brush chamber 422, and can extend toward the brushroll 441 to
interface with a portion
of the brushroll 441. More specifically, the scraper 496 is configured to
engage with a forward
portion of the brushroll 441, as defined by the direction of forward travel
417 of the robot 410. As
the brushroll 441 rotates, the scraper 496 can scrape liquid and debris off
the brushroll 441. The
scraper 496 can additionally can help redistribute liquid evenly along the
length of the brushroll
441, which can help to reduce streaking on the surface to be cleaned.
[00113] In one embodiment, the scraper 496 can be an elongated rib, wiper,
or blade that
generally spans the transverse length of the brushroll 441. The scraper 496
can have a thin or
[28]
Date Recue/Date Received 2020-06-10
narrow edge 497 that engages the brushroll 441, and can optionally taper to
the thin or narrow edge
497. Optionally, the edge 497 can be disposed generally orthogonally to the
portion of the brushroll
441 which it engages. Alternatively, the edge 497 can be disposed at an angle
to the brushroll 441.
[00114] The scraper 496 can be provided on the inside of the cover 427 to
project into the
brush chamber 422. The scraper 496 can be formed integrally with the cover
427, or can be formed
separately and attached within the cover 427 using any suitable joining
method.
[00115] Optionally, the scraper 496 can be rigid, i.e. stiff and non-
flexible, so the scraper
496 does not yield or flex by engagement with the brushroll 441. In one
example, the scraper 496
can be formed of rigid thermoplastic material, such as poly(methyl
methacrylate) (PMMA),
polycarbonate, or acrylonitrile butadiene styrene (ABS). Alternatively, the
scraper 496 can be
pliant, i.e. flexible or resilient, in order to deflect according to the
contour of the brushroll 441.
[00116] A squeegee 498 can be provided in the brush chamber 422,
rearwardly of the
brushroll 441, to wipe the surface to be cleaned while introducing liquid and
dirt into the brush
chamber 422 to reduce streaking on the surface to be cleaned, as well as to
prevent dry dirt from
scattering when the brushroll 441 is rotating during a dry mode of operation.
The squeegee 498
can be disposed on the cover 427, behind the brushroll 441, and is configured
to contact the surface
as the robot 410 moves across the surface to be cleaned. Moisture or debris
that contacts the
squeegee 498 as the robot 410 moves forwardly is entrained in the air flow
that goes through the
suction conduit 489 and into the debris receptacle 444. The squeegee 498 can
include nubs
or ribs on a rearward-facing surface that facilitates liquid and debris
passage under the
squeegee 498 when the robot 410 is moving in a rearward direction. The
opposite side, or forward-
facing side, of the squeegee 498 can be a smooth surface that effectively
moves surface moisture
to trap it within the brush chamber 422 for entrainment in the air flow when
the robot 410 is
moving in a forward direction. The squeegee 498 can be pliant, i.e. flexible
or resilient, in order
[29]
Date Recue/Date Received 2020-06-10
to bend readily according to the contour of the surface to be cleaned, yet
remain undeformed by
typical operation of the robot 410. Optionally, the squeegee 498 can be formed
of a resilient
polymeric material, such as ethylene propylene diene monomer (EPDM) rubber,
polyvinyl
chloride (PVC), a rubber copolymer such as nitrile butadiene rubber, or any
material known in
the art of sufficient rigidity to remain substantially undeformed during a
typical operation of the
robot 410. It is noted that FIG. 22 shows the squeegee 498 unbent, whereas in
operation, the
squeegee 498 may be bent backward where it engages the floor surface when the
robot 410 moves
forward in the direction indicated by arrow 417.
[00117] Referring to FIGS. 20 and 23, when the tank assembly 446 is
assembled or
reassembled with the housing 412, one or more connections are made between
components of the
tank assembly 446 and components of the housing 412. For example, the supply
tank 451 can be
connected with the pump 453 and the debris receptacle 444 can be connected
with the suction
source 438.
[00118] The supply tank 451 can further include a valve 458 that is coupled
with the valve
receiver 437 on the housing 412. When the tank assembly 446 is seated on the
housing 412, the valve
458 is opened by engagement with the valve receiver 437, and liquid can flow
to the pump 453 via
conduit 436. Alternatively, a direct connection can be made between the valve
458 and pump 453
upon seating of tank assembly 446 on the housing 412. In still another
alternative, various other
fluid connectors, conduits, ducts, or tubes can be provided to convey liquid
from the supply tank
451 to an inlet of the pump 453.
[00119] The debris receptacle 444 can include an air outlet port 499 that
is coupled with the
air inlet port 439 of the suction source 438, or otherwise provided on the
housing 12 and in fluid
communication with the suction source 438, when the debris receptacle 444 is
seated on the housing
412. The connection made between the air outlet port 499 and the inlet port
439 can be fluid-tight
[30]
Date Recue/Date Received 2020-06-10
and can include appropriate sealing. Alternatively, various other fluid
connectors, conduits, ducts,
or tubes can be provided to convey working air from the debris receptacle 444
to an inlet of the
suction source 438.
