Cleaner head for a vacuum cleaner

Abstract

A cleaner head for a vacuum cleaner includes a single agitator rotatably mounted within a housing, the agitator being arranged transversely within the housing such that it is perpendicular to the direction of travel of the cleaner head during use, the agitator being conical in shape, such that a first end has a larger diameter than a second end.

Claims

1. A cleaner head for a vacuum cleaner, the cleaner head comprising: a single agitator rotatably mounted within a housing, the agitator being arranged transversely within the housing such that the agitator is perpendicular to a direction of travel of the cleaner head during use, the agitator being frustoconical such that a first end has a larger diameter than a second end, wherein the first end of the agitator is cantilevered to the housing, and wherein a neck suitable for connection to the vacuum cleaner projects from the housing at a point between the first and second ends of the agitator.

2. The cleaner head of claim 1, wherein the agitator has a main body with an outer conical surface, and a lowermost portion of the conical surface is parallel with a flat supporting surface when the cleaner head is in use.

3. The cleaner head of claim 1, wherein an axis of rotation of the agitator is inclined with respect to a flat supporting surface on which the cleaner head is supported during use.

4. The cleaner head of claim 1, wherein the agitator extends transversely across less than a full width of the housing.

5. The cleaner head of claim 1, where the housing has a lower opening and the lower opening conforms in outline to a taper of the agitator.

6. The cleaner head of claim 1, wherein the agitator further comprises bristle tufts, bristle strips or a surface conforming material.

7. The cleaner head of claim 1, wherein the agitator is driven by a belt from a motor located outside of the agitator.

8. The cleaner head of claim 1, wherein a motor for driving rotation of the agitator is located inside the agitator.

9. The cleaner head of claim 1, wherein the housing is frustoconical.

10. The cleaner head of claim 1, wherein the neck projects from the housing at a mid-point between the first and second ends of the agitator.

11. The vacuum cleaner comprising the cleaner head of claim 1.

12. The cleaner head of claim 1, wherein the agitator is rotatably mounted to a support configured to be mounted to a belt drive system for driving the agitator.

13. The cleaner head of claim 1, wherein the agitator comprises a main body having a channel, wherein the channel is configured to receive a bristle strip, and wherein the main body comprises a first projection located on one side of the channel and a second projection located on the other side of the channel.

14. A cleaner head for a vacuum cleaner, the cleaner head comprising: an agitator rotatably mounted within a housing by a support configured to be mounted to a belt drive system for driving the agitator, the agitator comprising a bristle strip, the agitator being arranged transversely within the housing such that the agitator is perpendicular to a direction of travel of the cleaner head during use, the agitator being frustoconical such that a first end has a larger diameter than a second end, wherein the agitator is cantilevered to the housing at the first end, and wherein a neck suitable for connection to the vacuum cleaner projects from the housing at a point between the first and second ends of the agitator.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) In order to better understand the present invention, and to show more clearly how the invention may be put into effect, the invention will now be described, by way of example, with reference to the following drawings:

(2) FIG. 1 is a perspective view of an agitator;

(3) FIG. 2 is a schematic sectional view of the agitator of FIG. 1 taken transversely to a longitudinal axis of the agitator, with bristle strips removed;

(4) FIG. 3 is a schematic sectional view of the agitator of FIG. 1 taken transversely to a longitudinal axis of the agitator, with bristle strips inserted;

(5) FIG. 4 is a perspective view of a cleaner head comprising the agitator of FIG. 1, with an upper housing portion of the cleaner head removed;

(6) FIG. 5 is a schematic sectional view of the agitator of FIG. 1 taken transversely to a longitudinal axis of the agitator, with the agitator in contact with a surface to be cleaned;

(7) FIG. 6 is a front view of the agitator of FIG. 1 in combination with a debris removal mechanism;

(8) FIG. 7 is an upper view of an alternative cleaner head comprising the agitator of FIG. 1, with an upper housing portion of the cleaner head removed;

(9) FIG. 8 is an upper view of a further alternative cleaner head comprising a further alternative agitator, with an upper housing portion of the cleaner head removed;

(10) FIG. 9 is a schematic view of an alternative agitator according to the present invention;

(11) FIG. 10 is an upper view of a further alternative cleaner head comprising a further alternative agitator, with an upper housing portion of the cleaner head removed; and

(12) FIG. 11 is a perspective view of a vacuum cleaner according to the present invention.

