U.S. patent application number 12/610731 was filed with the patent office on 2010-05-06 for nozzle brush arrangements for vacuum cleaner assemblies.
Invention is credited to Mark Howie, James D. Jakubos.
Application Number | 20100107356 12/610731 |
Document ID | / |
Family ID | 42129674 |
Filed Date | 2010-05-06 |
United States Patent
Application |
20100107356 |
Kind Code |
A1 |
Jakubos; James D. ; et
al. |
May 6, 2010 |
NOZZLE BRUSH ARRANGEMENTS FOR VACUUM CLEANER ASSEMBLIES
Abstract
A vacuum cleaner assembly is disclosed. The vacuum cleaner
assembly comprises at least one brushroll and at least one nozzle
brush. The brushroll is rotatably supported about a first axis
within the vacuum cleaner and is operatively connected to a motor.
The nozzle brush is operatively connected to the brushroll and
configured to rotate about a second axis. When the brushroll is
rotated about the first axis, the nozzle brush is actuated to
rotate about the second axis.
Inventors: |
Jakubos; James D.;
(Cadillac, MI) ; Howie; Mark; (Cadillac,
MI) |
Correspondence
Address: |
RADER, FISHMAN & GRAUER PLLC
39533 WOODWARD AVENUE, SUITE 140
BLOOMFIELD HILLS
MI
48304-0610
US
|
Family ID: |
42129674 |
Appl. No.: |
12/610731 |
Filed: |
November 2, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61110797 |
Nov 3, 2008 |
|
|
|
Current U.S.
Class: |
15/383 |
Current CPC
Class: |
A47L 9/0433 20130101;
A47L 9/0472 20130101; A47L 9/0444 20130101; A47L 9/0488
20130101 |
Class at
Publication: |
15/383 |
International
Class: |
A47L 5/26 20060101
A47L005/26 |
Claims
1. A vacuum cleaner, comprising: at least one brushroll rotatably
supported about a first axis housed within the vacuum cleaner,
wherein the brushroll is operatively connected to a motor; at least
one nozzle brush operatively connected to the brushroll and
configured to rotate about a second axis such that when the
brushroll is rotated about the first axis, the nozzle brush rotates
about the second axis; an air channel positioned within the vacuum
cleaner; and an air flow groove formed through a portion of the
vacuum cleaner such that the air flow groove communicates with an
exterior of the vacuum cleaner and the air channel formed in the
vacuum cleaner.
2. The vacuum cleaner of claim 1, further comprising a first gear
fixedly secured to one end of the brushroll, wherein the gear is
rotatably driven by the brushroll and is operatively connected to
the nozzle brush.
3. The vacuum cleaner of claim 2, wherein the first gear is
comprised of at least a driving portion and a driven portion.
4. The vacuum cleaner of claim 3, wherein the driving portion is
comprised of a metallic material.
5. The vacuum cleaner of claim 3, wherein the driven portion is
comprised of a plastic material.
6. The vacuum cleaner of claim 2, wherein the first gear may be one
of a spur, worm, hypoid, or bevel gear.
7. The vacuum cleaner of claim 1, wherein the nozzle brush includes
a base portion having a groove formed thereon.
8. The vacuum cleaner of claim 7, further including at least one
spindle fixedly secured to one end of the brushroll, wherein the
spindle is rotatably driven by the brushroll and is operatively
connected to the nozzle brush.
9. The vacuum cleaner of claim 8, further comprising a rotary belt
engaged with the spindle and the groove formed in the nozzle
brush.
10. The vacuum cleaner of claim 1, wherein the first axis about
which the brushroll rotates is positioned so as to be substantially
horizontal with respect to an engaged surface and wherein the
second axis about which the nozzle brush rotates is substantially
vertical with respect to the engaged surface.
11. The vacuum cleaner of claim 1, wherein a distance between the
brushroll and a surface to be engaged by the brushroll is
selectively adjustable.
12. The vacuum cleaner of claim 1, wherein a distance between the
nozzle brush and a surface to be engaged by the nozzle brush is
selectively adjustable.
