BRUSHBAR FOR A VACUUM CLEANER

Abstract

A brushbar for a vacuum cleaner is described. The brushbar includes a cylindrical body, one or more pairs of bristle strips and one or more plush strips arranged helically about the body. Each pair of bristle strips includes a first strip of first bristles and a second strip of second bristles, the first bristles being stiffer and shorter than the second bristles. The plush strips are arranged on either side of each pair of bristle strips and include a plush of fibres.

Claims

1: A brushbar for a vacuum cleaner comprising: a cylindrical body; one or more pairs of bristle strips arranged helically about the body, each pair of bristle strips comprising a first strip of first bristles and a second strip of second bristles, the first bristles being stiffer and shorter than the second bristles; and one or more plush strips arranged helically about the body, the plush strips being arranged on either side of each pair of bristle strips and comprising a plush of fibres.

2: The brushbar as claimed in claim 1, wherein the first and second bristles are formed of different materials.

3: The brushbar as claimed in claim 2, wherein the first bristles are formed of a plastic material, and the second bristles are formed of carbon fibre or a carbon composite material.

4: The brushbar as claimed in claim 1, wherein the second strip comprises third bristles located adjacent to the second bristles, and the third bristles are stiffer than the second bristles.

5: The brushbar as claimed in claim 4, wherein the second bristles are formed of carbon fibre or a carbon composite material, and the third bristles are formed of a plastic material.

6: The brushbar as claimed in claim 1, wherein the bristles of the second strip are canted in a direction away from the first strip.

7: The brushbar as claimed in claim 6, wherein the bristles of the second strip are canted at an angle of between 40 and 60 degrees.

8: The brushbar as claimed in claim 1, wherein, in a plane normal to a central longitudinal axis of the brushbar, each pair of bristle strips subtends a first central angle, each plush strip subtends a second central angle, and the second central angle is greater than the first central angle.

9: The brushbar as claimed in claim 1, wherein the fibres have a lower stiffness than the first bristles, and a shorter length than the second bristles.

10: The brushbar as claimed in claim 1, wherein the brushbar comprises a first circumferential spacing between each first strip and an adjacent plush strip, and the first circumferential spacing is no smaller than the length of the fibres.

11: The brushbar as claimed in claim 1, wherein the brushbar comprises a second circumferential spacing between each second strip and an adjacent plush strip, and the second circumferential spacing is no smaller than the length of the second bristles.

12: The brushbar as claimed in claim 1, wherein each of the bristle strips comprises castellations in the bristles.

13: The brushbar as claimed in claim 12, wherein castellations in the bristles of the first strip and castellations in the bristles of the second strip are aligned in planes normal to a central longitudinal axis of the brushbar.

14: The brushbar as claimed in claim 1, wherein the brushbar comprises two pairs of bristle strips.

15: The brushbar as claimed in claim 1, wherein each of the bristle strips spans at least 360 degrees about the body.

16: A cleaner head for a vacuum cleaner comprising: a housing having a suction chamber; the brushbar as claimed in claim 1, the brushbar being rotatably mounted within the suction chamber; and a suction opening formed on an underside of the housing through which the brushbar is able to agitate a surface.

17: The cleaner head as claimed in claim 16, wherein the cleaner head comprises one or more debris slots formed in a front of the housing through which debris may pass to the suction chamber.

18: The cleaner head as claimed in claim 16, wherein the cleaner head comprises one or more bars that extend across the suction opening, the bristle strips project downward beyond the bars, and the bristle strips comprise castellations in the bristles that are aligned with the bars.

19: The cleaner head as claimed in claim 16, wherein the second strip trails the first strip in a direction of rotation of the brushbar.

20: The cleaner head as claimed in claim 16, wherein the cleaner head comprises a drive assembly for driving the brushbar, the brushbar comprises two pairs of bristle strips, and the drive assembly drives the brushbar at an unloaded speed of between 2500 rpm and 3500 rpm.

21: A brushbar for a vacuum cleaner comprising one or more bristle strips arranged helically about a body, wherein each bristle strip comprises a strip of castellated bristles.

22: The brushbar as claimed in claim 21, wherein the brushbar comprises a plurality of bristle strips, and castellations in the bristle strips are aligned in planes normal to a central longitudinal axis of the brushbar.