[00120] Referring to FIGS. 24-25, to further aid the user in cleaning out
the tank assembly
446, the tank assembly 446 can optionally include an openable and/or removable
lid 500. The lid
500 can form a top or closure for the debris receptacle 444, and optionally
can include the supply
tank 451. The lid 500 can be secured to a lower portion 501 of the tank
assembly 446. The lower
portion 501 can include at least the debris receptacle 444, or at least the
receptacle reservoir 444R
of the debris receptacle 444. In the illustrated embodiment, the lower portion
501 further includes
the cover 427, brush chamber 422, the suction conduit 489, and the separator
487. In some
embodiments, the lid 500 can be openable while remaining attached to the
debris receptacle 444
or lower portion 501, such as by pivoting away from the debris receptacle 444
or lower portion
501 to open the receptacle reservoir 444R. In other embodiments, the lid 500
can be openable by
being fully removable from the debris receptacle 444 or lower portion 501.
[00121] A lid latch 502 can secure the lid 500 to a lower portion 501 of
the tank assembly
446. The lid latch 502 includes a latch button 503 that is depressed by the
user to release the lid
500 from the lower portion 501. The lid latch 502 can be any suitable latch,
catch, or other
mechanical fastener that can join the lid 500 and lower portion 501, while
allowing for the regular
separation of the lid 500 from the lower portion 501, such as a spring-biased
latch operable via the
latch button 503. A latch receiver 504 can be provided on the lid 500 to
accept the lid latch 502
and secure the lid 500 to the lower portion 501.
[00122] Further, the tank assembly 446 can include pivot coupling for
movement of the lid
500 about axis C, shown herein as a hook-and-catch mechanism that allows the
lid 500 to be fully
separated from the lower portion 501. The hook-and-catch mechanism shown
includes a hook 505
[31]
Date Recue/Date Received 2020-06-10
on the lower portion 501 that engages with a catch 506 on the lid 500.
Multiple hooks 505 and
catches 506 can be provided. Alternatively, the hooks 505 can be provided on
the lid 500 and the
catches 506 can be provided on the lower portion 501. In yet another
embodiment, the tank
assembly 446 can be pivotally mounted to the lower portion 501 about axis C
for rotation of the
lid 500 between open and closed positions, without full separation of the lid
500 from the lower
portion 501.
[00123] The lid 500 is shown in a partially-removed state from the lower
portion 501 in
FIGS. 24-25. The lid 500 can be removed by pressing the latch button 503 and
rotating the lid 500
away from the lower portion 501 about axis C as indicated by arrow D. Once the
hooks 505 have
cleared the catches 506, the lid 500 can be separated from the lower portion
501. After removing
the lid 500, the recovered liquid and dirt can be poured out of the debris
receptacle 444. The
entire lower portion 501, including the internal surface of the debris
receptacle 444 and the
internal surface of the brush chamber 422 can then be rinsed.
[00124] As shown in FIG. 25, in one embodiment, the separator 487 can be a
conduit or
duct having a bend for redirecting the working airstream with entrained liquid
and/or debris
approximately 90 degrees to travel though a separator outlet opening 488 and
into the debris
receptacle 444. The liquid and/or debris will strike the various walls of the
separator 487 and fall
downwardly into the receptacle reservoir 444R. Other degrees of bend for the
separator 487 are
possible, such as 90-180 degrees. The liquid and debris collect in the
receptacle reservoir 444R,
while the working airstream passes through the air outlet port 499 and to the
suction source 438.
The separator 487 can be oriented such that the airflow entering the debris
receptacle 444 through
the separator outlet opening 488 is positioned away from the air outlet port
499.
[00125] FIG. 26 shows an alternate embodiment of the lower portion 501 of
the tank
assembly 446, with the lid 500 removed. In some embodiments, the debris
receptacle 444 can
[32]
Date Recue/Date Received 2020-06-10
have a pour spout 507 to aid in conveying liquid and debris out of the
receptacle reservoir 444R.
The pour spout 507 can help show the user how to angle the debris receptacle
444 to optimally
empty the debris receptacle 444. The pour spout 507 can be provided at a
corner 508 of the debris
receptacle 444 disposed away from the brush chamber 422. Optionally, the pour
spout 507 can be
covered by the lid 501 (FIG. 25) when the lid 501 is closed and can be exposed
to view when the
lid 501 is open.