(13) FIG. 12A is a perspective view of a further embodiment of the cleaner head of the present invention.

(14) FIG. 12B is an underside view of the cleaner head shown in FIG. 12A.

(15) FIG. 12C shows a section through the cleaner head shown in FIGS. 12A and 12B.

(16) FIG. 12D is a perspective view of a vacuum cleaner according to the present invention.

(17) FIG. 13A is a perspective view of a further embodiment of the cleaner head of the present invention.

(18) FIG. 13B is an underside view of the cleaner head shown in FIG. 13a

(19) FIG. 13C shows a section through the cleaner head shown in FIGS. 13A and 13B.

(20) FIG. 13D is a perspective view of a vacuum cleaner according to the present invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

(21) A first embodiment of an agitator, generally designated 10, is shown in FIGS. 1 to 6.

(22) The agitator 10 takes the form of a brushbar, and these terms will be used interchangeably hereafter. The brushbar 10 comprises a main body 12, first 14 and second 16 projections (i.e., walls), a first bristle strip 18, first 20 and second 22 raised portions, and a second bristle strip 24.

(23) The main body 12 is substantially cylindrical in form, and is substantially hollow. The main body 12 has a first channel 26 for receiving the first bristle strip 18, and a second channel 28 for receiving the second bristle strip 24. Both the first 26 and second 28 channels have a substantially inverted T-shaped cross-section, substantially corresponding to the form of the first 18 and second 24 bristle strips, as can be seen in FIGS. 2 and 3. The first 26 and second 28 channels extend helically along the outer surface of the main body 12, with each of the first 26 and second 28 channels extending through 360° about the outer surface of the main body 12.

(24) The first 14 and second 16 projections are located either side of the first channel 26, and have a generally triangular transverse cross-sectional shape. In the present embodiment, the first 14 and second 16 projections constitute regions of the main body 12 having an increased radius relative to the main body 12, such that the first 14 and second 16 projections are integrally formed with the main body 12. The main body 12, and the first 14 and second 16 projections are formed of acrylonitrile butadiene styrene (ABS), and are relatively rigid in nature, such that the first 14 and second 16 projections do not suffer excessive deformation upon contact with a surface to be cleaned in use.

(25) The first 14 and second 16 projections each define respective tips 30, 32, and side walls 34, 36 of the first channel 26 extend to the base of the respective first 14 and second 16 projections. The first 14 and second 16 projections define walls having an angle of around 50° relative to nylon bristles 40 of the brushbar 10. The main body 12 has a radius R of around 25 mm, whilst the radius B, C in the region of the first 14 and second 16 projections at the tips 30, 32 is around 28 mm. The first 14 and second 16 projections are helical in form, and follow the shape of the first channel 26 along substantially the entire extent of the first channel 26.

(26) The first bristle strip 18 comprises a bristle base 38 and a plurality of tufts of bristles 40 woven to the bristle base 38. The bristle base 38 is elongate and planar in form, with the plurality of tufts of bristles 40 upstanding therefrom. The bristles 40 are formed of nylon, and have sufficient strength to agitate debris located upon a surface to be cleaned in use, whilst still having sufficient flexibility to resiliently deform relative to the bristle base 38. In a presently preferred embodiment, the bristles 40 have a height of around 7 mm from the bristle base 38.

(27) The first 20 and second 22 raised portions also constitute regions of the main body 12 having an increased radius relative to the main body 12, such that the first 20 and second 22 raised portions are integrally formed with the main body 12. The first 20 and second 22 raised portions define asymmetric peaks 42, 44, in contrast to the generally symmetrical angular tips of the first 14 and second 16 projections, although it is also envisaged that the first 20 and second 22 raised portions may have substantially the same form as the first 14 and second 16 projections. The main body 12 has a radius R of around 25 mm, whilst the radius E in the region of the first 20 and second 22 raised portions at the peaks 42, 44 is around 27 mm. The first 20 and second 22 raised portions are helical in form, and follow the shape of the second channel 28 along substantially the entire extent of the second channel 28.

