U.S. patent application number 11/414791 was filed with the patent office on 2006-08-31 for agitator construction.
Invention is credited to Eric E. Muhlenkamp, Jeffrey T. Roney.
Application Number | 20060191123 11/414791 |
Document ID | / |
Family ID | 23083453 |
Filed Date | 2006-08-31 |
United States Patent
Application |
20060191123 |
Kind Code |
A1 |
Roney; Jeffrey T. ; et
al. |
August 31, 2006 |
Agitator construction
Abstract
An agitator includes a high strength, continuous metal axle, a
pulley held on one end of the metal axle and a sleeve of
lightweight plastic material received over the axle. The agitator
is manufactured by molding a pulley body onto an underlying metal
support or D-nut, fitting an axle into the pulley, molding a sleeve
around the axle and securing a cleaning structure on the
sleeve.
Inventors: |
Roney; Jeffrey T.;
(Stanford, KY) ; Muhlenkamp; Eric E.; (Danville,
KY) |
Correspondence
Address: |
KING & SCHICKLI, PLLC
247 NORTH BROADWAY
LEXINGTON
KY
40507
US
|
Family ID: |
23083453 |
Appl. No.: |
11/414791 |
Filed: |
May 1, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10433851 |
Jun 5, 2003 |
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PCT/US02/11291 |
Apr 10, 2002 |
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11414791 |
May 1, 2006 |
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60282865 |
Apr 10, 2001 |
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Current U.S.
Class: |
29/527.1 ;
15/383; 29/428 |
Current CPC
Class: |
Y10T 29/49563 20150115;
Y10T 29/49826 20150115; A46B 2200/3066 20130101; A46B 13/001
20130101; A47L 9/04 20130101; Y10T 29/4998 20150115; A47L 9/0455
20130101 |
Class at
Publication: |
029/527.1 ;
029/428; 015/383 |
International
Class: |
B21B 1/46 20060101
B21B001/46; B21D 39/03 20060101 B21D039/03; A47L 5/26 20060101
A47L005/26 |
Claims
1-14. (canceled)
15. A method of manufacturing an agitator comprising: molding a
pulley onto a metal support; fitting an axle into the pulley; and
molding a sleeve around the axle.
16. The method of claim 15 including securing a cleaning structure
on the sleeve.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/282,865 filed Apr. 10, 2001.
TECHNICAL FIELD
[0002] This invention relates to vacuum cleaners, extractors and
the like and, more particularly, to an agitator for use in such
cleaning equipment.
BACKGROUND OF THE INVENTION
[0003] Upright vacuum cleaners, extractors and canister vacuum
cleaners with power nozzles incorporating rotary agitators are
presently manufactured and marketed by a number of different
companies. The agitators carry cleaning structures such as rubber
wipers, beater bars, brushes and tufted bristles to brush or beat
dirt and debris from an underlying surface such as a carpet being
cleaned.
[0004] The rotary agitators are rotated quickly at speeds up to
2,500-6,500 rpm and through engagement with the underlying carpet,
are subjected to significant sheer forces. As such, the agitators
must have relatively high inherent strength to withstand operation
over an extended service life.
[0005] The present invention relates to a relatively low profile
agitator constructed to have the necessary strength to reliably and
dependably function over a long service life. Such a low profile
agitator may, advantageously, be incorporated into a low profile
nozzle assembly of an upright vacuum cleaner, power head or
extractor which is capable of cleaning under overlying obstacles
such as the projecting margin of built-in bathroom and kitchen
cabinets or furniture such as beds, dressers and the like.
SUMMARY OF THE INVENTION
[0006] In accordance with the purposes of the present invention as
described herein, an improved agitator is provided for use in
upright vacuum cleaners, extractors and power nozzles of canister
vacuum cleaners or the like. The agitator includes a high strength,
continuous metal axle, a pulley held on one end of the metal axle
and a sleeve of lightweight plastic material received over the
axle. The sleeve carries a cleaning structure which may, for
example, be selected from a group consisting of a beater bar, a
brush, tufted bristles, a wiper and combinations thereof.
[0007] The sleeve may be cylindrical in shape and have a diameter
no greater than about 22.00 mm. The axle may have a diameter of
between about 4.00 mm to about 8.00 mm. In this way the axle acts
as a high strength backbone for the sleeve while the sleeve has the
necessary thickness to receive and securely hold the cleaning
structures. Advantageously, the total construction has a low
profile thereby allowing installation in even the most low profile
nozzle assemblies, power heads or extractors.
