U.S. patent application number 10/061768 was filed with the patent office on 2003-08-07 for two-piece brushroll.
This patent application is currently assigned to Royal Appliance Mfg. Co.. Invention is credited to Cipolla, Mark E., Stephens, Paul D..
Application Number | 20030145424 10/061768 |
Document ID | / |
Family ID | 27658490 |
Filed Date | 2003-08-07 |
United States Patent
Application |
20030145424 |
Kind Code |
A1 |
Stephens, Paul D. ; et
al. |
August 7, 2003 |
Two-piece brushroll
Abstract
A brushroll for a vacuum cleaner includes a roll body with a
first end, a second end and a rotational axis. A first bore extends
from the first end to the second end along the rotational axis. The
roll body further includes a first connecting element located at
the roll body second end. The brushroll further has a pulley
including a first end, a second end and a rotational axis. A second
centrally positioned bore extends from the pulley first end to the
pulley second end along the pulley rotational axis. The pulley
further includes a second connecting element located at the pulley
first end for engaging the first connecting element. A shaft
extends through the first and second bores. At least one bearing is
mounted on the shaft and rotatably mounts at least one of the roll
body and the pulley to the shaft.
Inventors: |
Stephens, Paul D.;
(Twinsburg, OH) ; Cipolla, Mark E.; (Chardon,
OH) |
Correspondence
Address: |
Jay F. Moldovanyi, Esq.
Fay, Sharpe, Fagan, Minnich & McKee, LLP
1100 Superior Avenue, 7th Floor
Cleveland
OH
44114-2518
US
|
Assignee: |
Royal Appliance Mfg. Co.
|
Family ID: |
27658490 |
Appl. No.: |
10/061768 |
Filed: |
February 1, 2002 |
Current U.S.
Class: |
15/392 ;
15/383 |
Current CPC
Class: |
A47L 5/30 20130101 |
Class at
Publication: |
15/392 ;
15/383 |
International
Class: |
A47L 005/30 |
Claims
Having thus described the preferred embodiment, the invention is
now claimed to be:
1. A roll assembly for use in a vacuum cleaner, comprising: a
housing; an elongated roll body and an agitator extending radially
away from the roll body; and a pulley section mounted to one end of
the elongated roll body wherein the roll body and the pulley
section are rotatably mounted to the housing.
2. The roll assembly as claimed in claim 1, wherein the pulley
section comprises a relatively hard, wear-resistant material.
3. The roll assembly as claimed in claim 1, wherein the elongated
roll body comprises a polypropylene material and the pulley section
comprises a glass-filled polypropylene material.
4. The roll assembly as claimed in claim 1, wherein the agitator
comprises at least one set of bristle tufts mounted on an outer
surface of the elongated roll body.
5. The roll assembly as claimed in claim 4, wherein the at least
one set of bristle tufts extends in a helical manner along a
longitudinal axis of the elongated roll body.
6. The roll assembly as claimed in claim 1, wherein the elongated
roll body includes a throughhole extending along a longitudinal
axis of said roll body and the pulley section includes a
throughhole extending along a longitudinal axis of said pulley
section, and further comprising a shaft disposed in said
throughholes and supported in said housing adjacent one end of the
roll body and adjacent one end of the pulley section.
7. The roll assembly as claimed in claim 6, further comprising
annular bearings connecting the shaft to the roll body.
8. The roll assembly as claimed in claim 1, further comprising: a
first threaded area located adjacent one end of said roll body; and
a second threaded area located adjacent one end of said pulley
section, wherein said first and second threaded areas cooperate to
allow said pulley section to be mounted on said roll body.
9. A roller assembly for use in a suction cleaner, comprising: a
housing having a suction opening; and a roller mounted adjacent
said suction opening, said roller comprising: an elongated roller
body comprising a first material; and a pulley section comprising a
second material, said pulley section being axially connected to the
elongated roller body.
10. A roller assembly as claimed in claim 9, wherein the second
material comprises a relatively hard, wear-resistant material.
11. The roller assembly as claimed in claim 9, wherein in the first
material comprises a polypropylene material and a second material
comprises a glass-filled polypropylene material.
12. The roller assembly as claimed in claim 9, wherein the
elongated roller body is threadedly connected to the pulley.