(28) The second bristle strip 24 comprises a bristle base 50 and a plurality of tufts of bristles 52 woven to the bristle base 50. The bristle base 50 is elongate and planar in form, with the plurality of tufts of bristles 52 upstanding therefrom. The bristles 52 are formed of carbon fibre, and hence are relatively softer than the nylon bristles 40. In a presently preferred embodiment, the bristles 52 have a height of around 12 mm from the bristle base 50. The use of carbon fibre bristles 52 is unlikely to have a negative impact with regard to debris wrapping around the brushbar 10 in use, as the soft nature of the bristles 52 means that debris is typically not entangled by the bristles 52, and hence cannot wrap around the brushbar 10.

(29) The first 18 and second 24 bristle strips are slidably inserted within the respective first 26 and second channels 28, such that the bristles 40, 52 are upstanding from their respective channels 26, 28. In an undeformed position, for example a position in which the bristles 40, 52 do not contact a surface to be cleaned and are not subjected to external forces, tips of the nylon bristles 40 define a radius A of around 29 mm from a central longitudinal axis of the brushbar 10, whilst tips of the carbon fibre bristles 52 define a radius F of around 33 mm from the central longitudinal axis of the brushbar 10. Furthermore, the nylon bristles 40 are spaced from the tips 30, 32 of the first 14 and second 16 projections by a distance D of around 3 mm in a generally circumferential direction.

(30) Thus it can be seen that the tips of the nylon bristles 40 define a greater radius than the tips 30, 32 of the first 14 and second 16 projections in a first configuration, i.e., in an undeformed position, such that the tips of the nylon bristles 40 extend past the tips 30, 32 of the first 14 and second 16 projections. This can be seen most clearly in FIG. 3, where the radius of the tips of the nylon bristles 40 is denoted by distance A, the radius of the tip 30 of the first projection 14 is denoted by distance B, and the radius of the tip 32 of the second projection 16 is denoted by distance C. The spacing of the nylon bristles 40 from the tips 30, 32 of the first 14 and second 16 projections in a substantially circumferential direction is denoted by distance D in FIG. 3.

(31) During use, the brushbar 10 is rotatably mounted within a housing 102 of a cleaner head 100 of a vacuum cleaner, as seen in FIG. 4. The cleaner head 100 has a dirty air inlet and a dirty air outlet, such that dirty air is able to flow through the cleaner head 100 in use. The brushbar 10 rotates within the cleaner head 100, for example as a result of being driven by a motor housed within the main body 12, such that the nylon bristles 40 contact a surface to be cleaned 300. As the nylon bristles 40 contact the surface to be cleaned 300, the nylon bristles 40 are able to deform as a result of their flexibility and the spacing between the bristles 40 and the tips 30, 32 of the first 14 and second 16 projections. When the nylon bristles 40 reach a second configuration, i.e., a position of maximum deformation, the tips of the bristles are located at or below the tips 30, 32 of the first 14 and second 16 projections. Such a configuration is shown in FIG. 5 where the tips of the bristles 40 are sub-flush relative to the tips 30, 32 of the first 14 and second 16 projections.

(32) Thus it can be seen that the tips of the nylon bristles 40 define a smaller radius than the tips 30, 32 of the first 14 and second 16 projections in a second configuration, i.e., in a deformed position, such that the tips of the nylon bristles 40 are at, or sub-flush relative to, the tips 30, 32 of the first 14 and second 16 projections. This second configuration has been found to have particularly advantageous effects in preventing wrapping of debris, for example hair or thread or the like, around the brushbar 10.

(33) In particular, entanglement of debris with bristles can lead to debris wrapping around the brushbar 10 in use, and bristles are typically more densely packed, and hence more prone to entangle debris, at the base thereof. As the nylon bristles 40 have a second configuration in which the tips of the nylon bristles 40 are at, or sub-flush relative to, the tips 30, 32 of the first 14 and second 16 projections, a lower proportion, for example none, of the length of the nylon bristles 40 may be exposed past the tips 30, 32 in the second configuration, and hence debris may be prevented from migrating toward the bristle base 38 of the nylon bristles 40. Furthermore, debris which would typically become entangled in the nylon bristles 40, for example at the bristle base 38 of the bristles 40, may be contacted by the projections 14, 16 and prevented from reaching the bristle base 38 of the bristles 40, or moved out of contact with the bristles 40, for example outwardly to the level of the tips 30, 32 of the projections 14, 16 or to a less densely packed region of bristles 40, and may thereby prevent such entanglement from occurring. Engagement between the tips 30, 32 of the projections 14, 16 and the surface to be cleaned 300 may move debris outwardly through the bristles 40 to a region where the bristle density is insufficient to trap debris. Hence debris may not necessarily reach the level of the tips 30, 32 of the projections 14, 16, but may still be prevented from becoming entangled in the bristles 40 in use.

