U.S. patent application number 17/208356 was filed with the patent office on 2021-07-08 for autonomous floor cleaner.
The applicant listed for this patent is BISSELL Inc.. Invention is credited to Michael T. Dillane, Tyler James Imhoff, Adam Luedke, Scott M. Rose, Jeffrey A. Scholten.
Application Number | 20210204782 17/208356 |
Document ID | / |
Family ID | 1000005466498 |
Filed Date | 2021-07-08 |
United States Patent
Application |
20210204782 |
Kind Code |
A1 |
Scholten; Jeffrey A. ; et
al. |
July 8, 2021 |
AUTONOMOUS FLOOR CLEANER
Abstract
An autonomous floor cleaner includes a base that is movable over
a surface to be cleaned, a top plate coupled with the base, a
collection chamber, at least one dirt inlet in communication with
the collection chamber, and at least one sweeping element for
sweeping dirt on the surface to be cleaned toward the collection
chamber.
Inventors: |
Scholten; Jeffrey A.; (Ada,
MI) ; Dillane; Michael T.; (Grand Rapids, MI)
; Imhoff; Tyler James; (Cedar Springs, MI) ; Rose;
Scott M.; (Allendale, MI) ; Luedke; Adam;
(Holland, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BISSELL Inc. |
Grand Rapids |
MI |
US |
|
|
Family ID: |
1000005466498 |
Appl. No.: |
17/208356 |
Filed: |
March 22, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16115731 |
Aug 29, 2018 |
10952584 |
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17208356 |
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15677317 |
Aug 15, 2017 |
10111570 |
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16115731 |
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14294532 |
Jun 3, 2014 |
9775485 |
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15677317 |
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61830282 |
Jun 3, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 11/4069 20130101;
A47L 11/4066 20130101; A47L 11/4061 20130101; A47L 11/4038
20130101; A47L 11/4025 20130101; A47L 2201/00 20130101; A47L
11/4013 20130101; A47L 11/4036 20130101; A47L 11/4072 20130101;
A47L 11/24 20130101; A47L 11/33 20130101 |
International
Class: |
A47L 11/24 20060101
A47L011/24; A47L 11/33 20060101 A47L011/33; A47L 11/40 20060101
A47L011/40 |
Claims
1. An autonomous floor cleaner, comprising: a base; a top operably
coupled with the base; a drive system provided with the base and
adapted for moving the base over a surface to be cleaned; a
collection chamber having an inlet; and at least one sweeping
element extending beyond a portion of the base or a portion of the
top and configured to mechanically move dirt towards the inlet of
the collection chamber.
2. The autonomous floor cleaner of claim 1 wherein the top is a top
plate and the drive system is operably coupled to the top plate to
rotate the top plate relative to the base about a top axis.
3. The autonomous floor cleaner of claim 2 wherein the top axis is
generally perpendicular to a direction of movement of the base over
the surface to be cleaned.
4. The autonomous floor cleaner of claim 2 wherein the at least one
sweeping element comprises at least one rotating brush and the
drive system rotates the at least one rotating brush about a brush
axis.
5. The autonomous floor cleaner of claim 4 wherein the top axis is
generally perpendicular to a direction of movement of the base over
the surface to be cleaned.
6. The autonomous floor cleaner of claim 2 wherein the top axis is
non-perpendicular to the base.
7. The autonomous floor cleaner of claim 2 wherein the drive system
further comprises a motor coupled with the top plate for rotating
the top plate about the top axis.
8. The autonomous floor cleaner of claim 7 wherein the drive system
further comprises at least one wheel coupled with the motor and the
base for propelling the base over the surface to be cleaned.
9. The autonomous floor cleaner of claim 1 wherein the at least one
sweeping element comprises at least one of a brush strip, a
resilient film, or a rotating brush.
10. The autonomous floor cleaner of claim 9 wherein the brush strip
comprises a plurality of bristles, with at least some of the
bristles extending outwardly beyond a periphery of the top.
11. An autonomous floor cleaner, comprising: a base; a top plate
operably coupled with the base; a collection chamber; and at least
one sweeping element located at least partially between the base
and the top plate, wherein the at least one sweeping element is
configured to mechanically move dirt toward the collection
chamber.
12. The autonomous floor cleaner of claim 11, further comprising a
drive system associated with the base, wherein the drive system is
coupled to the top plate to rotate the top plate relative to the
base about a top axis.
13. The autonomous floor cleaner of claim 12 wherein the drive
system is further coupled with the base for moving the base over a
surface to be cleaned, wherein the top axis is generally
perpendicular to a direction of movement of the base over the
surface to be cleaned.