13. The roller assembly as claimed in claim 9, further comprising
an agitator carried on an outer surface of the elongated roller
body.
14. The roller assembly as claimed in claim 9, wherein the
elongated roller body and the pulley section together define a
central through hole extending along a longitudinal axis of the
roller brush, and further comprising a shaft disposed in said
through hole and supported in said housing at opposed ends of said
shaft.
15. The roller assembly as claimed in claim 14, further comprising
at least two annular bearings which mount at least one of the
roller body and the pulley section on said shaft.
16. The roller assembly as claimed in claim 13, wherein said
agitator comprises at least one bristle tuft carried on at least
one of said roller body and said pulley section.
17. A brushroll for a vacuum cleaner comprising: a roll body
including a first end, a second end and a rotational axis, wherein
a first bore extends from said first end to said second end of said
roll body along said rotational axis, and further including a first
connecting element located at said roll body second end; a pulley
section including a first end, a second end and a pulley rotational
axis, wherein a second centrally positioned bore extends from said
first end to said second end of said pulley section along said
pulley rotational axis, and further including a second connecting
element located at said pulley first end for engaging said first
connecting element; a shaft extending through said first and second
bores; and at least one bearing mounted on said shaft and rotatably
positioning said roll body and said pulley on said shaft.
18. The brushroll of claim 17 wherein the first connecting element
comprises one of an internally threaded female connector and an
externally threaded male connector and wherein the second
connecting element comprises the other of the internally threaded
female connector and the externally threaded male connector.
19. The brushroll of claim 17 wherein the at least one bearing
comprises a first annular bearing located adjacent said roll body
first end for rotatably mounting said shaft to said roll body and a
second annular bearing located adjacent said pulley second end for
rotatably mounting said shaft to said pulley.
20. The brushroll of claim 17 further comprising at a pair of end
caps for connecting the shaft to a vacuum cleaner housing.
21. The brushroll of claim 17 wherein the pulley section is
constructed from a harder material than is a material of the roll
body.
22. The brushroll of claim 17 further comprising at least one
bearing support for connecting said at least one bearing to one of
said roll body and said pulley.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates in general to suction
cleaners. More particularly, the invention relates to an improved
rotary brushroll assembly for mounting in a suction inlet of a
suction cleaner, such as a vacuum cleaner, and will be described
with particular reference thereto. However, it is to be appreciated
that the present invention may also be amenable for other
applications.
[0002] The use of rotary brushrolls in cleaning apparatus such as
vacuum cleaners is well known. Prior art vacuum cleaner brushrolls
generally include an elongated cylindrical roll body rotatably
supported in various constructions at either end by bearings
connected to adjacent sides of a vacuum cleaner suction opening.
The roll body is rotated by a belt operably connected to a vacuum
cleaner motor. The motor driven belt rotates the brushroll to
dislodge dirt and debris on a surface to be cleaned allowing
permanent removal of the dislodged dirt and debris by appropriate
air suction into the suction opening.
[0003] More specifically, the brushroll body carries on its outer
surface an array of tufted bristles or tufts extending radially
outward from the outer surface. The tuft array is distributed
regularly about the periphery of the roll body to balance the
moments of inertia about the roll body axis. As the roll body
rotates, the tufts contact the surface, such as a carpet, and
loosen dirt or debris from carpet fibers. The tufts are generally
mounted in a helical pattern to better facilitate this removal of
debris from the carpet fibers as the vacuum cleaner moves over the
carpet surface. Suction within the suction opening then moves the
loosened dirt and debris to a filter/storage area of the vacuum
cleaner.
[0004] Previously, wooden dowels were used for brushrolls. Now,
many manufactures have switched to plastic. The prior art plastic
brushroll bodies are each often fabricated as a single, unitary
piece from a relatively expensive plastic material using
conventional manufacturing techniques, such as injection molding,
for durability. If an inexpensive type of plastic were used, the
brushrolls would function properly initially but after extended use
the portion of the brushroll body that is contacted by the motor
driven belt would degrade. Eventually this degradation can cause
the engagement between the belt and the brushroll to fail thereby
disabling the rotation function of the brushroll.
