CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 62/960,826, filed January 14, 2020, the entire contents of which are hereby incorporated by reference herein.

BACKGROUND

[0002] The present invention relates to cleaning heads for floor cleaners.

SUMMARY

[0003] In one embodiment a floor cleaner is disclosed including a dirt collection chamber and a cleaning head in fluid communication with the dirt collection chamber. The cleaning head includes a housing, a brushroll chamber, and a brushroll. The brushroll chamber has an opening in a bottom side of the housing. The brushroll is operably mounted in the brushroll chamber. The brushroll includes an agitator body with a first end, a second end opposite the first end, and a longitudinal axis that extends through the first end and the second end. The agitator body is rotatable about the longitudinal axis and includes a first and a second concentric annular protrusion on the first end, extending along the longitudinal axis. The cleaning head further includes a bearing in rotatable communication with the first end of the agitator body. The end cap retains the bearing and is removable mounted to the housing, positioning the first end of the brushroll in the brushroll chamber. The end cap includes an outer side facing away from the agitator body and an inner side facing the first end of the agitator body. The inner side includes a first and a second concentric annular rib. The first and the second annular ribs and the first and the second annular protrusions overlap, so as to form a plurality of annular recesses between the adjacent annular ribs and the annular protrusions. An outermost annular recess is formed between the first annular rib and the first annular protrusion. The cleaning head includes a plurality of agitating members extending along the agitator body between the first end and the second end extend through the opening. A deformable member extends from the agitator body transverse to the longitudinal axis and is positioned along a circumference of the agitator body between the plurality of agitating members and the end cap. The deformable member is positioned adjacent the outermost annular recess and configured to inhibit debris from encountering the outermost annular recess.

[0004] In another embodiment a cleaning head for a floor cleaner is disclosed including a housing, a brushroll chamber, and a brushroll. The brushroll chamber has an opening in a bottom side of the housing. The brushroll is operably mounted in the brushroll chamber. The brushroll includes an agitator body extending between a first end and a second end opposite the first end. The agitator body includes a plurality of agitating members extending through the opening and configured to contact a surface to be cleaned. The agitating members include a vane extending longitudinally along the agitator body. The vane is connected to the agitator body along a first vane edge and a second vane edge such that the vane forms a loop extending outwardly from the agitator body. The vane includes a plurality of apertures along the longitudinal direction, aligning with a corresponding plurality of bristle holes in the agitator body under the loop. A row of bristles extending from the plurality of bristle holes in the agitator body through the corresponding plurality of apertures aligned therewith. The bristles are configured to contact the surface to be cleaned.

[0005] A cleaning head for a floor cleaner comprising a housing, a brushroll chamber, a brushroll assembly. The brushroll assembly is mounted in the brushroll chamber. The brushroll assembly includes an agitator body and a cleaning member coupled to the agitator body between a first end and a second end. The cleaning member includes a plurality of cylindrical portions extending outwardly from the agitator body spaced in a longitudinally extending pattern along the agitator body. Each cylindrical portion is connected to the adjacent spaced cylindrical portion by a webbed portion. The webbed portion extends outwardly from the agitator body.

[0006] In another embodiment a cleaning head for a floor cleaner is disclosed including a housing, a brushroll chamber, and a brushroll. The brushroll chamber has an opening in a bottom side of the housing. The brushroll is operably mounted in the brushroll chamber. The brushroll includes an agitator body extending between a first end and a second end opposite the first end. The agitator body includes a plurality of agitating members extending through the opening during operation to contact a surface to be cleaned. The agitating members include a vane extending longitudinally along the agitator body. The vane is connected to the agitator body along a first vane edge and a second vane edge such that the vane forms a loop extending outwardly from the agitator body. The vane includes a plurality of bristle receptacles integrally molded along the longitudinal direction. A row of bristles are tufted into the bristle receptacles and extending outwardly from the loop, such that the row of bristles are configured to contact the surface to be cleaned.

[0007] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig. 1 is a perspective view of a floor cleaner according to one embodiment.

[0009] Fig. 2 is another perspective view of the floor cleaner of Fig. 1.