23: A cleaner head for a vacuum cleaner comprising a housing having a suction chamber, brushbar rotatably mounted within the suction chamber, a suction opening formed in an underside of the housing, and one or more bars that extend across the suction opening, wherein the brushbar comprises one or more bristle strips arranged helically about a body, the bristle strips project downward beyond the bars, and the bristle strips comprise castellations in the bristles that are aligned with the bars.

24: A vacuum cleaner comprising the brushbar as claimed in claim 1.

25: The vacuum cleaner as claimed in claim 24, wherein the vacuum cleaner is an autonomous vacuum cleaner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Embodiments will now be described, by way of example, with reference to the accompanying drawings in which:

[0027] FIG. 1 is a plan view of an underside of a vacuum cleaner;

[0028] FIG. 2 is a perspective view of a portion of the vacuum cleaner;

[0029] FIG. 3 is a front view of the vacuum cleaner;

[0030] FIG. 4 is a front view of a brushbar forming part of the vacuum cleaner;

[0031] FIG. 5 is a section through the brushbar along the line A-A of FIG. 4; and

[0032] FIG. 6 is a section through a second bristle strip forming part of the brushbar of FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The autonomous vacuum cleaner 10 of FIGS. 1 to 3 comprises a main body 20 and a cleaner head 30.

[0034] The main body 20 comprises a battery pack, a drivetrain, a navigation system, a vacuum motor, and a dirt separator. Of these, only the wheels 22 of the drivetrain and the underside of the dirt separator 24 are visible in the Figures. The battery pack provides electrical power to the various electrical components of the vacuum cleaner, such as the drivetrain, the navigation system, the vacuum motor, and the drive assembly of the cleaner head. The drivetrain, under the control of the navigation system, manoeuvres the vacuum cleaner within a room or the like. The navigation system is responsible for guiding the vacuum cleaner within the room. The navigation system may comprise sensors for sensing the surrounding environment, which the navigation system then uses to locate the vacuum cleaner within the room and to determine a suitable cleaning path along which the vacuum cleaner is moved. The vacuum motor causes air to be drawn into the cleaner head and carried to the dirt separator, e.g. via ducting within the main body. Dirt entrained in the air is then separated by the dirt separator and the cleansed air is exhausted from the vacuum cleaner.

[0035] The cleaner head 30 comprises a housing 32, a brushbar 40, and a drive assembly (not shown) for driving the brushbar 40.

[0036] The housing 32 comprises a suction chamber 33 within which the brushbar 40 is rotatably mounted. A suction opening 34 is provided on an underside of the housing 32, and a plurality of debris slots 35 are provided in a front of housing 32. Although not shown, the cleaner head comprises an outlet in fluid communication with the vacuum motor, through which air is drawn from the suction chamber 33 to the dirt separator 24. The cleaner head 30 further comprises a plurality of bars 36, sometimes referred to as rug strips, that extend across the suction opening 34.

[0037] In this particular example, the drive assembly is located inside the brushbar 40 and comprises an electric motor and a transmission for transmitting torque generated by the electric motor to the brushbar 40. The electric motor is then powered by the battery pack within the main body. In an alternative example, the drive assembly may be located outside of the brushbar 40. Moreover, rather than an electric motor, the drive assembly could conceivably comprise alternative means, such as an air turbine, for generating the torque necessary to drive the brushbar 40.

[0038] Referring now to FIGS. 4 and 5, the brushbar 40 comprises a cylindrical body 41, a plurality of bristle strips 42,43, and a plurality of plush strips 44. The bristles strips 42,43 and the plush strips 44 are each arranged helically about the body 41. The term plush as used herein refers to a fabric with an even pile that is longer and less dense than that of velvet. By way of example, the pile of plush fabrics is no less than 0.3 cm high whilst the pile of velvet fabrics is less than 0.3 cm.

[0039] The bristles strips 42,43 are grouped into pairs. In this particular example, there are four bristle strips 42,43 grouped into two pairs. Each pair of bristle strips comprises a first strip 42 of first bristles 48 and a second strip 43 of second bristles 49. The first strip 42 and the second strip 43 are intended to agitate dirt from different surface types. The first bristles 48 are stiffer and shorter than the second bristles 49, and are intended to agitate dirt from carpeted surfaces. The second bristles 49, being longer and more flexible, are intended to agitate or sweep dirt from hard surfaces, such as wooden or tiled surfaces.