[0005] Thus, there remains a need for a brushroll that remains
reliable over an extended use period while continuing to be
relatively simple and inexpensive to fabricate, assemble, and
operate. The present invention provides a new and improved
brushroll for use in a vacuum cleaner for overcoming the
above-referenced drawbacks and others.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, a new and improved
roll assembly for use in a vacuum cleaner is provided.
[0007] More particularly in accordance with this aspect of the
invention, the roll assembly comprises a housing, an elongated roll
body and an agitator extending radially away from the roll body,
and a pulley section mounted to one end of the elongated roll body
wherein the roll body and the pulley section are rotatably mounted
to the housing.
[0008] According to another aspect of the present invention, a new
and improved roller assembly for use in a suction cleaner is
provided.
[0009] More particularly in accordance with this aspect of the
invention, the roller assembly comprises a housing having a suction
opening and a roller mounted adjacent the suction opening. The
roller comprises an elongated roller body comprising a first
material and a pulley section comprising a second material. The
pulley section is axially connected to the elongated roller
body.
[0010] According to still another aspect of the present invention,
a new and improved brushroll for a vacuum cleaner is provided.
[0011] More particularly in accordance with this aspect of the
invention, the brushroll comprises a roll body including a first
end, a second end and a rotational axis. A first bore extends from
the first end to the second end of the roll body along the
rotational axis. The roll body further includes a first connecting
element located at the roll body second end. The brushroll further
comprises a pulley section including a first end, a second end and
a pulley rotational axis. A second centrally positioned bore
extends from the pulley first end to the pulley second end of the
pulley section along the pulley rotational axis. The pulley further
includes a second connecting element located at the pulley first
end for engaging the first connecting element. A shaft extends
through the first and second bores. At least one bearing is mounted
on the shaft and rotatably positions the roll body and the pulley
on the shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention may take physical form in certain parts and
arrangements of parts, a preferred embodiment of which will be
described in detail in this specification and illustrated in the
accompanying drawings which form a part hereof and wherein:
[0013] FIG. 1 is a bottom plan view of a vacuum cleaner showing a
brushroll assembly mounted in a suction opening of the vacuum
cleaner in accordance with the present invention;
[0014] FIG. 2 is an exploded perspective view of a mirror image of
the brushroll assembly of FIG. 1 showing a roll body, a pulley, and
a pair of mounting assemblies;
[0015] FIG. 3 is an enlarged exploded side elevational view of the
brushroll assembly of FIG. 2 showing a pulley end thereof;
[0016] FIG. 4 is an assembled cross-sectional view of the pulley
end of FIG. 3;
[0017] FIG. 5 is an enlarged exploded side elevational view of the
brushroll assembly of FIG. 2 showing a roll body end thereof;
and
[0018] FIG. 6 is an enlarged assembled cross-sectional view of a
portion of the roll body end of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring now to the drawings wherein the showings are for
purposes of illustrating the preferred embodiment of the invention
only and not for purposes of limiting the same, FIG. 1 shows the
underside of a vacuum cleaner A having a main suction opening B
formed therein. The vacuum cleaner A comprises a filter chamber
(not shown) for separating dust and dirt from a suction air stream
and a suction source (not shown) in fluid communication with the
main suction opening B. A brushroll assembly 10 is operatively
mounted for rotation within the suction opening B. A selectively
moving motor-driven belt C frictionally engages a portion of the
brushroll assembly 10 providing a means for rotating the brushroll
assembly 10. While the vacuum cleaner A is of an upright type, it
should be appreciated by those of average skill in the art that the
present invention described and illustrated herein could also be
employed for use on remote nozzle vacuum cleaners such as canister
vacuum cleaners, wet/dry vacuums and central vacuums which can
employ a rotating brushroll as well as carpet extractors and
hand-held vacuum cleaners and in a variety of other brushroll type
cleaners.
[0020] With reference now to FIG. 2, the brushroll assembly 10
comprises a brushroll 12 including an elongated roll body 14
threadedly connected to a pulley section 16. A shaft 18 extends
through both the roll body 14 and the pulley section 16, since they
are both hollow. A pair of substantially identical end mounting
assemblies 20, 22 accommodate the ends of the shaft 18 and allow
the brushroll 12 to be rotatably mounted. Each end assembly 20, 22
is operably connectable with a respective brushroll mounting
structure (not shown) in the vacuum cleaner suction opening B (FIG.