14. The autonomous floor cleaner of claim 12 wherein the at least
one sweeping element comprises at least one rotating brush, and the
drive system rotates the at least one rotating brush about a brush
axis.
15. The autonomous floor cleaner of claim 14 wherein the drive
system is further coupled with the base for moving the base over a
surface to be cleaned, wherein the top axis is generally
perpendicular to a direction of movement of the base over the
surface to be cleaned.
16. The autonomous floor cleaner of claim 12 wherein the top axis
is non-perpendicular to the base.
17. The autonomous floor cleaner of claim 12 wherein the drive
system further comprises a motor coupled with the top plate for
rotating the top plate about the top axis, and wherein the drive
system further comprises at least one wheel coupled with the motor
and the base for propelling the base over the surface to be
cleaned.
18. The autonomous floor cleaner of claim 11 wherein the at least
one sweeping element comprises at least one of a brush strip, a
resilient film, or a rotating brush.
19. An autonomous floor cleaner, comprising: a base adapted for
movement over a surface to be cleaned and having a bottom surface;
a top plate operably coupled with the base; a collection chamber
having at least one opening; and a bottom plate attached to the
bottom surface of the base and wherein the bottom plate is at least
partially removably from the base to enable emptying of the
collection chamber.
20. The autonomous floor cleaner of claim 19, further comprising:
at least one dirt inlet at a periphery of the base and in
communication with the collection chamber, the dirt inlet
comprising: a ramped surface at least near the at least one
opening; and a guide provided adjacent to the ramped surface and on
the base for directing direct into the collection chamber and
wherein the guide comprises a curved vane which projects upwardly
from the base and extends along the ramped surface.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/115,731, filed Aug. 29, 2018, now allowed,
which is a continuation of U.S. patent application Ser. No.
15/677,317, filed Aug. 15, 2017, now U.S. Pat. No. 10,111,570,
issued Oct. 30, 2018, which is a continuation of U.S. patent
application Ser. No. 14/294,532, filed Jun. 3, 2014, now U.S. Pat.
No. 9,775,485, issued Oct. 3, 2017, which claims the benefit of
U.S. Provisional Patent Application No. 61/830,282, filed Jun. 3,
2013, all 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 in order 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 and/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.
BRIEF SUMMARY
[0003] In one aspect of the invention, an autonomous floor cleaner
includes a base adapted for movement over a surface to be cleaned,
a top plate operably coupled with the base, a collection chamber,
and at least one sweeping element extending beyond a portion of the
base, wherein the at least one sweeping element is configured to
mechanically move dirt on a surface to be cleaned into the
collection chamber.
[0004] In another aspect of the invention, an autonomous floor
cleaner includes a base adapted for movement over a surface to be
cleaned, a top plate operably coupled with the base for rotation
relative to the base, and at least one sweeping element, wherein
the at least one sweeping element is configured to mechanically
move dirt on a surface to be cleaned into the collection
chamber.
[0005] In yet another aspect of the invention, an autonomous floor
cleaner includes a base adapted for movement over a surface to be
cleaned and having a bottom surface, a top plate operably coupled
with the base, a bottom plate attached to the bottom surface of the
base, and a collection chamber, wherein the bottom plate is at
least partially removably from the base to enable the emptying of
the collection chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the drawings:
[0007] FIG. 1 is a perspective view of an autonomous floor cleaner
according to a first embodiment of the invention;
[0008] FIG. 2 is an exploded view of the autonomous floor cleaner
from FIG. 1;
[0009] FIG. 2A is a cross-sectional view through line 2A-2A of FIG.
2;
[0010] FIG. 3 is a bottom view of the autonomous floor cleaner from
FIG. 1;
[0011] FIG. 4 is a schematic view of a drive system for the
autonomous floor cleaner from FIG. 1;
[0012] FIG. 5 illustrates a portion of the operation of the floor
cleaner 10 from FIG. 1;
[0013] FIG. 6 is a perspective view of an autonomous floor cleaner
according to a second embodiment of the invention;
[0014] FIG. 7 is an exploded view of the autonomous floor cleaner
from FIG. 6;
[0015] FIG. 8 is a close-up view of section VIII of the autonomous
floor cleaner from FIG. 6;
[0016] FIG. 9 illustrates a portion of the operation of the floor
cleaner from FIG. 6;
[0017] FIG. 10 is a perspective view of an autonomous floor cleaner
according to a third embodiment of the invention;
[0018] FIG. 11 is an exploded view of the autonomous floor cleaner
from FIG. 10;
[0019] FIGS. 12A-B illustrate a portion of the operation of the
floor cleaner from FIG. 10;
[0020] FIG. 13 is a perspective view of an autonomous floor cleaner
according to a fourth embodiment of the invention; and
[0021] FIG. 14A-C illustrate a portion of the operation of the
floor cleaner from FIG. 13.