13. The vacuum cleaner of claim 1, wherein the nozzle brush further
comprises removably attached bristles.
14. The vacuum cleaner of claim 1, wherein the brushroll further
comprises removably attached bristles.
15. The vacuum cleaner of claim 1, further comprising a casing that
houses the brushroll within the vacuum cleaner, wherein the casing
further comprises an angled recess configured to facilitate the
uptake of debris.
16. The vacuum cleaner of claim 15, wherein one edge of the recess
is positioned to direct debris into an aperture formed in a housing
of the vacuum cleaner, wherein the aperture is in fluid
communication with an air channel formed in the housing that
fluidly communicates with an opening of the vacuum chamber.
17. The vacuum cleaner of claim 1, further including a motor shaft
mechanically communicating with the motor, wherein the motor arm
engages a drive belt that is operatively connected to the
brushroll.
18. The vacuum cleaner of claim 1, further including a drive shaft
connected with the motor, wherein the drive shaft is operatively
connected to the brushroll to rotate the brushroll.
19. The vacuum cleaner claim 1, wherein the nozzle brush rotates in
sync with the brushroll.
20. The vacuum cleaner of claim 1, wherein the brushroll operates
at a first predetermined rotational speed and the nozzle brush
operates at a second predetermined rotational speed.
21. The vacuum cleaner of claim 20, wherein the ratio of the first
and second predetermined rotational speeds ranges from 1:1 to
1:20.
22. The vacuum cleaner of claim 1, further comprising a recess
formed adjacent the brushroll, wherein the recess comprises an
angled surface configured to direct debris toward an aperture of
the air channel and away from the brushroll.
23. A vacuum cleaner assembly, comprising: a base having an outer
portion, a panel cover, and one or more wheels; a motor positioned
within a housing, the housing having an aperture that is in
communication with an air channel that fluidly communicates with an
opening of a vacuum chamber within a body of the vacuum cleaner
assembly; a motor shaft connected to the motor and engaged with a
drive belt, wherein the drive belt is operatively connected to a
brushroll positioned in the base; a worm gear is attached to each
end of the brushroll, such that rotation of the brushroll also
rotates each worm gear in sync with the brushroll; a nozzle brush
in operative engagement with each worm gear, wherein rotation of
the brushroll rotates the nozzle brush to facilitate loosening and
uptake of debris on a surface engaged by the vacuum cleaner
assembly; and a recess formed adjacent the brushroll, wherein the
recess comprises an angled surface configured to direct debris
toward the aperture and away from the brushroll.
24. A vacuum cleaner assembly, comprising: a base having an outer
portion, a panel cover, and one or more wheels; a motor positioned
within a housing that is seated within the base, the housing having
an aperture in communication with an air channel that fluidly
communicates with an opening of a vacuum chamber within a body of
the vacuum cleaner assembly; a motor shaft connected to the motor
and engaged with a drive belt, wherein the drive belt is
operatively connected to a brushroll positioned in the base;
wherein the brushroll further includes at least one spindle
positioned at an end thereof; at least one nozzle brush positioned
within the base; a rotary belt wrapped around the spindle and a
portion of the nozzle brush, wherein the nozzle brush rotates in
response to the rotation of the brushroll to facilitate loosening
and uptake of debris on a surface engaged by the vacuum cleaner
assembly.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/110,797 filed Nov. 3, 2008 which is hereby
incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This disclosure is generally related to vacuum cleaners and,
more particularly to vacuum cleaner bases with rotating brush
arrangements.
BACKGROUND
[0003] Vacuum cleaners are used to pick up dirt and debris that has
become deposited or embedded into various floor types. To improve
performance of vacuum cleaners, some vacuum cleaners employ a
revolving brushroll to loosen up dirt and debris, so an air flow
created by the vacuum cleaner may entrain such dirt and debris.
Additionally, brushrolls have generally been configured to rotate
in a manner to push the dirt and debris toward an opening to a
vacuum chamber, in the pathway of the air flow, such that the dirt
and debris get picked up and deposited into canister for
disposal.