[0010] Fig. 3 is a view of a brushroll assembly of the floor cleaner of Fig. 1.

[0011] Fig. 3a is an exploded view of the brushroll assembly of the floor cleaner of Fig. 1 showing two deformable members in a removed position.

[0012] Fig. 4 is an exploded view of the brushroll assembly of the floor cleaner of Fig. 1 showing a bearing and an end cap in a removed position.

[0013] Fig. 4a is an exploded view of an alternate brushroll assembly of the floor cleaner of Fig. 1 showing an alternate deformable member in a removed position.

[0014] Fig. 5 is a cross-sectional view through the housing and the brushroll assembly of Fig. 1.

[0015] Fig. 6 is an alternate cross-sectional view through the housing and the brushroll assembly of Fig. 1.

[0016] Fig. 7 is a cross-sectional view through the brushroll assembly of Fig. 3 showing an end cap and a bearing of the brushroll assembly.

[0017] Fig. 7a is a detail view of the cross-section of Fig. 7.

[0018] Fig. 8 is a perspective view of an alternate brushroll embodiment of the floor cleaner of Fig. 1.

[0019] Fig. 9 is a perspective view of an alternate brushroll embodiment. [0020] Fig. 10 is a perspective view of an alternate brushroll embodiment.

[0021] Fig. 11 is a schematic cross-sectional view of an alternate brushroll embodiment.

[0022] Fig. 12 is a schematic cross-sectional view of an alternate brushroll embodiment.

[0023] Fig. 13 is a schematic perspective view of the brushroll of Fig. 11, shown without bristles.

[0024] Fig. 13a is a schematic perspective view of the brushroll of Fig. 11, shown with bristles.

[0025] Fig. 14 is a perspective view of an alternate brushroll embodiment.

[0026] Fig 15 is a cross-sectional view of the alternate brushroll shown in Fig. 14.

[0027] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

DETAILED DESCRIPTION

[0028] The disclosure relates to a brushroll assembly 20 for a floor cleaner, such as a vacuum cleaner, an extractor, or the like. Figs. 1 and 2 illustrate a floor cleaner 10 The floor cleaner 10 includes a cleaning head 12 having a housing 14, a brushroll chamber 16, and a longitudinal brushroll assembly 20 The brushroll assembly 20 is rotatably mounted within the housing 14 and configured to rotate about a bearing 28 located on at least one end thereof. In one embodiment, the brushroll assembly 20 includes a deformable member 38 adjacent the bearing 28 configured to inhibit ingress of debris, hair, threads, and the like from entering the bearing 28 In the illustrated embodiment, the deformable member 38 is an annular felt material.

[0029] The brushroll chamber 16 includes an opening 18 in a bottom side of the housing 14. The brushroll assembly 20 is operably longitudinally mounted in the brushroll chamber 16 and extends through the opening 18 to contact a surface 50 to be cleaned. The brushroll assembly 20 includes an agitator body 22 that rotates relative to the housing 14 about a longitudinal axis 100. The longitudinal axis 100 extends through a first end 24 and a second send 26 of the agitator body 22. The bearing 28 facilitates rotation of the agitator body 22 about the longitudinal axis 100.

[0030] The brushroll assembly 20 further includes an end cap 30 on one or both ends of the brushroll body 22 rotationally supporting and positioning the brushroll in the brushroll chamber 16. The cleaning head 12 may include an agitator drive mechanism in the housing 14. In the illustrated embodiment, the brushroll body 22 includes one end cap 30 positioning the first end 24 of the brushroll in the brushroll chamber 16, and the drive mechanism includes a drive element 54 operably engaging the second end 26 of the agitator body 22, such as by a coaxial spline or gear drive engaging a splined recess 55 on the second end. In one embodiment, the brushroll assembly 20 includes the end cap 30 on the first end 24 and on the second end 26 and the drive element 54 operably engages the brushroll body, such as by a gear or belt. In operation, the drive mechanism drives rotation of the agitator body 22 about the bearing 28 forming the longitudinal axis 100 shown in Fig. 3. The bearing 28 may be operably mounted on the end cap 30. The agitator body 22 is rotatable to agitate, wipe, and clean the surface 50 to be being cleaned.