[0040] The first bristles 48 and the second bristles 49 may be formed of different materials. As a result, the characteristics of the bristles may be better targeted at the different surface types. In one example, the first bristles 48 are formed of a plastic material, such as polyamide, and the second bristles 49 are formed of carbon fibre or a carbon composite material. The first bristles 48, being formed of a plastic material, are then relatively robust and non-brittle and are well-suited to agitating carpeted surfaces. The second bristles 49, bring formed of a carbon fibre or carbon composite material, are less likely to charge hard surfaces with static electricity. As a result, dirt may be more easily lifted from the hard surfaces.

[0041] Each of the bristle strips 42,43 may comprise a mixture or blend of different bristles. By way of example, the second strip 43 may comprise third bristles 50 in addition to the second bristles 49. The third bristles 50 may be stiffer than the second bristles 49, and may be located adjacent to the second bristles 49 so as to support the second bristles 49. In the particular example shown in FIG. 6, the third bristles 50 abut against the second bristles 49 and are located behind or rearwardly of the second bristles 49 relative to a direction of rotation of the brushbar 40. This then has the benefit that relatively long and fine bristles may be used for the second bristles 49 to provide a gentle sweeping action across hard surfaces. Without the support provided by the third bristles 50, the direction and movement of the second bristles 49 may be poorly controlled, resulting in poor dirt pickup. In one example, the second bristles 49 may be formed of carbon fibre or a carbon composite material, and the third bristles 50 may be formed of a plastic material, such as polyamide.

[0042] The second strip 43 trails the first strip 42. Additionally, the bristles of the second strip 43 are canted rearwards in a direction away from the first strip 42. Canting should be understood to mean that, in a plane normal to the central longitudinal axis 45 of the brushbar 40, the bristles of the second strip 43 are angled relative to a radial line passing through the base of the bristles. Canting the bristles of the second strip 43 has at least two advantages. First, longer bristles may be employed. By employing longer bristles, the required flexibility in the bristles may be achieved using thicker bristles, thereby improving the robustness and reliability of the bristles. Second, by canting the bristles rearward, the bristles perform a sweeping action on contact with the cleaning surface. As a result, the load on the brushbar 40 is reduced, and thus the power drawn by the brushbar 40 (i.e. the electrical power drawn by the drive assembly to drive the brushbar 40 at a given torque and/or speed) is reduced. In the particular example shown in FIG. 5, the bristles of the second strip 43 are canted at an angle, ?, of about 50 degrees relative to the radial line. However, a relatively good balance between pickup performance and power draw may be achieved with a cant angle of between 40 and 60 degrees.

[0043] Each of the bristles strips 42,43 is castellated, i.e. has notches. The castellations 47 or notches in the bristles of the first strip 42 are aligned with those in the second strip 43. More particularly, the castellations 47 in the bristles are aligned in planes normal to the central longitudinal axis 45 of the brushbar 40. As noted above, the cleaner head 30 comprises bars 36 that extend across the suction opening 34. The bars 36 prevent rugs, carpet, or the like being lifted up into the suction chamber 33 of the cleaner head 30. When the brushbar 40 is mounted within the suction chamber 33, the bristle strips 42,43 project downward beyond the bars 36 such they can agitate dirt from the cleaning surface. The castellations 47 in the bristle strips 42,43 are aligned with the bars 36 such that, as the brushbar 40 rotates, the castellations 47 pass over the bars 36. If the bristle strips 42,43 were continuous rather than castellated, the bristles would beat against the bars 36 as the brushbar 40 rotates, consuming power and generating noise. By providing castellations 47 in the bristle strips 42,43 that are aligned with the bars 36, the power drawn by the brushbar 40 is reduced. Additionally, the level of the noise generated by the brushbar 40 is reduced and/or the quality is improved.

[0044] The plush strips 44 are arranged on either side of each pair of bristle strips 42,43. In contrast to the bristle strips 42,43, which are relatively narrow, each of the plush strips 44 is relatively wide. Each of the plush strips 44 comprises a plush of fibres. The fibres have a relatively low stiffness and a relatively high density (e.g. 2000-3000 fibres per mm.sup.2), which gives the fibres a soft or plush feel. The fibres have a lower stiffness than the first bristles 48, and a shorter length than the second bristles 49. In this particular example, the fibres are formed of the same material as the first bristles 48 (e.g. polyamide) and have the same length of the first bristles 48. However, the fibres have a significantly smaller diameter, thereby giving the fibres a much lower stiffness.