DETAILED DESCRIPTION
[0022] FIG. 1 is a front perspective view of an autonomous floor
cleaner 10 according to a first embodiment of the invention. The
autonomous floor cleaner 10 has been illustrated as a robotic
sweeper that mounts the components of the sweeper in an
autonomously moveable unit, including components of a sweeping and
collection system for mechanically moving dirt on a surface to be
cleaned into a collection space on the floor cleaner 10, and a
drive system for autonomously moving the floor cleaner 10 over the
surface to be cleaned. While not illustrated, the autonomous floor
cleaner 10 could be provided with additional capabilities, such as
a navigation system for guiding the movement of the floor cleaner
10 over the surface to be cleaned, a dispensing system for applying
a treating agent stored on the floor cleaner 10 to the surface to
be cleaned, and a vacuum system for generating a working air flow
for removing dirt, liquid and/or a treating agent from a surface to
be cleaned.
[0023] The autonomous floor cleaner 10 includes a base or platform
12 and an enclosure or top plate 14 on the platform 12. The
platform 12 provides the basic structure for the robotic sweeper on
which many of the components of the floor cleaner 10 depend for
structural support. As shown herein, both the platform 12 and top
plate 14 are substantially circular in shape, and each define an
outer periphery 16, 18, respectively. Other shapes for the floor
cleaner 10 are possible.
[0024] The drive system moves the platform 12 over the surface to
be cleaned. The sweeping and collection system rotates the top
plate 14 about a rotational axis X above the platform 12,
independently of the movement of the platform 12 over the surface
to be cleaned. The rotational axis X can be generally vertically
oriented with respect to the surface to be cleaned, such that the
rotational axis X is perpendicular to the direction of movement of
the platform 12. The sweeping and collection system further
includes one or more sweeping elements 20 mounted to the top plate
14 and multiple dirt inlets 22. The dirt inlets 22 are located at
the outer peripheries 16, 18 of the platform 12 and top plate
14.
[0025] FIG. 2 is an exploded view of the autonomous floor cleaner
10 from FIG. 1. The sweeping and collection system further includes
a collection chamber 24 adapted to collect dirt and other
contaminants for later disposal, a dusting cloth 26 that can at
least partially form the collection chamber 24, and a motor 28
coupled to the top plate 14 for rotating the top plate 14 about the
rotational axis X.
[0026] The one or more sweeping elements 20 are at least partially
in register with the floor surface, and can include multiple
sweeping elements 20 which extend downwardly from the underside of
the top plate 14. The floor cleaner 10 shown herein uses brushes as
sweeping elements 20, each of which includes a plurality of bristle
tufts 30 arranged in a strip 32. The brush strips 32 can be
disposed at the periphery 18 of the top plate 14 and can be spaced
from each other and diametrically offset relative to the top plate
14. The bristle tufts 30 can be arranged in generally linear rows
such that the brush strips 32 are straight; alternatively, the
bristle tufts 30 can be arranged in curved or helical rows.
Optionally, the outboard tufts 30 can be angled or flared outwardly
so that the ends of those tufts 30 extend beyond the periphery 18
of the top plate 14. The platform 12 can cover the inner ends of
the brush strips 32, such that only the outermost portions of the
brush strips 32 are in register with the floor surface. The
remaining portions of the brush strips 32 are in register with the
top or inner surface of the platform 12.
[0027] With additional reference to FIG. 2A, the dirt inlets 22 are
at least partially defined by ramped surfaces on the top or inner
side of the platform 12 which help direct dirt swept by the
sweeping elements 20 toward the collection chamber 24 and which can
correspond in number to the number of sweeping elements 20. The
dirt inlets 22 can be formed by an angled flange 34 extending
around the perimeter of the platform 12 and a ramp 36 likewise
extending around the perimeter of the platform 12 but inwardly of
the angled flange 34. The angled flange 34 and ramp 36 can each
have continuous angles of incline around the perimeter of the
platform 12, but can be inclined at different angles from each
other. As shown here, the angled flange 34 is steeper than the ramp
36. The angled flange 34 can have inlet extensions 38 which project
radially outwardly from the periphery 16 of the platform 12 and
form an entrance for dirt to the dirt inlets 22.