[0004] Brushrolls are generally contained in housings that prevent
the brushroll from extending all the way to the edge or through the
edge of the housing so as prevent the rotating brushroll from
projecting dirt and debris up into the air rather than into the
opening of a vacuum chamber. As a result, brushrolls are generally
contained within a housing which, in turn, creates a gap between
the outer edge of the housing and the brushroll. When vacuuming up
against a wall in a room this gap prevents the brushroll from being
able to loosen dirt and debris on the edge of the floor abutting
the wall. While one solution to cleaning this edge of the floor
abutting the wall is to use an attachment wand and nozzles that are
connect to the vacuum chamber, such an arrangement requires
reconfiguring the setup of a vacuum cleaner, increasing cleaning
time.
[0005] Therefore, what is needed is a vacuum cleaner design that
can effectively loosen dirt and debris, like the rotating
brushroll, but also provide such action to the edge of a vacuum
cleaner housing without requiring additional reconfiguration of the
vacuum cleaner through the use of external attachment
accessories.
SUMMARY
[0006] A vacuum cleaner assembly is disclosed. The vacuum cleaner
assembly comprises at least one brushroll and at least one nozzle
brush. The brushroll is rotatably supported about a first axis
within the vacuum cleaner and is operatively connected to a motor.
The nozzle brush is operatively connected to the brushroll and
configured to rotate about a second axis. When the brushroll is
rotated about the first axis, the nozzle brush is actuated to
rotate about the second axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a partial perspective view of a vacuum cleaner
base.
[0008] FIG. 2 is a partial plan view of a first nozzle brush
arrangement.
[0009] FIG. 3 is a perspective view of a vacuum cleaner base.
[0010] FIG. 4 a plan view of an underside of the vacuum cleaner
base of FIG. 3, illustrating a second nozzle brush
configuration.
[0011] FIG. 5 a plan view of the underside of the vacuum cleaner
base of FIG. 4, with a cover panel removed.
[0012] FIG. 6 is a partial perspective view of a gear housing used
with a brushroll and nozzle brush arrangement.
[0013] FIG. 7 is a cross-sectional view of a forward portion of a
vacuum cleaner base.
[0014] FIG. 8 is an exploded view of a casing that mounts a
brushroll and nozzle brush arrangement.
[0015] FIG. 9 is a partial cross-sectional view of a vacuum cleaner
base having a nozzle brush therein, wherein the vacuum cleaner is
engaged against a wall.
DETAILED DESCRIPTION OF THE DRAWINGS
[0016] Referring now to the drawings, illustrative and exemplary
embodiments of the present disclosure are shown in detail. Although
the drawings represent some embodiments of the present disclosure,
the drawings are not necessarily to scale and certain
characteristics may be exaggerated to better illustrate and explain
the present disclosure. Further, the embodiments set forth herein
are not intended to be exhaustive or otherwise limit or restrict
the disclosure to the precise forms and configurations disclosed in
the following detailed description.
[0017] FIGS. 1-8 provide alternative arrangements of a brushrolls
and nozzle brushes used in vacuum cleaners. While shown positioned
in a vacuum cleaner base, such as vacuum cleaner bases 10 and 100,
respectively, it is understood that the brushroll and nozzle brush
arrangements may be used in other types of vacuum cleaner
configurations. The vacuum cleaner assemblies employing the
brushrolls and nozzle brushes arrangements may be used on a variety
of surfaces such as generally planar flooring, including tiles,
cement, wood, paneling; as well as on carpeting or other textured
surfaces.
[0018] Referring now to FIG. 1, a perspective view of an exemplary
embodiment of vacuum cleaner base 10 is shown. Vacuum cleaner base
10 includes an outer portion 12, a panel cover 14, one or more
wheels 16, a projection portion 18, and a nozzle brush 20. A light
(not shown), may also be attached to outer portion 12. Outer
portion 12 may be made of a unitary piece of durable material, such
as plastic, or a blend of synthetic materials that are durable and
sturdy. In one exemplary embodiment, outer portion 12 is injection
molded for ease of manufacturer. It is contemplated that outer
portion 12 may be made of more than one piece of durable sturdy
material, held together with suitable fasteners of various types.