(34) In addition to preventing debris from wrapping around the brushbar 10, the first 14 and second 16 projections may also act to move debris along the brushbar 10 in use. For example, the helical nature of the first 14 and second 16 projections may result in staged engagement between the projections 14, 16, debris, and the surface to be cleaned 300, and this may act to move debris along the brushbar 10.

(35) To this end, the brushbar 10 also comprises a debris collection channel 54 formed at an end of the brushbar 10. In use, the interaction between the brushbar 10 and the surface to be cleaned 300 moves debris along the length of the brushbar 10, such that debris is collected within the debris collection channel 54. A debris removal mechanism 56 may be located at the debris collection channel 54 for automatic removal of debris, or the brushbar 10 may be removable from the cleaner head 100 such that a user can manually remove debris from the debris collection channel 54. In the embodiment shown in FIG. 6, it will be recognised that the debris removal mechanism 56 defines the debris collection channel 54, in that the debris removal mechanism 56 comprises a pair of scissors which can be selectively opened and closed to define the debris collection channel 54.

(36) An alternative form of a cleaner head 400 is shown schematically in FIG. 7. The cleaner head 400 is substantially the same as the cleaner head 100, and comprises the same brushbar 10, but differs in that the brushbar 10 is cantilevered within the cleaner head 400. In this regard, only one end of the brushbar 10 is mounted to a housing 402 of the cleaner head 400, such that there is a free end 404 of the brushbar 10 within the housing 402. In such an embodiment, the brushbar 10 may act to migrate debris along the brushbar 10 toward the free end 404, such that debris is able to fall off the free end 404 and become re-entrained within the air flow through the cleaner head 400.

(37) An alternative cleaner head 500 is shown in FIG. 8. The cleaner head 500 is substantially the same as the cleaner head 100, and differs only in the form of the brushbar 502. The brushbar 502 has substantially the same structure as the brushbar 10 previously described, but also has a further debris collection channel 504 located centrally along the brushbar 502. This may be beneficial as debris may have to travel a reduced distance along the brushbar 502, and hence there is a reduced risk of debris wrapping around the brushbar 502 as it travels along the brushbar 502 in use. The further debris collection channel 504 is a region of the brushbar 502 that has a reduced diameter relative to the remainder of the brushbar 502, and the further debris collection channel 504 extends about substantially the entire circumference of the brushbar 502. A debris removal slot 506 extends transversely across the further debris collection channel 504, and enables insertion of a debris removal member, for example a blade or a pair of scissors, to remove debris from the further debris collection channel 504.

(38) A further alternative brushbar 600 according to the present invention is shown in FIG. 9, The brushbar 600 is substantially the same as the brushbar 10, and differs in that the brushbar 600 is tapered along its length, such that the hrushhar 600 guides debris towards the debris collection channel 54 in use. This may be beneficial as the brushbar 600 may further guide debris toward the debris collection channel 54 in use. The taper angle at the brushbar 600 may be greater than 5°, or indeed greater than 10°, and at least sufficient to guide debris along the brushbar 10 and toward the debris collection channel 54 in use. A cleaner head is also envisaged wherein the brushbar 600 is cantilevered within the cleaner head, such that the cleaner head resembles the cleaner head 400 discussed previously. The brushbar 600 appears frustoconical in form. An offset drive may be used to ensure that a portion of the brushbar 600 always lies parallel to a surface to be cleaned in use.