[0028] As illustrated, the angled flange 34 and ramp 36 are formed
integrally as a portion of the entire platform 12, which can
comprise a rigid thermoplastic material such as acrylonitrile
butadiene styrene (ABS), for example. Alternatively, the inner
portion of the platform 12 can be formed of a rigid thermoplastic
material as indicated previously, whereas the peripheral portion of
the platform 12, including the flange 34 and ramp 36, can be formed
of a dissimilar material, such as a flexible, resilient material
with a low coefficient of friction. Representative examples are
polypropylene (PP) or polyethylene (PE), for example. The flexible,
resilient portion of the platform 12 can be chemically or
mechanically bonded to the rigid portion of the platform 12 by
adhesive, mechanical fasteners, plastic welding or a conventional
overmolding injection molding process, for example. The flexible,
resilient portion of the platform 12 can be configured to conform
to variations in the surface to be cleaned so that the angled
flange 34 slides on the surface to be cleaned for improved cleaning
performance.
[0029] The dirt inlets 22 are further defined by guides 40 which
catch and guide dirt into the collection chamber 24. The brush
strips 32 can be configured to slide up and over the guides 40 to
push dirt inwardly toward the collection chamber 24. The guides 40
can be formed as curved or arcuate vanes which project upwardly
from the top or inner surface of the platform 12, and which extend
along the angled flange 34 and ramp 36. The guides 40 are disposed
at the periphery 16 of the platform 12 and extend generally
radially from the center of the platform 12 in a spiral
pattern.
[0030] The top plate 14 is coupled to the motor 28 by a drive shaft
42 that defines the rotational axis X. The motor 28 can be located
within a motor chamber 44 provided on the platform 12, above the
collection chamber 24, having a shaft aperture 46 through which the
drive shaft 42 can protrude to couple with the top plate 14 at a
coupling 48. The shaft 42 can be directly driven by the motor 28,
or can be indirectly driven by the motor 28, such as by the
provision of a transmission between the motor 28 and the shaft
42.
[0031] The platform 12 further includes a centrally located
recessed region 50 that is inward of the ramp 36. One or more dirt
openings 52 are formed in the recessed region 50 and lead to the
collection chamber 24. The dirt openings 52 can be positioned at or
near the ends to the guides 40 such that dirt guided up the ramp 36
by the sweeping elements 20 is deposited in the collection chamber
24.
[0032] The collection chamber 24 includes a bottom plate 54 that is
attached to a bottom surface of the platform 12. The bottom plate
54 defines the bottom of the collection chamber 24 and the dirt
openings 52 are open to the space above the bottom plate 54. The
bottom plate 54 can have one or more plate opening(s) 56 formed
therein.
[0033] In addition to defining the bottom of the collection chamber
24, the bottom plate 54 also removably mounts the dusting cloth 26.
The dusting cloth 26 can be a pad or sheet of non-woven material
such as polypropylene or microfiber. Alternatively, the dusting
cloth 26 can comprise a conventional woven material such as cotton
fabric rag, for example. The dusting cloth 26 wraps around and
covers the plate opening 56. The bottom plate 54 can be provided
with grippers 58 for holding the dusting cloth 26 on the bottom
plate 54. Other means for holding the dusting cloth 26 on the
bottom plate 54 include high friction, elastomeric strips and hook
and loop fasteners.
[0034] The bottom plate 54 can be at least partially removable from
the platform 12 to enable the attachment or detachment of the
dusting cloth 26, as well as the emptying of the collection chamber
24. To mount the dusting cloth 26 to the bottom plate 54, the
bottom plate 54 is opened or removed from the platform 12, the
dusting cloth 26 is wrapped around the plate with the ends of the
dusting cloth 26 held by the grippers 58, and the bottom plate 54
is reattached to the platform 12 using the fasteners.
[0035] FIG. 3 is a bottom view of the autonomous floor cleaner 10
from FIG. 1. For clarity, the dusting cloth 26 is indicated in
phantom line in FIG. 3. A fastener can be provided for securing the
bottom plate 54 in a closed position on the platform 12. As shown
herein, the bottom plate 54 includes two detents 62 that fit within
detent receivers 64 on the bottom of the platform 12 to fasten the
bottom plate 54 to the platform 12 in the closed position. Other
fasteners can be used, such as, but not limited to, latches,
screws, snaps or hook and loop fasteners. The bottom plate 54 can
be completely removable from the platform 12 as shown in the
illustrated embodiment, or can be hinged to the platform 12 to
selectively move between open and closed positions.
[0036] The dusting cloth 26 can be removed from the floor cleaner
10 without removing the bottom plate 54, such that removal of
dusting cloth 26 opens the collection chamber 24 by exposing the
plate opening 56. During operation, dirt collects both in the
collection chamber 24 and on the bottom of the dusting cloth 26.