[0045] The plush strips 44 cover the majority of the body 41, the benefits of which are described below. In order to maximise the area of the body 41 covered by the plush strips 44, the bristles strips 42,43 are positioned as close as possible to one another. Each of the bristles strips 42,43 comprises a base to which the bristles are secured (e.g. by overmoulding the base onto the bristles). The base of each bristle strip 42,43 is then seated within a slot or track in the body 41 of the brushbar 40. The proximity of the bristle strips 42,43 of each pair is then constrained or limited by the minimal permissible wall thickness between the two slots in the body 41. The second strip 43 trails the first strip 42. By having the longer, more flexible bristles of the second strip 43 trail the shorter, stiffer bristles of the first strip 42, the two bristle strips 42,43 may be brought closer together whilst ensuring that the leading bristles, upon flexing rearwards during use, do not interfere with or get caught up in the trailing bristles. By bringing the bristle strips 42,43 closer together in this way, the available area for the plush strips 44 is increased.

[0046] Each pair of bristle strips 42,43 may be said to subtend a first central angle, A1, in a plane normal to the central longitudinal axis of the brushbar, and each plush strip may be said to subtend a second central angle, A2. By arranging the bristle strips 42,43 in the manner described above, it is possible to achieve a second central angle, A2, that is greater than the first central angle, A1. As a result, the majority of the body 41 of the brushbar 40 is covered with plush fibres, the benefits of which are described below.

[0047] In spite of the desire to maximise the area covered by the plush strips 44, a minimal circumferential spacing is nevertheless maintained between the bristle strips 42,43 and the plush strips 44. In particular, a first circumferential spacing is provided between the first strip 42 and the adjacent plush strip 44, which is no smaller than the length of the fibres. This then has the advantage that, when the fibres of the plush strip 44 flex or deform rearwards on contacting the cleaning surface, the fibres do not interfere with or get caught up in the bristles of the first strip 42. Similarly, a second circumferential spacing is provided between the second strip 43 and the adjacent plush strip 44, which is no smaller than the length of the second bristles. Again, this then has the advantage that, when the bristles of the second strip 43 flex or deform rearwards on contacting the cleaning surface, the bristles do not interfere with or get caught up in the fibres of the plush strip 44.

[0048] During use of the cleaner head 30, the brushbar 40 rotates to agitate dirt from the cleaning surface. As noted, the first bristle strips 42 and the second bristle strips 43 are intended to agitate dirt from different types of surface. More particularly, the first strips 42 are intended to agitate dirt from carpeted surfaces, and the second strips 43 are intended to agitate dirt from hard surfaces. The brushbar 40 is mounted within the suction chamber 33 such that, when the cleaner head 30 is on a hard surface, the bristles of the first strip 42 are spaced from and do not contact the surface. Dirt is then agitated from the surface by the bristles of the second strip 43. Although not readily apparent from FIG. 5, the radial extent or outer diameter of the bristles of the second strip 43 is slightly greater than that of the first strip 42. Moreover, as the brushbar 40 rotates, the bristles of the second strip 43 straighten slightly due to centrifugal forces, i.e. the cant angle, ?, decreases. As a result, the radial extent or outer diameter of the bristles of the second strip 43 increases. In the present example, the fibres of the plush strips 44 are also spaced from hard surfaces. In an alternative example, the length of the fibres of the plush strips 44 may be longer such that the fibres contact hard surfaces to provide a buffing or polishing effect.

[0049] As noted above, the second bristle strip 43 trails the first 42. This then has the advantage that the two bristle strips 42,43 of each pair may be brought closer together, thereby increasing the available area for the plush strips 44. A further advantage of this arrangement is that the first bristles 48, being stiffer and potentially less brittle than the second bristles 49, may protect the second bristles 49 from the impact of large debris, which might otherwise damage the second bristles 49.

[0050] The suction generated by the vacuum motor creates a negative pressure within the suction chamber 33. As a result, air is drawn into the suction chamber 33 from outside the cleaner head 30 via the suction opening 34. Dirt agitated by the brushbar 40 is then entrained by this moving air. The cleaner head 30 also comprises debris slots 35 provided in a front of housing 32. Each slot 35 provides a path through which large debris may pass into the suction chamber 33. Without the debris slots 35, the cleaner head 30 may push or snowplough large debris around the cleaning surface. However, in addition to large debris, each slot 35 provides a path through which air may be drawn into the suction chamber 33. In the absence of the plush strips 44, air would be drawn in through the debris slots 35, around the top of the brushbar 40, and out through the outlet of the cleaner head 30. The pressure within the suction chamber 33 would then increase, i.e. there would be a loss of negative pressure within the suction chamber 33. As a consequence of the loss in negative pressure, the flow rate of the air drawn in through the suction opening 34 would decrease. Less dirt would then be entrained by the air and thus the pickup performance of the cleaner head 30 would worsen.