[0031] The agitator body 22 includes a plurality of agitating members 32. In one embodiment, the agitating members 32 include a plurality of vanes 34 and at least one row of bristles 36. The agitating members 32 extend between the first end 24 and the second end 26, and are spaced around the circumferential surface 47 of the agitator body 22, extending outwardly from the agitator body 22. In the illustrated embodiment shown in Figs. 3-6, the bristles 36 are shown schematically. Any suitable material may be used for the bristles, such as polymer bristles, fiber or rubber bristles, cloth strips or pads, beater bars, wipers, bristle strips, microfiber, and the like.

[0032] The agitator body 22 extends along the longitudinal axis 100, with the end cap 30 received on the agitator body 22 to surround the bearing 28, and the deformable member 38 positioned around a circumferential surface of the agitator body 22. The deformable member 38 is in contacting engagement with at least one of the end cap 30 and the agitator body 22, however, the deformable member 38 may be in contacting engagement with both the end cap 30 and the agitator body 22. [0033] In the illustrated embodiment, the deformable member 38 is positioned between the plurality of agitating members 32 and the end cap 30. The deformable member 38 extends radially outwardly from the agitator body 22 and is configured to inhibit the ingress of hair and debris into the bearing 28. The agitating members 32 extend from the agitator body a radial distance, and in one embodiment, the deformable member 38 extends beyond the radial distance of the agitating members 32. In one embodiment, the deformable member 38 extends through the opening 18 during operation to contact the surface 50 to be cleaned. The deformable member 38 may be composed of a felted material, tufted bristles, microfiber, felt, thermoplastic elastomeric, rubber, sponge, foam, nonwoven fabric, woven fabric, or a similar material. The deformable member 38 is compressible and configured to allow the brushroll assembly 20 to be removed out a lateral side 15 of the housing for cleaning and/or maintenance.

[0034] In one embodiment, the end cap 30 includes an outer side 53 facing away from the agitator body 22 and an inner side 51 facing the first end 24 of the agitator body. When the end cap 30 is mounted in the housing 14, the outer side 53 forms a portion of an exterior surface 57 of the housing. The inner side 51 includes a plurality of concentric annular ribs facing the first end 24. In one embodiment, there is a first concentric annular rib 64’ located radially outward of a second concentric annular rib 64”. The first end 24 of the agitator body includes a corresponding plurality of concentric annular protrusions 66 extending axially towards the end cap 30. In one embodiment, there is a first concentric annular protrusion 66’ located radially outward of a second concentric annular protrusion 66”. The first and the second annular ribs 64’, 64” are configured to overlap the corresponding first and second annular protrusions 661, 66”, so as to form a plurality of annular recesses 67 between the adjacent annular ribs and the annular protrusions. An outermost annular recess 67’ is formed between the first annular rib 64’ and the first annular protrusion 66’. The deformable member 38 is positioned adjacent the outermost annular recess 67’ and configured to inhibit debris from encountering the outermost annular recess 67’. In one embodiment, the deformable member 38 is an annular seal adjacent the first end 24 of the agitator body and adjacent the end cap 30, where the deformable member 38 is configured to inhibit debris from encountering the outermost annular recess 67’ of the end cap. In order for the deformable member 38 to effectively inhibit debris ingress to the bearing 28 or adjacent area, it is useful for the deformable member 38 to be received and retained between the plurality of agitating members 32 and the end cap 30. In the embodiment shown in Fig. 3a, the circumferential surface 47 of the agitator body 22 includes a groove or depression 37 at the first end 24 between the plurality of agitating member 32 and the end cap 30. The groove 37 is configured to receive and retain the deformable member 38 during operation of the floor cleaner 10. The groove 37 inhibits the movement of the deformable member 38 during operation, specifically movement along the longitudinal axis 100 inward, away from the end cap 30. In one embodiment, the deformable member 38 fits within the groove 37 such that the outer diameter of the deformable member 38 corresponds with the end cap 30. The deformable member 38 is attached to the agitator body in the groove 37 by friction fit, adhesive, press-fit, mechanical fasteners, or a similar mechanism.