When a cleaning operation is done, the user can hold the floor
cleaner 10 over a waste receptacle, and pull off and throw away the
dirty dusting cloth 26 in one motion, which simultaneously also
effectively "opens" the collection chamber 24 and allows collected
dirt in the collection chamber 24 to fall though the plate opening
56.
[0037] Alternatively, the bottom plate 54 can be hingedly mounted
to the platform 12 to permit facile emptying of the collection
chamber 24 and to eliminate potential for dropping the plate 54
into the waste receptacle. One example of a hingedly mounted dust
cloth mounting panel configuration is more fully disclosed in U.S.
Pat. No. 7,013,528, issued Mar. 21, 2006, which is incorporated
herein by reference in its entirety. In yet another configuration,
the bottom plate 54 can be eliminated and the dusting cloth 26 can
be attached directly to the bottom surface of the platform 12.
[0038] The drive system includes one or more wheels for propelling
the floor cleaner 10 over a surface to be cleaned. As illustrated,
the drive system includes three wheels; a drive wheel 66 and two
roller wheels 68. The drive wheel 66 is rotatably mounted on the
platform 12 and at least partially protrudes through a
corresponding drive wheel receiver 70 located along a diameter D of
the platform 12, between the center and the outer periphery 16 of
the platform 12. The two roller wheels 68 are likewise rotatably
mounted on the platform 12 and at least partially protrude through
corresponding roller wheel receivers 72 which are located in spaced
relation to the diameter D of the platform 12, between the center
and the outer periphery 16 of the platform 12.
[0039] The drive wheel 66 can be coupled to the motor 28 such that
activation of the motor 28 results in a corresponding rotation of
the drive wheel 66 and movement of the floor cleaner 10. The drive
wheel 66 can be coupled to the motor 28 via a suitable transmission
(not shown). Alternatively, separate motors can be provided for
rotating the top plate 14 for sweeping and for rotating the drive
wheel 66 for driving the floor cleaner 10. The roller wheels 68 are
not drivingly coupled to the motor 28, but rather are indirectly
rotated by the movement of the floor cleaner 10 over the surface to
be cleaned.
[0040] FIG. 4 is a schematic view of the drive system for the
autonomous floor cleaner 10 from FIG. 1. The drive system further
includes a power source 74 operably coupled to the motor 28 for
selectively powering the motor 28, and a controller 76 operably
coupled with various components of the floor cleaner 10 to
implement one or more cycles of operation, such as cleaning or
recharging. The power source 74 can include a plurality of
batteries mounted on the floor cleaner 10 that are rechargeable or
replaceable. The batteries may be any commonly known battery
including alkaline, nickel-cadmium, nickel-metal hydride (NiMH), or
lithium ion. When rechargeable batteries are used, a recharging
circuit can be provided to transform available facility voltage
(such as a household outlet) to a level usable for the batteries. A
charging plug or docking station (not shown) can be provided for
connecting the floor cleaner 10 to the available facility voltage
to complete the circuit and recharge the batteries.
[0041] The controller 76 may be operably coupled with one or more
components of the floor cleaner 10 for communicating with and
controlling the operation of the components to complete a cycle of
operation. Power supply from the power source 74 can be controlled
by a user-engageable switch 78 coupled to the controller 76. When
switch 78 is closed, power flows to the motor 28, and the
controller 76 provides output to drive the drive wheel 66. The
output provided by the controller 76 may be conditioned by input
from the drive system. For example, the drive system can be
configured to turn the platform 12 when the floor cleaner 10
encounters an obstacle. One example of a suitable drive system in
this regard is disclosed in U.S. Pat. No. 8,032,978 to Haegermarck,
issued Oct. 11, 2011. Alternatively, the drive system can be
configured for random movement and can comprise a drive wheel
mounted within a pocket near the center of a housing as more fully
disclosed in U.S. Pat. No. 6,938,298 to Aasen, issued Sep. 6, 2005.
Alternatively, the floor cleaner 10 can be provided with a
navigation system for guiding the movement of the floor cleaner 10
over the surface to be cleaned. In one example, the navigation
system can employ one or more proximity sensors which provide
navigation input to the controller 76, as more fully disclosed in
U.S. Pat. No. 7,346,428 to Huffman et al., issued Mar. 18,
2008.
[0042] FIG. 5 illustrates a portion of the operation of the floor
cleaner 10 from FIG. 1. For clarity, the top plate 14 and sweeping
elements 20 are shown in phantom line. In operation, as the top
plate 14 rotates, the brush strips 32 are configured to sweep dirt
inwardly in a skimming or scooping motion through peripheral dirt
inlets 22 formed in the platform 12, towards the centrally located
collection chamber 24.