[00126] Referring to FIG. 27, as described above, the suction conduit 489
pulls debris and
excess liquid from the brushroll 441. The brush chamber 422 helps define the
air flow that goes
through the suction conduit 489 and into the debris receptacle 444. In the
illustrated embodiment,
the brush chamber 422 includes lateral ends 509, with the suction conduit 489
in fluid
communication with a portion of the brush chamber 422 between the lateral ends
509. The suction
conduit 489 can in particular fluidly communicate with a middle portion 510 of
the brush chamber
422 centered between the lateral ends 509, such that each lateral end 509 is
substantially
equidistant from the suction conduit 489, or can be otherwise located relative
to the lateral ends
509.
[00127] The brush chamber 422 can taper to become smaller (e.g. shorter)
at the lateral
ends 509. The taper helps develop air flow across the entire length of the
brushroll 441 and
improves recovery. At least an inner surface of an upper wall 511 of the brush
chamber 422 can
be tapered toward the lateral ends 509. The upper wall 511 can be smoothly
angled toward the
suction conduit 489 to substantially continuously increase the height of the
brush chamber 422
toward the suction conduit 489. In the illustrated embodiment, the brush
chamber 422 has a height
HI at one or both of the lateral ends 509 and a height H2 at the suction
conduit 489 which is
greater than the height HI. With the suction conduit 489 in fluid
communication with the middle
portion 510 of the brush chamber 422 centered between the lateral ends 509 as
shown herein, the
[33]
Date Recue/Date Received 2020-06-10
height H2 can be measured at the middle portion 510 of the brush chamber 422
centered between
the lateral ends 509.
[00128] In an alternative embodiment of the robot 410 shown in FIGS. 16-
27, the tank
assembly 446 can combine the debris receptacle 444 and the brush chamber 422
in one unitary
assembly or module. The supply tank 451 can be separate from the tank assembly
446 such that
it is removable from the housing 412 separately from the tank assembly 446.
The supply tank
451 can be configured such that it is removable from the housing 412 before or
after the tank
assembly 446. Alternatively, the supply tank 451 and the tank assembly 446 can
have an
interlocking mounting arrangement such that the supply tank 451 must be
removed prior to
removal of the tank assembly 446, or vice versa.
[00129] Several alternative embodiments of tank assemblies 446 for the
robot 410 are shown
in FIGS. 28-30. The tank assemblies 446 are similar to the tank assembly 446
described above
with reference to FIGS. 16-27, therefore like parts will be identified with
like reference numerals,
with it being understood that the description of the like parts of the tank
assembly 446 and robot
410 applies to the tank assemblies 446 shown in FIGS. 28-30, except where
noted.
[00130] Referring to FIG. 28, the illustrated tank assembly 446 differs by
including a fully
removable lid 500 that is separate from the supply tank 451. The lower portion
501 can therefore
include the supply tank 451, in addition to the debris receptacle 444, cover
427, and brush chamber
422. Another difference is that the lid latch 502 securing the lid 500 to the
lower portion 501 of
the tank assembly 446 is accessible from the top rear side of the tank
assembly 446, and the lid
500 can lift off the lower portion 510 without pivoting.
[00131] Another difference is that the tank assembly 446 includes a
pivoting handle 449 and
The handle 449 can pivot against the tank assembly 446 to lie substantially
flush with the upper
surface of the tank assembly 446 and pivot away upwardly away from the upper
surface of the tank
[34]
Date Recue/Date Received 2020-06-10
assembly 446 for a user to grasp. The pivoting handle 449 can be provided on
top of the supply
tank 451, separate from the lid 500.
[00132] Referring to FIG. 29, the illustrated tank assembly 446 differs
from the tank
assembly 446 shown in FIG. 28 by having the supply tank 451 integral with the
lid 500 and the
pivoting handle 449 on the lid 500.
[00133] Referring to FIG. 30, the illustrated tank assembly 446 differs
from the tank
assembly 446 shown in FIG. 28 by having the lid latch 502 accessible from the
top of the tank
assembly 446, at a forward side of the debris receptacle 444, and by providing
finger indentations
512 at a rear side of the debris receptacle 444. The consumer can grip the
handle 449 in one hand
and, using their other hand, simultaneously operate the lid latch 502 with
their thumb while lifting
the lid 500 away from the lower portion 501 to separate the lid 500 from the
lower portion 501.
[00134] There are several advantages of the present disclosure arising
from the various
aspects or features of the apparatus, systems, and methods described herein.
For example, aspects
described above provide an autonomous cleaning robot that sweeps and mops a
floor surface in a
single pass, including a single pass in a "forward" or "backward" direction.
The present disclosure
provides a single autonomous floor cleaner that sweeps directly in front of
the dusting assembly.
This eliminates the need for either two floor cleaning apparatus to completely
clean or a single
robot that cleans by multiple passes.