[0035] In one embodiment schematically shown in Fig. 4a, the deformable member 38 includes an interior region and an exterior region, the interior region having a first connecting member 43 that is coupled to a second connecting member 45 on the circumferential surface 47 of the agitator body 22, retaining the deformable member 38 on the agitator body 22 in operation. In one embodiment, the interior region may be a rigid material and a deformable exterior region having a flexible elastomer coupled to the circumferential exterior forms the rest of the deformable member 38. The deformable exterior region may have a felt, foam, microfiber, or other deformable material coupled to the circumferential exterior to complete the deformable member 38.

[0036] Most of the dust, hair, and debris is drawn into a working air path of the floor cleaner 10 by a working airflow and into a dirt collection chamber 52. However, some amount of hair, string, thread, or debris can become wrapped around the brushroll assembly 20 and agitator body 22 and can eventually migrate towards the ends 24 and 26 of the agitator body 22, toward the bearing 28. The deformable member 38 acts as a barrier between the hair/debris and the bearing 28. As shown in Figs. 3 and 3a, the brushroll assembly 20 further includes a second deformable member 38’. The second deformable member 38’ extends from the agitator body 22 between the plurality of agitating members 32 and the drive element 54. The second deformable member 38’ is configured to inhibit ingress of debris into the drive mechanism. The second deformable member 38’ may be received and retained by a second groove 37’ on the agitator body 22. In one embodiment, the height of the second deformable member 38’ extending outwardly from the agitator body 22 is greater than or equal to the height of the adjacent agitating member 32 extending outwardly from the agitating body 22, such that any hair or debris wrapped around the agitating member 32 is obstructed by the second deformable member 38’ prior to reaching the drive mechanism. In the event the height of the hair or debris on the agitating member 32 exceeds the height of the second deformable member 38’, the hair or debris then may enter the drive mechanism. In the embodiment shown in Figs. 3 and 7, the height of the deformable member 38 and the second deformable member 38’ extending outwardly from the agitator body 22 is equal to or slightly less than the height of the adjacent agitating members 32. The deformable member 38 and second deformable member 38’ act as a first defense to inhibit hair and debris reaching the bearing 28 and the drive mechanism, respectively.

[0037] Hair and debris entering the end cap 30 and bearing 28 interfere with the rotation of the agitator body 22 on the bearing 28, which negatively impacts the overall cleaning performance of the floor cleaner 10 and may require service or maintenance. In one embodiment, shown in Fig. 7, there is a labyrinth seal 52 arrangement defined in the relationship between overlapping relationship of the annular ribs 64 of the end cap and the annular protrusions 66 of the agitator body. The labyrinth seal 52 creates a tortuous path to inhibit hair and debris that overcomes the deformable member 38 from entering the bearing 28 through the outermost annular recess 67’. The plurality of annular recesses 67 create space, making the path more difficult for hair and debris to reach the bearing 28. The labyrinth seal 52 arrangement between the end cap 30 and the agitator body 22 inhibits hair and debris from entering the bearing 28 or the drive element 54.

[0038] The agitator body 22 extends between the first end 24 and the second end 26 opposite the first end 24. The agitating members 32 rotate along with the agitator body 22, contacting the surface 50 through the opening 18 and facilitating surface debris pick-up. The agitator members 32 are configured to improve surface debris pick-up and reduce brushroll maintenance by inhibiting hair and debris wrap around the brushroll. In the embodiment shown in Figs. 14 and 15, the agitating members 32 include only a plurality of vanes 34. The plurality of vanes 34 inhibit hair wrap, in part, by increasing the circumference of the agitator body 22, and preventing hair and debris below a predetermined length from wrapping fully around the agitator body 22. Further, the solid nature of the vanes 34 from the first end 24 to the second end 26 create a surface that is more difficult for hair to wrap around when compared to tufted bristles with gaps between adjacent tufts. The vanes 34 can be made of rubber, nylon, vinyl, thermoplastic elastomer, nonwoven fabric, woven fabric, among other materials. The flexibility of the vanes 34 allows bending and flexing during operation, which further reduces debris wrap around the agitator body 22 by not allowing the hair and debris a stationary portion to wrap around.