[0043] Some exemplary positions of one of the sweeping elements 20
are shown in FIG. 5 to illustrate the skimming or scooping motion.
As the sweeping element 20 sweeps over the surface to be cleaned as
indicated at 5A, dirt is guided toward the dirt inlet 22. The dirt
enters the floor cleaner 10 at the inlet extension 38 and is guided
up the angled flange 34 and onto the ramp 36. As the brush strip 32
rotates past the guide 40, the bristle tufts 30 begin to break over
the guide 40 as indicated at 5B. The guide 40 prevents dirt from
being carried with the top plate 14 as the brush strip 32 moves
over the guide 40. The dirt is guided into collection chamber 24
via the dirt opening 52 located at the end of the guide 40; as
shown herein the brush strips 32 may not push the dirt all the way
into the collection chamber 24, but may provide enough motive force
to move the dirt up the ramp 36 and into the dirt opening 52 as
indicated at 5C.
[0044] FIG. 6 is a perspective view of an autonomous floor cleaner
10 according to a second embodiment of the invention. The second
embodiment is substantially similar to the first embodiment, and
like elements will be referred to with the same reference numerals.
The second embodiment differs from the first embodiment in the
configuration of the sweeping elements mounted to the top plate 14
and the dirt inlets 22. The sweeping elements can include flexible
skimmers 80 that are at least partially in register with the floor
surface. The skimmers 80 include resilient fins 82 which extend
outwardly and downwardly from a central portion 84 of the top plate
14 and a sweeping material 86 on the floor-facing side of the fins
82.
[0045] FIG. 7 is an exploded view of the autonomous floor cleaner
10 from FIG. 6. The fins 82 can be radially spaced from each other
and each fin 82 includes a circumferentially-extending surface 88
connected to a radially-extending surface 90 at an outer corner of
the fin 82, with both surfaces 88, 90 joining the central portion
84 of the top plate 14. The fin 82 can extend outwardly and
downwardly from the central portion 84, with the
circumferentially-extending surface 88 curving downwardly and the
radially-extending surfaces 90 oriented at a downward angle with
respect to the central portion 84.
[0046] The platform 12 can cover the inner ends of the skimmers 80,
such that only the outermost portions of the sweeping material 86
on the fins 82 are in register with the floor surface. The
remaining portions of the sweeping material 86 are in register with
the top or inner surface of the platform 12.
[0047] The dirt inlets 22 are defined by the skimmers 80 and ramps
92 on the top or inner side of the platform 12 which help direct
dirt swept by the sweeping elements 20 toward the collection
chamber 24 and which can correspond in number to the number of
sweeping elements 20. The ramps 92 extend around the perimeter of
the platform 12, and can each have continuous angles of incline
around the perimeter of the platform 12.
[0048] The dirt inlets 22 are further defined by guides 94 that
catch and guide dirt into the collection chamber 24. The ramps 92
are separated from each other by the guides 94. The guides 94 can
be formed as curved or arcuate vanes which project upwardly from
the top or inner surface of the platform 12. The guides 94 are
disposed at the periphery 16 of the platform 12 and extend
generally radially from the center of the platform 12 in a spiral
pattern.
[0049] FIG. 8 is a close-up view of section VIII of the autonomous
floor cleaner 10 from FIG. 6. The sweeping material 86 includes a
base layer 96 of foam applied to the fin 82, and an outer layer 98
of flexible bristles made of a non-woven material that are used to
trap and move dirt. In one example, the foam layer 96 can have a
thickness of 5-15 mm and the non-woven bristles of the outer layer
98 can have a length of 2-7 mm. The foam thickness and/or bristle
length can be uniform, or can vary over the extent of the fin 82 to
impart more or less stiffness to the skimmer 80. Specific examples
of foam for the base layer are cellular silicone foam such as
Bisco.RTM. Silicone Foam or a microcellular urethane foam, such as
Poron.RTM. Foam, which are both commercially available from Rogers
Corporation. Specific examples of the non-woven material for the
outer bristle layer are polypropylene, polyethylene or polyester
micro-fibers, which can be attached to a non-woven backing layer or
woven fabric, scrim or screen layer, for example. The layers 96, 98
can be attached using any suitable method, including using a glue
or adhesive 100. Alternatively, the sweeping material 86 can be
omitted and the fins 82 can be configured to contact the surface to
be cleaned directly.
[0050] FIG. 9 illustrates a portion of the operation of the floor
cleaner 10 from FIG. 6. For clarity, the top plate 14 and skimmers
80 are shown in phantom line. In operation, as the top plate 14
rotates, the skimmers 80 are configured to sweep dirt inwardly in a
skimming or scooping motion through the peripheral dirt inlets 22.