[0051] The plush strips 44 create a restriction between the brushbar 40 and the surrounding housing 32. This restriction significantly reduces the flow of air over the top of the brushbar 40. As a result, a good negative pressure is maintained within the suction chamber 33, which in turn provides a good pickup performance. Large debris is then drawn into the debris slots 35, not so much by air moving through the slots 35, but by the forward movement of the cleaner head 30. The cleaner head 30 is therefore capable of picking up large debris via the slots 35 at the front of the housing 32 whilst also ensuring good pickup of fine dirt from beneath the housing 32.

[0052] Cleaner heads having large debris slots are known. However, such cleaner heads typically include an actuator, such as a switch or slider, to selectively open and close the slots. A user then opens the slots momentarily upon identifying large debris, and close the slots shortly thereafter once the large debris has been picked up. With an autonomous vacuum cleaner, such control is not straightforward. However, with the brushbar 40 and the cleaner head 30 described herein, the debris slots 35 may be left permanently open. The plush strips 44 then ensure that, in spite of the permanently open slots, a good head pressure, and thus good dirt pickup, is maintained.

[0053] In the example described above, the brushbar 40 comprises two pairs of bristle strips 42,43. Conceivably, the brushbar 40 may comprise a single pair of bristle strips, thereby increasing the available area of the body 41 that may be covered by plush fibres. There are, however, benefits in having two pairs of bristle strips. By having two pairs of bristle strips, the bristle strips 42,43 contact the cleaning surface twice during each rotation of the brushbar 40. Consequently, in comparison to a single pair of bristle strips which contacts the cleaning surface only once, the same degree of agitation may be achieved (i.e. the same power may be driven into the cleaning surface) using less dense or more flexible bristles. This in turn may reduce the noise generated by the brushbar 40. As noted, by employing two pairs of bristles 42,43, the available area of the body 41 that may be covered by the plush fibres is reduced and thus there may be a loss of pressure within the suction chamber 33, in comparison to a single pair of bristle strips. However, this potential loss in pressure may be recovered by increasing the speed of the brushbar 40. For a brushbar 40 having two pairs of bristle strips 42,43, a good balance between pickup performance and noise may be observed at speeds of between 2500 rpm and 3500 rpm.

[0054] Conceivably, the bristle strips 42,43, rather than being grouped into pairs, could be arranged evenly about the body 41. However, by grouping the bristle strips 42,43 into pairs, the number of plush strips 44 is halved, thereby simplifying the manufacture and assembly of the brushbar 40. Additionally, the total surface area of the plush strips 44 can be increased, which in turn provides a greater restriction and thus improved head pressure. There may also be acoustic benefits in grouping the bristle strips 42,43 into pairs. For example, if the brushbar 40 were to comprise four bristle strips spaced evenly about the body 41, the bristle strips would impact the cleaning surface four times with each rotation of the brushbar 40. By grouping the bristles strips 42,43 into pairs, each pair of bristle strips 42,43 may be regarded as generating a single impact. Accordingly, the bristle strips 42,43 impact the cleaning surface twice with each rotation. By halving the number of impacts with each rotation, the level of noise may be reduced and/or the quality may be improved.

[0055] Each of the bristle strips 42,43 spans 360 degrees about the body 41. Conceivably, the bristle strips 42,43 may span a different angle, in particular a smaller angle. However, by spanning at least 360 degrees, each bristle strip 42,43 is in constant contact with the cleaning surface. This may then have benefits in terms of noise and power draw during rotation of the brushbar 40. By contrast, if the bristle strips 42,43 spanned a smaller angle then the level and/or quality of the noise may worsen and/or the power drawn by the brushbar 40 may vary as different bristle strips come into contact and then leave the cleaning surface.

[0056] Whilst the vacuum cleaner described above is autonomous, the brushbar 40 and/or the cleaner head 30 may be used with other types of vacuum cleaner, such as upright, canister or stick vacuum cleaners. In particular, the brushbar 40 may provide increased head pressure in cleaner heads having debris slots. Moreover, the brushbar 40 makes possible the use of debris slots that are permanently open, thus avoiding the need to manually open and close the debris slots.