[0008] The pulley includes a hub for securing to the axle. The
pulley also includes a metal D-nut for engaging a stub shaft of a
drive gear typically carried on the nozzle assembly, power head or
housing of the vacuum cleaner or extractor to which the agitator is
mounted. Still further the pulley includes a pair of projecting box
ribs and the sleeve includes a pair of projecting flanges for
receiving and engaging the box ribs. The sleeve also includes a
collar and a pair of projecting lugs for engaging in the pair of
box ribs. Together, the hub, projecting box ribs, collar, flanges
and lugs provide an interlocking structure for securely fixing the
pulley on the axle.
[0009] In accordance with yet another aspect of the present
invention, a method of manufacturing an agitator is provided. The
method includes the molding of a pulley onto a D-nut. This is
followed by the step of fitting an axle into the pulley. Next is
the step of molding a sleeve around the axle. Then comes the step
of securing a cleaning structure on the sleeve.
[0010] In the following description there is shown and described
one embodiment of the invention, simply by way of illustration of
one of the modes best suited to carry out the invention. As it will
be realized, the invention is capable of other different
embodiments, and its several details are capable of modification in
various, obvious aspects all without departing from the invention.
Accordingly, the drawing and descriptions will be regarded as
illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING
[0011] The accompanying drawing incorporated in and forming a part
of the specification, illustrates several aspects of the present
invention, and together with the description serves to explain the
principles of the invention. In the drawing:
[0012] FIG. 1 is an exploded perspective view of the agitator of
the present invention;
[0013] FIG. 2a is a detailed cross-sectional view of the agitator
shown in FIG. 1;
[0014] FIG. 2b is a full cross-sectional view of that agitator;
[0015] FIG. 3a is a perspective view of the end of the pulley
secured to the axle of the agitator;
[0016] FIG. 3b is an end elevational view of the pulley shown in
FIG. 3a;
[0017] FIG. 3c is a perspective view of the axle and sleeve;
[0018] FIG. 3d is an end elevational view of the end of the axle
and sleeve shown in FIG. 3b; and
[0019] FIG. 4 is a detailed elevational view showing the connection
of the pulley on the axle and sleeve.
[0020] Reference will now be made in detail to the embodiment of
the invention illustrated in the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Reference is now made to the drawing figures and
particularly FIGS. 1 and 2 showing the agitator 10 of the present
invention. The agitator 10 generally comprises four component
parts, the axle 12, the sleeve 14 on the axle and the pulley 16
including the metal support, mounting fixture or D-nut 18.
[0022] The axle 12 is a single continuous shaft of high strength
metal and may have a diameter between about 4.00 to about 8.00 mm.
The sleeve 14 around the axle 12 is preferably formed from molded
plastic such as polypropylene/ABS or any other appropriate
material. The sleeve 14 may include spaced through slots 20 and
spaced, axially extending grooves 21. The slots 20 allow the axle
12 to be held during the sleeve molding process. The slots 20 and
grooves 21 are also of sufficient size and depth to receive a
scissor blade so that one may easily cut hair, string or other
elongated material that might become entangled on and wrapped
around the agitator 10. Thus, these slots 20 and grooves 21 greatly
simplify the cleaning process.
[0023] The sleeve 14 is cylindrical in overall shape and has a
diameter no greater than about 22 mm. As a result, the agitator 10
may be utilized in very low profile vacuum cleaners that provide
the necessary clearance for cleaning under low overhangs such as
furniture and kitchen and bathroom cabinet margins. The high
strength metal axle 12 provides rigidity, strength and balance or
TIR to the agitator 10 yet the relatively small diameter of the
axle advantageously allows the agitator to be made with a small
diameter or low overall profile as described.
[0024] As illustrated, the sleeve 14 includes two helical patterns
of tufted bristles 22 which function as cleaning structures for
brushing and beating the nap of a carpet as the agitator 10 is
rotated at rpms up to 2,500-6,500 by the cleaning equipment (e.g.
vacuum cleaner, power head, extractor) to which it is operatively
mounted. More particularly, a series of holes are drilled in the
sleeve 14 and the tufted bristles 22 are secured in those holes
with an appropriate adhesive or by mechanical fastening means such
as staples.