The skimmers 80 are configured to slide up the ramps 92 and over
the guides 94 to push dirt inwardly toward the centrally located
collection chamber 24. The fins 82, as well as the entire top plate
14, can be made from a resilient plastic or foam, that can
elastically bend and flex over the guides 94 as the top plate 14
rotates.
[0051] Some exemplary positions of one of the skimmers 80 are shown
in FIG. 9 to illustrate the skimming or scooping motion. As the
skimmer 80 sweeps over the surface to be cleaned as indicated at
9A, dirt is guided toward the dirt inlet 22 defined between the
skimmer 80 and ramp 92 by the sweeping material 86 on the fin 82.
The dirt enters the floor cleaner 10 and is guided up the ramp 92.
As the skimmer 80 rotates past the guide 94, the fin 82 flexes over
the guide 94 as indicated at 9B. The guide 94 prevents dirt from
being carried with the top plate 14 as the sweeping material 86
moves over the guide 94. The dirt is guided into collection chamber
24 via the dirt opening 52 located at the end of the guide 94; as
shown herein the sweeping material 86 may not push the dirt all the
way into the collection chamber 24, but may provide enough motive
force to move the dirt up the ramp 92 and into the dirt opening 52
as indicated at 9C.
[0052] FIG. 10 is a perspective view of an autonomous floor cleaner
10 according to a third embodiment of the invention. The third
embodiment is substantially similar to the first embodiment, and
like elements will be referred to with the same reference numerals.
The third embodiment differs from the first embodiment in the
configuration of the sweeping elements mounted to the top plate 14
and the dirt inlets 22. Here, the sweeping and collection system
includes multiple rotatable sweeping elements 110 mounted to the
top plate 14 and multiple corresponding dirt inlets 112. The dirt
inlets 112 are located at the outer peripheries 16, 18 of the
platform 12 and top plate 14.
[0053] In addition to rotating the top plate 14 about rotational
axis X, the drive system can further be configured to rotate each
sweeping element 110 about a rotational axis Y above the platform
12, independently of the movement of the platform 12 over the
surface to be cleaned. The rotational axis Y can be generally
vertically oriented with respect to the surface to be cleaned, such
that the rotational axis Y is parallel to rotational axis X, or, as
shown herein, can be non-vertical such that each rotational axis Y
is slightly tilted away from the rotational axis X about the
perimeter of the floor cleaner 10.
[0054] FIG. 11 is an exploded view of the autonomous floor cleaner
10 from FIG. 10. The sweeping elements 110 can include rotating
satellite brushes that are at least partially in register with the
floor surface. The satellite brushes include a disc-shaped brush
housing 114 rotatably mounted on the top plate 14 and brushes 116
mounted on the underside of the brush housing 114, each of which
includes a plurality of bristle tufts 118 arranged in multiple
strips 120. The brush strips 120 can be disposed around the
periphery of the brush housing 114 and can be diametrically offset
on brush housing 114. The bristle tufts 118 can be arranged in
generally linear rows such that the brush strips 120 are straight;
alternatively, the bristle tufts 118 can be arranged in curved or
helical rows. Optionally, the outboard bristle tufts 118 can be
angled or flared outwardly so that the ends of those tufts 118
extend beyond the periphery of the brush housing 114. The platform
12 can cover the innermost portion of the sweeping elements 110,
such that only the outermost brush strips 120 are in register with
the floor surface as the sweeping elements 110 rotate relative to
the top plate 14. The remaining portions of the brush strips 120
are in register with the top or inner surface of the platform
12.
[0055] The dirt inlets 112 are at least partially defined by ramps
122 on the top or inner side of the platform 12 which help direct
dirt swept by the sweeping elements 110 toward the collection
chamber 24 and which can correspond in number to the number of
sweeping elements 110. The ramps 122 extend around the perimeter of
the platform 12, and can each have continuous angles of incline
around the perimeter of the platform 12. The ramps 122 can have
inlet extensions 124 which project radially outwardly from the
periphery 16 of the platform 12 and form an entrance for dirt to
the dirt inlets 112.
[0056] The dirt inlets 112 are further defined by guides 126 which
catch and guide dirt into the collection chamber 24. The brush
strips 120 can be configured to slide along the guides 126 to push
dirt inwardly toward the collection chamber 24. The guides 126 can
be formed as curved or arcuate vanes which project upwardly from
the top or inner surface of the platform 12. The guides 126 are
disposed at the periphery 16 of the platform 12 and extend
generally radially from the center of the platform 12 in a spiral
pattern. In an alternate configuration of this embodiment, the
inlet extensions 124 and guides 126 can be omitted.