[00135] Another advantage of aspects of the disclosure relates to the
consistency and
robustness of the liquid distribution system. In contrast to prior art wicking
pads, the disclosed
pump and spray nozzle provide fluid at a consistent low flowrate that does not
degrade over time.
The low flowrate of the applied liquid results in a clean floor surface that
is substantially dry after
contact with the rotating pads of the dusting assembly concludes. The use of a
pulse-width
modulation signal as described herein can further provide for custom-tailoring
of a fluid delivery rate
[35]
Date Recue/Date Received 2020-06-10
for a variety of floor surfaces, including the adjustment of fluid dwelling
times.
[00136] Yet another advantage of aspects of the disclosure relates to the
configuration of
the brushroll of the sweeper, the wheels of the drive mechanism and the
spinning pads of the
dusting assembly. By aligning the outer edges of the wheels, the brushroll and
the spinning pads
as shown and described above, entrainment of debris in the wheels and spinning
pads is reduced
thereby improving the driving and cleaning performance of the floor cleaning
robot.
[00137] Still another advantage of aspects of the disclosure relate to the
use of a pulse-width
modulated signal to drive operation of one or more components such as the
fluid pump. Such a
modulated signal provides for a reduction in circuit complexity for driving
the pump at a variety of
flowrates, including at low flow rates, without use of a variable resistor
(which can generate
undesirable amounts of heat) or use of other, more complex methods of reducing
the voltage provided
to the pump by the battery pack.
[00138] Another advantage of aspects of the disclosure relate to the ease
of access to one
or more tanks within the autonomous floor cleaner, including the unitary or
integrated tank
assembly being selectively removable from the robot housing. Removal of a
single unit can
improve the ease of refilling the supply tank or cleaning out the debris
receptacle without need of
manipulating the entire robot for a cleanout or refill operation.
[00139] Another advantage of aspects of the disclosure relate to a floor
cleaning apparatus
including a housing moveable over a surface to be cleaned, a supply tank
configured to store a
supply of cleaning fluid, and a unitary assembly removably mounted to the
housing, wherein the
unitary assembly is configured to be selectively detached from the moveable
housing, the unitary
assembly having a brush chamber, a brushroll located in the brush chamber, at
least one fluid
distributor, and a debris receptacle fluidly coupled to the brush chamber. The
at least one fluid
distributor can be in fluid communication with the supply tank and a fluid
delivery pump can be
[36]
Date Recue/Date Received 2020-06-10
provided to control a flow of cleaning fluid from the supply tank to the at
least one fluid distributor.
[00140] Yet another advantage of aspects of the disclosure relates to the
configuration of
the latch, handle, and pivot coupling for the unitary or integrated tank
assembly. In some
embodiments disclosed herein, the user provides opposing forces to actuate the
latch and lift the
tank assembly upwardly away the housing. This helps create a clean breakaway
between the two
assemblies and keeps the housing in position during removal of the tank
assembly.
[00141] Still another advantage of aspects of the disclosure relate to the
configuration of the
brush chamber and suction conduit leading to the debris receptacle. In some
embodiments disclosed
herein, the brush chamber tapers to become smaller in a direction away from
the suction conduit,
which can help develop air flow across the entire length of the brushroll and
improve recovery.
[00142] While various embodiments illustrated herein show an autonomous
floor cleaner
or floor cleaning robot, aspects of the invention may be used on other types
of surface cleaning
apparatus and floor care devices, including, but not limited to, an upright
extraction device (e.g.,
a deep cleaner or carpet cleaner) having a base and an upright body for
directing the base across
the surface to be cleaned, a canister extraction device having a cleaning
implement connected to
a wheeled base by a vacuum hose, a portable extraction device adapted to be
hand carried by a
user for cleaning relatively small areas, or a commercial extractor. Still
further, aspects of the
invention may also be used on surface cleaning apparatus which include a fluid
recovery system
and not a fluid supply system, or on surface cleaning apparatus which include
a fluid supply
system and not a fluid recovery system. Still further, aspects of the
invention may also be used
on surface cleaning apparatus other than extraction cleaners, such as a steam
cleaner or a vacuum
cleaner. A steam cleaner generates steam by heating water to boiling for
delivery to the surface to
be cleaned, either directly or via cleaning pad. Some steam cleaners collect
liquid in the pad, or
may extract liquid using suction force. A vacuum cleaner typically does not
deliver or extract
[37]
Date Recue/Date Received 2020-06-10
liquid, but rather is used for collecting relatively dry debris (which may
include dirt, dust, stains,
soil, hair, and other debris) from a surface.
[00143]
While the invention has been specifically described in connection with certain
specific embodiments thereof, it is to be understood that this is by way of
illustration and not of
limitation. Reasonable variation and modification are possible with the scope
of the foregoing
disclosure and drawings without departing from the spirit of the invention
which, is 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.
[38]
Date Recue/Date Received 2020-06-10