[0039] In one embodiment, the plurality of vanes 34 have a first vane end 31 adjacent the first end 24 and a second vane end 33 adjacent the second end 26. The vanes 34 include a surface engaging portion 35 longitudinally extending along the agitator body 22 between the first vane end 31 and the second vane end 33. The surface engaging portion 35 promotes surface debris pick-up and inhibits hair and debris wrap around the agitator body 22. In this embodiment, the deformable member 38 is positioned between the first vane end 31 and the end cap 30 to inhibit debris from encountering the end cap 30. The second deformable member 38’ is positioned between the second vane end 33 and the drive element 54 to inhibit debris from encountering the drive element 54.

[0040] In one embodiment, the plurality of agitating members 32 wrap around the agitator body 22 between the first end 24 and the second end 26 in a helical pattern. The helical pattern can be defined by a single helix, such that all of the agitating members 32 he in a single, common helix with respect to the longitudinal axis 100. In the embodiment shown in Figs. 3 and 4, the agitating members 32 may be a plurality of vanes 34 and bristles 36 that have the same helical pattern around the brushroll assembly 20, however each having a different starting point. The congruent helical pattern of the agitating members 32 helps provide even and consistent debris pick-up, while inhibiting hair and debris wrap around the brushroll 20.

[0041] In one embodiment, the helical pattern of the plurality of vanes and the helical pattern of the bristles extend around the agitator body in opposite directions. In the embodiment illustrated in Fig. 9, the plurality of vanes 234 wrap helically approximately 180 degrees around the agitator body between the first end 224 and the second end 226 in a first direction, while the bristles 236 wrap helically approximately 360 degrees around the agitator body in a second direction, opposite the first direction. In another embodiment, the plurality of vanes 234 wrap helically between approximately 200 degrees and 400 degrees around the agitator body in the first direction, while the bristles 236 wrap helically approximately 360 degrees to 720 degrees in the second direction. A greater difference between the opposing helical patterns, i.e. where the opposing helical patterns have higher rotations about the agitator body, results in a greater intersection angle where the vanes 234 and the bristles cross 236. A greater intersection angle can be advantageous because it results in less bristles being removed due to interference with the vanes.

[0042] In the embodiment shown in Fig. 8, the vanes 34 define a constant helical pattern about the agitator body 22 from the first end 24 to the second end 26, and the one or more rows of bristles 36 define an oscillating or variable pattern about the agitator body 22 from the first end 24 to the second end 26. The oscillating pattern of the bristles 36 extends between two adjacent vanes 34. This oscillating pattern allows for a variable distance between the row of bristles 36 and the adjacent vanes 34, which can result in improved cleaning and reduced wrapping of hair and debris around the agitator body 22. Further, it has been found that hair and debris wrap is most prevalent in the space between adjacent tufted bristles. Having bristles with an oscillating pattern creates a more angled path for hair and debris to get embedded in the space between adjacent bristles, thus making for a more difficult path and reducing hair and debris wrap around the agitator body 22.

[0043] In the embodiment shown in Fig. 10, an agitator body 322 has two or more cleaning members 332 extending between a first end 324 and a second end 326 of the agitator body 322. The cleaning members 332 includes a plurality of spaced cylindrical portions 336 between the first end 324 and the second end 326 that are connected by a webbed portion 334. The spaced cylindrical portions 336 provide agitation to the surface 50 to be cleaned to enhance debris pick-up, while the webbed portion 334 inhibits hair, threads, and debris from becoming wrapped between the cylindrical portions 336, and around the agitator body 322. The cleaning members 332 may be elastomeric, vinyl, or any suitable material. This arrangement has been found to increase the time between required cleaning and maintenance, while providing desired surface debris pick-up.

[0044] In the embodiment shown schematically in Figs. 11-13, the brushroll assembly 420 has a plurality of couplers 440a, 440b circumferentially arranged on a circumferential surface of the agitator body 422, extending axially along the agitator body 422. A first cleaning vane434 has a longitudinal first edge 434a and a longitudinal second edge 434b.