[0025] The pulley 16 may be formed from nylon or other appropriate
material and is molded on the D-nut 18. The D-nut 18 is preferably
formed from a high strength material such as sintered powder metal.
The D-nut 18 includes an oblong socket 24 that is sized and shaped
to receive a stub shaft (not shown) of an appropriate drive gear
which is held for relative rotation on the cleaning equipment to
which the agitator is mounted.
[0026] As best shown with reference to FIGS. 3a, 3b and 4, the
molded portion of the pulley 16 includes a hub 26 and a pair of
projecting box ribs 28, 30: the two box ribs extending in opposing
radial directions from the hub. As best shown in FIGS. 3c, 3d and
4, the sleeve 14 includes a pair of projecting, arcuate flanges 32,
34 and a pair of projecting lugs 36, 38 with the flanges and lugs
alternating around the axle 12. An annular gap 40 is provided
between axle 12 and each of the flanges 32, 34 as well as each of
the lugs 36, 38. The pulley 16, including the belt receiving
channel 17, is secured to the axle 12 by pressing the two parts
together so that (1) the hub 26 is received down in the gap 40, (2)
the lug 36 is received in the slot 42 between the box ribs 28, (3)
the lug 38 is received in the slot 44 between the box ribs 30 and
(4) the flanges 32, 34 are received in respective slots 33, 35 in
the pulley between the box ribs. Simultaneously, it should be
appreciated that the walls of the box ribs 28, 30 are received in
the channels 46 provided between each of the flanges 32, 34 and the
lugs 36, 38.
[0027] The pulley 16 is press fit onto the end of the axle 12 and
sleeve 14 until the walls of the box ribs 28, 30 are fully received
in the cooperating slots 49 in the reinforced collar 47. In this
position, the block-like bases 37, 39 of the respective lugs 36, 38
are fully received in and fill the slots 42, 44. It is the
engagement of (1) the bases 37, 39 in the slots 42, 44 and (2) the
walls of the box ribs 28, 30 in the channels 46 and the slots 49 in
the collar 47 that keys the pulley 16 to the axle 12 and sleeve 14
so that they are fixed and rotate together.
[0028] The radially projecting collar 47 and similar radial
projections 50 at the ends of the sleeve 14 function as barriers to
prevent string, hair and other dirt and debris from contaminating
and/or becoming entwined in the drive belt and agitator
bearings.
[0029] The agitator 10 of the present invention is relatively easy
to manufacture. The first step in the manufacturing process is the
molding of the nylon portion of the pulley 16 onto the metal D-nut
18. This is followed by the fitting of the axle 12 into the hub 26
of the pulley 16. Next is the injection molding of the sleeve 14
around the axle 12. Following injection molding is the securing of
a cleaning structure such as the tufted bristles 22 onto the sleeve
14. As noted above, this may be accomplished by drilling an
appropriate pattern of apertures in the sleeve 14 and then
utilizing a friction fit and an adhesive or staples to secure the
bristles 22 in those apertures. Alternatively, dovetail channels,
grooves or other structures may be provided for receiving and
holding a wiper, a brush, a beater bar or other appropriate
structures. Of course, such structures may also be molded
integrally with the sleeve 14 when the sleeve is molded onto the
axle 12 if desired.
[0030] In summary, numerous benefits result from employing the
concepts of the present invention. The agitator 10 is made from
inexpensive materials by means of a relatively simple and
inexpensive manufacturing process. Further, the agitator 10
includes a high strength metal axle which forms a rigid spine over
which relatively inexpensive plastic materials may be molded to
provide a sleeve for receiving and holding the selected cleaning
structure. Further, the overall agitator 10 may be produced with a
relatively low profile for receipt and use in low profile cleaning
equipment better capable of reaching under obstructions.
Advantageously, the low profile of the agitator is achieved without
compromising strength so that the agitator will function dependably
and reliably over a long service life.
[0031] The foregoing description of the preferred embodiment of the
invention has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form disclosed. Obvious modifications or
variations are possible in light of the above teachings. The
embodiment was chosen and described to provide the best
illustration of the principles of the invention and its practical
application to thereby enable one of ordinary skill in the art to
utilize the invention in various embodiments and with various
modifications as are suited to the particular use contemplated. All
such modifications and variations are within the scope of the
invention as determined by the appended claims when interpreted in
accordance with the breadth to which they are fairly, legally and
equitably entitled.
* * * * *