(39) A further alternative cleaner head 800 is shown in FIG. 10. The cleaner head 800 comprises a brushbar 900 having first 902 and second 904 brushbar portions, each of which is cantilevered within the housing 906 of the cleaner head 800, such that a gap 908 is formed between the first 902 and second 904 brushbar portions. Each of the first 902 and second 904 brushbar portions has substantially the same form as the brushbar 10 according to the first aspect of the present invention, only reduced in size, such that the first 902 and second 904 brushbar portions migrate debris toward the gap 908 in use, thereby allowing debris to be re-entrained in air flow through the cleaner head 800.

(40) A vacuum cleaner 200 comprising a cleaner head 100 according to the present invention is shown schematically in FIG. 11.

(41) Further alternative cleaner heads according to the present invention are shown in FIGS. 12A to 13D.

(42) In these alternative embodiments the cleaner head 60 can be seen to include a single agitator 62 which is conical in shape. The agitator 62 is rotatably mounted within a housing 64 which is also substantially conical in shape. The housing 64 covers at least the upper and side portions of the agitator 62. The housing 64 also has an opening 66 through which a portion of the agitator 62 can project. During use of the cleaner head 60 the projecting portion of the agitator 62 will be able to contact and agitate a surface to be cleaned. The opening 66 may conform in outline to the taper of the agitator 62. This is shown in FIG. 13B. Alternatively the opening 66 may be rectangular as shown in FIG. 12B. The agitator 62 may further comprise surface agitating means 74 in the form of bristle tufts, bristle strips or a surface conforming material, for example felt or fleece.

(43) The agitator 62 is arranged transversely within the housing 64 such that it is perpendicular to the direction of travel of the cleaner head 60 during use. It can be seen in the Figures that the agitator 62 has a main body 68 with an outer conical surface. The lowermost surface 70 of the conical surface is parallel with a flat supporting surface 72 when the cleaner head 60 is in use. This means that any bristles 74 on the agitator 62 can be of a uniform length all along the agitator 62. This is achieved by having the axis of rotation (X) of the agitator 62 inclined with respect to the flat supporting surface 72 on which the cleaner head 60 is supported during use. It can be seen that the agitator 62 extends transversely across substantially the full width of the housing 64.

(44) In the embodiments shown in FIGS. 12A to 13D it can be seen that the agitator 62 is cantilevered to the housing 64 at its first end 76. Two different embodiments are shown in FIGS. 12C and 13C. In 12c the agitator 62 is driven by a motor 78 which is housed inside the agitator 62. In 13c the agitator is driven by a motor and drive belt 80. The motor (not shown) in this embodiment is housed in a motor housing 82 which forms part of the cleaner head housing 64 and is located next to the first end 76 of the agitator 62.

(45) In FIG. 13C it can be seen that the drive belt 80 and the belt drive system 84 are located at the first end 76 of the agitator 62. The cantilever support 86 is mounted to the belt drive system 84. The cantilever support projects 86 away from the belt drive system 84 and provides a mount onto which the agitator 62 is rotatably mounted via bearings 88 and agitator fixings 90. A drive dog 92 projects through the cantilever support 86 and is connected to the agitator 62 for driving rotation.

(46) In FIG. 12C it can be seen that a motor 78 is located inside the agitator 62. A motor mounting 93 is fixed to the housing 64 via any suitable means, for example screws 94. The motor mounting 93 also forms a housing for the motor 78. The motor mounting 93 forms a recessed channel 95 at the first end 76 of the agitator 62 into which bearings 88 are provided. These bearings 88 and agitator fixings 90 which are fixed to the first end of the agitator 62 form the cantilevered mounting in this embodiment. A gear box 96 is also proved within the agitator 62. The drive dog 92 projects from the gear box and is connected to the agitator 62 for driving rotation.

(47) The second end 97 is not mounted to the housing 64 and therefore any debris that gets tangled on the agitator 62 during use of the cleaner head 60 can fall of the second end 97 and can be sucked up into a vacuum cleaner 98 to which the cleaner head 60 is attached. FIGS. 12D and 13C show these embodiments attached to a vacuum cleaner 98.

(48) The housing 64 further comprises a neck 99 suitable for connection to a vacuum cleaner 98. The neck 99 is arranged such that it projects rearwardly from the housing 64 at a point between the first 76 and second 97 ends of the agitator 62. In the embodiments shown in FIGS. 12A to 13D the neck 99 projects from the housing 64 at a mid-point between the first 76 and second 97 ends of the agitator 62.