The first edge 434a and the second edge 434b of the cleaning vane 434 slidably connect to a corresponding first coupler 440a and second coupler 440b of the plurality of couplers 440. In the embodiment illustrated in Fig. 13, the cleaning vane 434 covers the length of the agitator body 422, however, in other embodiments, the cleaning vane 434 covers only a portion of the length of the agitator body 422. In one embodiment, the first end 434a and the second end 434b of the cleaning vane 434 are integrally molded with the first coupler 440a and second coupler 440b, respectively. When the first and second ends 434a and 434b are coupled to the agitator body, the first cleaning vane 434 forms a loop 435 between the longitudinal edges that extends outwardly away from the agitator body 422. In one embodiment, the cleaning vane 434 includes a plurality of holes 442 extending through the cleaning vane 434 between the first edge 434a and the second edge 434b. A row of bristles 436 may be tufted through the plurality of holes 442 in the cleaning vane 434 and attached to a corresponding plurality of bristle holes 437 on the agitator body 422 (Fig. 11). In the embodiment shown in Fig. 12, a plurality of bristle receptacles 439 are integrally molded with the cleaning vane 434 along the length of the cleaning vane. The row of bristles 436 are tufted into the bristle receptacles 439. The bristle receptacles 439 secure and retain the bristles 436. In this embodiment, the bristles 436 and bristle receptacles 439 are separate and apart from the agitator body 422.

[0045] The first cleaning vane 434 may be composed of an elastomeric material, vinyl, woven fiber or a similar material. The flexibility of the first cleaning vane 434 material increases durability and longevity of the cleaner. Further, the flexibility of the first cleaning vane 434 allows the cleaner to flex and bend during operation, which reduces debris wrap around the agitator body 422 by not allowing the hair and debris a stationary portion to wrap around. The row of bristles 436 provide agitation to the surface 50 to be cleaned to improve cleaning performance and debris pick-up. The loop 435 of the first cleaning vane 434 increases the circumference of the agitator body 422. By increasing the circumference of the agitator body 422, fewer hairs are able to wrap entirely around the agitator body 422, resulting in less overall hair, thread, and debris wrap. Additionally, the agitator body 422 may include secondary cleaning members 444 configured to further enhance debris pick-up and inhibit debris and hair wrap around the agitator body 422. The secondary cleaning members 444 may be composed of the same material as the first cleaning vane 434, or a different material.

[0046] In the embodiment shown in Figs. 5 and 6, the housing 14 further includes an extending portion or protrusion 56 directed inwardly towards the agitator body 22. The extending portion or protrusion 56 may extend from a central location of the housing 14, as shown in Figs. 5 and 6, however the protrusion may extend anywhere in the housing 14 between the first end 24 and the second end 26. The extending portion 56 is configured to contact the surface engaging portion 35 of the agitating members. The extending portion 56 provides a flicking-type action to the agitating members 32 to inhibit hair and debris wrap around the agitator body 22. The flicking action inhibits hair and debris wrap primarily by creating vibration and movement of the agitating members 32 that then vibrate and move the hair and debris, facilitating removal through a suction opening 58. Another beneficial aspect of the flicking action by the extending portion 56 is the direct contact with the hair and debris. This direct contact helps inhibit the hair and debris from becoming tightly wound around the agitator body 22. In the illustrated embodiment, the extending portion 56 is positioned adjacent the suction opening 58 to facilitate the uptake of the dislodged hair and debris into the working air path. In one embodiment, the extending portion 56 has a length along the brushroll axis in the longitudinal direction between 3 and 25 millimeters contacting the surface engaging portion 35 of the vane as the vane rotates past the extending portion 56 in operation. In other embodiments, the extending portion 56 has a length in the longitudinal direction of between 25 and 50 millimeters contacting the surface engaging portion 35 of the vane as the vane rotates past the extending portion 56 in operation. By facilitating removal and inhibition of hair wrap around the agitator body 22, the extending portion 56 also inhibits hair and debris overcoming the deformable member 38 and entering the bearing 28.

[0047] Various features and advantages of the invention are set forth in the following claims.