[0057] Each sweeping element 110 is indirectly coupled to the motor
28 by a drive link that operably couples the rotation of the
sweeping element to the rotation of the top plate 14. The drive
link shown herein is a gear train 128, but may be another suitable
linkage system including one or more gears, cranks, belts, or a
combination thereof. The illustrated gear train 128 can include a
drive gear 130 carried on the coupling 48, a driven gear 132
carried on the brush housing 114, and at least one intermediate
gear 134 coupling the drive gear 130 and the driven gear 132. In
one example, the gear ratio between the sweeping elements 110 and
the top plate 14 can be about 3:1; however, the gear ratio can be
adjusted to achieve rotational speeds of the top plate 14 and
sweeping elements 110 for optimal sweeping and debris pick-up
performance. Additionally, the gear ratio can be adjusted so that
the brush strips 120 are oriented in a generally orthogonal
orientation relative to the guides 126 as the strips 120 intersect
the guides 126.
[0058] FIGS. 12A-B illustrate a portion of the operation of the
floor cleaner 10 from FIG. 10. For clarity, the top plate 14 and
sweeping elements 110 are shown in phantom line. In operation, as
the top plate 14 rotates, the sweeping elements 110 also rotate and
the brush strips 120 are configured to sweep dirt inwardly in a
skimming or scooping motion through peripheral dirt inlets 112
formed in the platform 12, towards the centrally located collection
chamber 24.
[0059] Some exemplary positions of one of the sweeping elements 110
are shown in FIGS. 12A-B to illustrate the skimming or scooping
motion. As the sweeping element 110 sweeps over the surface to be
cleaned as shown in FIG. 12A, dirt is guided toward the dirt inlet
112. The dirt enters the floor cleaner 10 at the inlet extension
124 and is guided up the ramp 122. As the brush strips 120 rotates
past the guide 126, the bristle tufts 118 begin to break over the
guide 126 as shown in FIG. 12B. The guide 126 prevents dirt from
being carried with the top plate 14 as the brush 116 moves over the
guide 126. The dirt is guided into collection chamber 24 via the
dirt opening 52 located at the end of the guide 126; as shown
herein the brush 116 may not push the dirt all the way into the
collection chamber 24, but may provide enough motive force to move
the dirt up the ramp 122 and into the dirt opening 52.
[0060] FIG. 13 is a perspective view of an autonomous floor cleaner
10 according to a fourth embodiment of the invention. The fourth
embodiment is substantially similar to the first embodiment, and
like elements will be referred to with the same reference numerals.
The fourth embodiment differs from the first embodiment in the
configuration of the top plate 14. Here, the top plate 14 is tipped
at an angle relative to platform 12, and is rotatable about a
rotational axis X that is generally non-vertical with respect to
the surface to be cleaned. The rotational axis X is also offset
from a center axis C of the platform 12.
[0061] FIGS. 14A-C illustrate a portion of the operation of the
floor cleaner from FIG. 13. The tilted, offset orientation of the
rotating top plate 14 causes the sweeping elements 20 to reach up
and over dirt on the surface to be cleaned; as the top plate 14
rotates further, the sweeping elements 20 that were in contact with
the surface to be cleaned sweep dirt toward the center of the floor
cleaner 10.
[0062] The autonomous floor cleaner disclosed herein includes an
improved sweeping system. One advantage that may be realized in the
practice of some embodiments of the described autonomous floor
cleaner is that dirt is collected around the entire periphery of
the floor cleaner 10. Prior art autonomous sweepers are
directional, and only pick up dirt only at one side of the floor
cleaner. Further, prior autonomous sweepers often just push dirt in
front of the floor cleaner without actually picking up the dirt.
The autonomous floor cleaner disclosed herein uses a rotating top
plate to carry the sweeping elements, which draws dirt up
corresponding ramps and into the collection chamber using a
scooping or skimming motion.
[0063] Another advantage that may be realized in the practice of
some embodiments of the described autonomous floor cleaner is that
the floor cleaning combines the sweeping action of the rotating top
plate 14 with the dusting action of the dusting cloth 26 for a more
comprehensive cleaning performance. The dusting cloth 26 further
forms a portion of the collection chamber 24 and provides an easy
and convenient way to empty collected dirt from the floor cleaner
10.
[0064] To the extent not already described, the different features
and structures of the various embodiments may be used in
combination with each other as desired. That one feature may not be
illustrated in all of the embodiments is not meant to be construed
that it cannot be, but is done for brevity of description. Thus,
the various features of the different embodiments may be mixed and
matched as desired to form new embodiments, whether or not the new
embodiments are expressly described.
[0065] 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.
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