1). The generally tubular brushroll 12 receives the shaft 18
therethrough. A first, pulley end 24 of the brushroll 12 connects
to the first, pulley end assembly 20. A second, roll body end 26
connects to the second, roll body end assembly 22. The shaft 18
connects between the end assemblies 20, 22 and defines a brushroll
rotational axis 28 along the brushroll 12 between its first and
second ends 24, 26.
[0021] More specifically, the roll body 14 includes a first roll
body end 30 and, axially opposite, a second roll body end 32 that
is the same as the second brushroll end 26. The roll body 14 is
formed as an elongated tube-like structure having an outer surface
34 and a coaxially cylindrical inner surface 36. The inner surface
36 runs completely through the length of the roll body 14 defining
a throughhole 38 (FIG. 6) therein for receiving the shaft 18. Thus,
the throughhole 38 extends from the first roll body end 30 to the
second roll body end 32 along the brush roll rotational axis 28.
With reference now to FIG. 5, at the second roll body end 32, a
raised lip 40 extends radially outward around the circumference of
the roll body 14.
[0022] With additional reference to FIG. 2, the roll body 14
includes an agitator means which can be a pair of brush tufting
arrays 50, 52 extending radially outwardly from the outer surface
34 of the roll body 14 and spiral in a helical manner along the
length of the roll body 14. Of course, other types of conventional
agitation means, such as beater bars, or the like could also
protrude radially from a dowel instead of bristle tufts. In the
embodiment illustrated, the brush tufting arrays 50, 52 are
positioned one-hundred and eighty degrees apart from each other.
The tufting arrays may include gaps 53 extending around the
circumference of the roll body 14 to accommodate structural
elements extending across the suction opening B (FIG. 1). Further,
with specific reference to FIG. 5, each pair of brush tufting
arrays 50, 52 may be mounted on a raised portion 54 of the outer
surface 34 and has a plurality of tufts 56 extending therefrom. The
brush tufts 56 may be attached to the raised portion 54 by any
known conventional means. During rotation of the brushroll 12, the
brush tufting arrays 50, 52 are effective to loosen and pick up
dirt and debris from a surface, such as carpeting, which is to be
cleaned by the vacuum cleaner A.
[0023] With reference to FIG. 4, a first connecting element 58 is
provided adjacent the first roll body end 30. The connecting
element 58 can be a counterbore 60 immediately adjacent the first
roll body end 30 and a set of internal threads 62 defined along a
portion of the inner surface 36 near the first roll body end 30 and
immediately adjacent the counterbore 60. With reference to FIG. 6,
an angled mating surface 42 is provided for engagement with one of
the end assemblies 22 at the second roll body end 32. Adjacent the
angled mating surface 42, an axial flange 44 is provided.
[0024] With reference to FIG. 3, the pulley section 16 includes a
first pulley end 64 that is the same as the brushroll end 20.
Axially opposite the first pulley end 64, the pulley section 16
includes a second pulley end 66. Similar to the roll body 14, the
pulley section 16 is formed as a tube-like structure and includes a
raised lip 67 extending radially outward around the circumference
of the pulley section 16. With reference to FIG. 4, the pulley
section 16 includes an inner surface 68 and a generally coaxially
cylindrical outer surface 70. The inner surface 68 extends along
the length of the pulley section 16 defining a throughhole 72
therein. However, unlike the roll body 14, the elongation of the
pulley section 16 is abbreviated. Further, with additional
reference to FIG. 3, the pulley section 16 includes three unique
sections, a tuft section 74, a belt section 76, and a connector
section 78.
[0025] The tuft section 74 includes a pair of pulley brush tufting
arrays 80, 82 extending radially outwardly from the pulley outer
surface 70 along the longitudinal length of the tuft section 74 and
helically relative to the brushroll rotational axis 28. Like the
roll body 14, each of the pulley brush tufting arrays 80, 82 is
positioned one-hundred and eighty degrees relative to each other
and each of the pair of pulley brush tufting arrays 80, 82 includes
a raised portion 84 relative to the outer surface 70 with a
plurality of tufts 86 extending therefrom. The tufts 86 are
attached to the raised portion 84 in the manner described above in
reference to the roll body tufting 56. The tuft section 74 carrying
the array of brush tufting 80, 82 is adjacent the first pulley end
64. With reference to FIG. 4, a second angled mating surface 98 is
provided for engagement with the other of the end assemblies 20 at
the first pulley end 64. Ajacent the angled mating surface 98, an
axial flange 99 is provided.
