Evacuation station

• US 9,924,846 B2
• Filed: 09/08/2016
• Issued: 03/27/2018
• Est. Priority Date: 06/25/2015
• Status: Active Grant

• Current Assignee: iRobot Corporation
• Original Assignee: iRobot Corporation
• Inventors: Morin, Russell Walter, Boeschenstein, Harold, Swett, David Orrin, Jonas, Jude Royston
• Primary Examiner(s): REDDING, DAVID A
• Application Number:
  US15/259,732
• Publication Number:
  US 20160374528A1
• Time in Patent Office: 565 Days
• Field of Search: 15319, 15352
• CPC Class Codes: A47L 11/4011 Regulation of the cleaning machine by electric means; Control systems and remote control systems therefor
• CPC Class Codes: A47L 11/4025 Means for emptying
• CPC Class Codes: A47L 2201/00 Robotic cleaning machines, i.e. with automatic control of the travelling movement or the cleaning operation
• CPC Class Codes: A47L 2201/022 Recharging of batteries
• CPC Class Codes: A47L 2201/024 Emptying dust or waste liquid containers
• CPC Class Codes: A47L 2201/04 Automatic control of the travelling movement; Automatic obstacle detection
• CPC Class Codes: A47L 9/149 Emptying means; Reusable bags
• CPC Class Codes: A47L 9/19 Means for monitoring filtering operation
• CPC Class Codes: A47L 9/2821 Pressure, vacuum level or airflow
• CPC Class Codes: A47L 9/2842 Suction motors or blowers

Abstract

A mobile robot includes a body configured to traverse a surface and to receive debris from the surface, and a debris bin within the body. The debris bin includes a chamber to hold the debris received by the mobile robot, an exhaust port through which the debris exits the debris bin; and a door unit over the exhaust port. The door unit includes a flap configured to move, in response to air pressure at the exhaust port, between a closed position to cover the exhaust port and an open position to open a path between the chamber and the exhaust port. The door unit, including the flap in the open position and in the closed position, is within an exterior surface of the mobile robot.

Claims

1. A mobile robot comprising:

a debris bin comprising;

a chamber to hold debris retrieved by the mobile robot from a surface while the mobile robot traverses the surface;

an exhaust port through which the debris exits the debris bin, the exhaust port being at a bottom of the debris bin; and

a door unit comprising a flap configured to move, in response to air pressure at the exhaust port, between a closed position to cover the exhaust port and an open position to open a path between the chamber and the exhaust port;

wherein the door unit, including the flap in the open position and in the closed position, is above a plane parallel to a bottom surface of the robot.

2. The mobile robot of claim 1, wherein the door unit comprises a support structure within the debris bin, and the flap is curved and is mounted on the support structure.

3. The mobile robot of claim 1, wherein the exhaust port and the door unit are adjacent to a corner proximate a lateral side of the debris bin and are positioned so that the flap faces outwardly relative to the corner.

4. The mobile robot of claim 1, wherein the door unit comprises a support structure and one or more hinges connecting the flap to the support structure.

5. The mobile robot of claim 1, wherein the door unit comprises a support structure and a biasing mechanism connecting the flap to the support structure, the biasing mechanism comprising a spring having a nonlinear response to the air pressure at the exhaust port.

6. The mobile robot of claim 5, wherein the spring is configured such that at least a first air pressure is required to place the flap in an open position and at least a second air pressure is required to place the flap in the open position, the first air pressure being greater than the second air pressure.

7. The mobile robot of claim 1, further comprising:

a drive operable to navigate the mobile robot about the surface,

a suction mechanism to suction debris from the surface into the debris bin, and

a controller to operate the drive to cause the mobile robot to traverse the surface while operating the suction mechanism to suction debris from the surface into the debris bin.

8. The mobile robot of claim 1, further comprising an electrical contact to electrically connect to a docking station for a charging operation.

9. The mobile robot of claim 1, further comprising a leaf spring to apply a force on the flap to bias the flap into the closed position.

10. The mobile robot of claim 1, wherein the door unit and a corner of the debris bin are separated by 0% to 25% of an overall length of the debris bin.

11. The mobile robot of claim 1, wherein the door unit is at least partially located within a rearward portion of the debris bin.

12. The mobile robot of claim 1, wherein the door unit comprises a support structure and a flexible coupler connecting the flap to the support structure.

13. The mobile robot of claim 1, wherein the door unit is configured such that a seal is formed between the exhaust port and an interior of the debris bin when the flap is in the closed position.

14. The mobile robot of claim 5, wherein the biasing mechanism further comprises a hinge connecting the flap to the support structure, and the spring is a torsion spring to apply a torque about a rotational axis of the hinge.

15. The mobile robot of claim 5, wherein the spring is configured to relax as the flap moves from the closed position to the open position.

16. The mobile robot of claim 7, wherein the door unit is positioned on a first lateral half of the debris bin, and the suction mechanism is positioned on a second lateral half of the debris bin.

17. The mobile robot of claim 7, further comprising a roller rotatable to direct debris from the surface towards the debris bin.

18. The mobile robot of claim 7, wherein the controller is configured to initiate transmission of a signal to an evacuation station to cause the evacuation station to initiate evacuating debris from the debris bin.

19. The mobile robot of claim 18, wherein the signal is provided by an optical signal.

20. The mobile robot of claim 1, wherein the door unit is located on a first lateral half of the debris bin, and the flap faces a second lateral half of the debris bin.

21. The mobile robot of claim 1, wherein the flap is configured to open toward the surface traversed by the robot.

22. The mobile robot of claim 1, wherein the flap extends from an upper portion of the door unit toward a bottom surface of the debris bin.

23. The mobile robot of claim 1, wherein:

the door unit comprises a support structure protruding from a bottom surface of the debris bin into an interior of the debris bin, and

the flap is connected to a top portion of the support structure and extends downward toward a bottom portion of the support structure.