[0026] With reference again to FIG. 3, the connector section 78
includes a second connecting element 88 located adjacent the pulley
section second end 66 for engaging the first connecting element 58
of the roll body 14. With additional reference to FIG. 4, the
second connecting element 88 includes a nose portion 90 for
engaging the inner surface 36 of the roll body 14, an externally
threaded portion 92 for threaded engagement with the internal
threads 62 defined on the roll body inner surface 36, and a raised
portion 94 for mating engagement with the counterbore 60 of the
roll body 14. When the pulley section 16 and the roll body 14 are
threadedly engaged to one another, the first roll body end 30 mates
with a radial edge 96 of the pulley section 16 and the respective
outer surfaces 34, 70 of the pulley section 16 and the roll body 14
are circumferentially flush or contiguous with one another near the
mated engagement of the radial edge 96 and the first roll body end
30.
[0027] With specific reference to FIG. 3, the belt engaging section
76 extends along a central portion of the outer surface 70 between
the tuft section 74 and the connector section 78 and around the
entire circumference of the pulley section 16. As shown in FIG. 4,
the belt engaging section 76 is thickened and adapted to be
frictionally engaged by the belt C (FIG. 1) of the vacuum cleaner
A. As discussed above, the belt C is selectively motor driven and,
through the frictional engagement with the belt section 76, rotates
the pulley section 16, and hence the entire brushroll 12, when
actuated.
[0028] When the pulley section 16 and the roll body 14 are
connected to one another, the pulley throughhole 72 and the roll
body throughhole 38 together form a single, elongated brushroll
throughhole extending along the entire length of the brushroll and
concentric with the brush roll rotational axis 28. The shaft 18 is
received through the brushroll throughhole 38, 72 for operatively
supporting the brushroll 12 within the suction opening B of the
vacuum cleaner A (FIG. 1). More specifically, the brushroll 12 is
connected to the shaft 18 by the end assemblies 20, 22 and together
the shaft 18 and the end roll assemblies 20, 22 operatively and
rotatably support the brushroll 12 in the suction opening B.
[0029] With reference to FIG. 2, the mounting assemblies 20, 22
each include an annular bearing 100, a bearing support 102, and an
end cap 104. With additional reference to FIGS. 4 and 6, each
annular bearing 100 is fitted onto the shaft 18 and positioned near
an end thereof. The engagement between the shaft 18 and the annular
bearing 100 may be characterized as frictional and nonrotational.
Each bearing support 102 connects between the bearing 100 and the
brushroll 12. More specifically with reference to FIG. 4, the
bearing support 102 is positioned at the first end 24 of the
brushroll 12 and connects between the respective bearing 100 and
the pulley section 16. With reference to FIG. 6, the bearing
support 102 is positioned at the second end 26 of the brushroll 12
and connects between the respective bearing 100 and the roll body
14.
[0030] With reference to FIGS. 4 and 6, each bearing support 102
includes a nose 106 for engagement with either the inner surface 36
of the roll body 14 at the second brushroll end 26 or the inner
surface 68 of the pulley section 16 at the first brushroll end 24.
The nose extends in a direction parallel to the brushroll
rotational axis 28 (FIG. 2). An angled surface 108 extends radially
outwardly from the nose 106 and mates with respective first and
second mating surfaces 42, 98 of the roll body 14 and the pulley
section 16. A thread-retarding flange 110 extends from the axially
distal end of the angled surface 108 and parallel to the nose 106.
The thread retarding flange 110 extends axially a dimension
sufficient to retard thread and like string material from
undesirably becoming wound on the shaft 18.
[0031] The end of the shaft 18 and the corresponding thread
retarding flange 110 rotatably engage or mount into a respective
end cap 104. The end caps 104 are securely received within the ends
of the suction opening B (FIG. 1) and serve as holding devices for
the shaft 18 and the brushroll 12. The end caps 104 each include a
centrally positioned cup 114 generally concentric with the
brushroll rotational axis 28 (FIG. 2). The cups 114 each receive an
end of the shaft 18 and prevent radial movement of the shaft 18
relative to the end cap 104. The pair of cups 114, one at each end
of the shaft 18, together prevent axial movement of the shaft 18
relative to the opposing, pair of end caps 104 and the suction
opening B. The end caps 104 also each include an outer annular cup
116 for receiving the thread retarding flange 110 of the respective
bearing supports 102. Together, the annular cup 116 and the flange
110 form a labyrinth seal. The outer annular cups 116 are axially
shorter relative to the cups 114 but are concentric therewith.
[0032] Prior art brushrolls were commonly formed as a single
unitary piece of wood. More recently, plastic has become the
material of choice. It has been found, however, that the frictional
engagement between the vacuum belt C and the pulley portion of a
prior art brushroll often caused a significant amount of wear on
the pulley portion and premature failure thereof. To prevent such
failure, brushrolls could be constructed of a more wear resistant
material, such as glass-filled polypropylene, which is known to
have increased wear resistance as compared to softer plastics.
However, manufacturing an entire brushroll of glass-filled
polypropylene can be rather expensive and may be cost
prohibitive.
[0033] Therefore, the present invention provides a two-piece
brushroll 12 wherein the roll body 14 may be constructed of
conventional, softer, less expensive plastic materials, such as
polypropylene, and only the pulley section 16 may be made of a
relatively hard, wear-resistant, more expensive material, such as a
glass-filled polypropylene material. Conventional manufacturing
techniques, such as injection molding, may be employed to make the
roll body 14 and the pulley section 16.
[0034] As discussed above, the pulley section 16 includes the male
threaded portion 92 that threadedly engages the female threads 62
of the roll body 14. In this arrangement, the glass-filled
polypropylene pulley section 16 which includes a belt engaging
section 76 is able to withstand the increased wear caused by
engagement with the vacuum belt C. However, the increased material
and manufacturing costs associated with the more wear resistant
material, in this case a glass-filled polypropylene material, are
not added to the entire brushroll 12. Rather, the more expensive
material is used only in the region of the brushroll 12 requiring
increased wear resistant properties.
[0035] It should be appreciated by those of average skill in the
art that other materials can be used to manufacture or form the
pulley section 16 and the roll body 14. One of the features of this
invention is the use of differing materials for the brushroll 12 to
increase the wear resistance to belt-wear of the brushroll 12 in
the area of the brushroll 12 that is engaged to the belt C. Another
feature of this invention is the use of differing materials in a
brushroll 12 to limit or lessen both the material and manufacturing
costs associated with making the brushroll 12 more wear resistant.
Accordingly, other materials could be used to achieve similar
results and all such combinations of materials are to be considered
within the scope of the present invention.
[0036] Yet another feature of this invention is the use of multiple
components threadedly connected to one another, in this case the
roll body 14 and the pulley section 16. Although the embodiment
herein described includes a pulley section 16 having a male
threaded portion 92 and a roll body 14 having female threads 62 for
threadedly connecting to the male threaded portion 92, the male and
female threaded relationship could be reversed. Preferably, in
either arrangement, the threading relationship is such between the
roll body 14 and the pulley section 16 that as the brushroll 12 is
rotated, the roll body 14 and the pulley section 16 are spun into
closer engagement with each other, rather than being spun away from
each other.
[0037] Furthermore, it should also be appreciated by those of
average skill in the art that other means of connecting the pulley
section 16 and the roll body 14 can be used. For example, the
pulley section 16 and the roll body 14 can be connected by a press
fit connection wherein one of the pulley section 16 and the roll
body 14 is pressed into the other of the pulley section 16 and the
roll body 14. Also, adhesives could be used to connect the
components 14, 16, or a fusion process could be used to weld the
roll body 14 and the pulley section 16 together. These and other
known connecting means are to be considered within the scope of the
present invention.
[0038] The invention has been described with reference to a
preferred embodiment. Obviously, modifications and alterations will
occur to others upon reading and understanding the preceding
detailed description. It is intended that the invention be
construed as including all such modifications and alterations
insofar as they are within the scope of the appended claims or the
equivalents thereof.
* * * * *