The shape of outer portion 12 may be designed and manufactured to
fit the contents and structures contained within vacuum cleaner
base 10. Thus, it is contemplated that the shape of outer portion
12 may vary greatly between embodiments.
[0019] Wheels 16 are depicted in FIG. 1 as being positioned
adjacent a rear end 17 of vacuum cleaner base 10, also adjacent
projection portion 18 of the vacuum cleaner base 10. However, it is
contemplated that there may be more than one wheels 16 and that any
of wheels 16 may be rearranged to different positions within vacuum
cleaner base 10, depending on the desired design of the vacuum
cleaner base 10. Wheels 16 help facilitate the movement of vacuum
cleaner base 10 when attached to a vacuum cleaner body (not shown).
Wheels 16 may vary in size, type (such as swivel, mechanized,
spherical, etc.), and the types of materials used to make wheels 16
may range from a variety of durable materials including plastics,
rubber or a blend of thereof.
[0020] In one exemplary embodiment, projection portion 18 may be
pivotally attached to the body of the vacuum cleaner (not shown).
Projection portion 18 serves as a conduit to deliver debris to a
vacuum receptacle of the vacuum cleaner body (not shown). As shown,
projection portion 18 may be configured to extend outwardly from
the vacuum cleaner base 10. Further, projection portion 18 may
serve to provide stability and support between vacuum cleaner base
10 and the vacuum cleaner body (not shown). For example, projection
portion 10 may support an attached vacuum canister, vacuum motor
and a handle in an upright vacuum cleaner arrangement. In yet
another exemplary arrangement, projection portion 10 may support a
handle and a hose leading to the vacuum cleaner body.
[0021] Further, projection portion 18 may be configured to
facilitate a pivoting motion of the vacuum body with respect to
vacuum cleaner base 10 during operation. Projection portion 18,
together with wheels 16, facilitates the ease of moving vacuum
cleaner base 10 over and across a targeted surface. Projection
portion 18 may be made of the same material as outer portion 12.
Projection portion 18 may also be made out of the same piece as
outer portion 12 or may be made from a separate piece and then
attached to vacuum cleaner base 10 using a variety of suitable
fasteners. It is contemplated that other materials, such as those
materials suitable for outer portion 12, may also be used to make
projection portion 18.
[0022] FIG. 2 depicts the underside of the vacuum cleaner base 10.
As shown, in addition to nozzle brush 20, positioned within vacuum
cleaner base 10 is also at least one brushroll 26. Brushroll 26 is
generally configured as an elongated member and has a plurality of
bristles 27 extending from an external surface 29 thereof. While
shown as being arranged in a spiral pattern, it is understood that
bristles 27 may be arranged in a variety of patterns. Brushroll 26
is mounted within a cavity 28 such that at least bristles 27 extend
through an opening 30 formed in panel cover 14 and positioned
adjacent a forward edge 31 of vacuum cleaner base 10. Bristles 27
may be directly attached to external surface 29 of brushroll 26.
Cavity 28 is in fluid communication with an air flow channel (not
shown).
[0023] In an alternative arrangement, bristles 27 may be mounted on
a substrate. In such an arrangement, brushroll 26 includes a slot
that is configured to receive bristles 27 such that bristles 27
extend outward from the slot (as explained below in connection with
FIG. 8 in greater detail).
[0024] In one exemplary embodiment, brushroll 26 is configured to
be predominantly cylindrical in shape, but may include various
grooves or channels formed in external surface 29 of brushroll 26
to facilitate mechanical communication with other structures within
vacuum cleaner base 10. For example, a center portion 32 of the
elongate brushroll 26 may be configured with a groove 34 to which a
drive belt (not shown) is mounted to facilitate mechanical
communication between a motor (not shown) and brushroll 26. In one
particular arrangement, disposed on either side of groove 34 is a
retaining flange 34 that assists with retaining the drive belt on
brushroll 26. In another embodiment, a pair of brushrolls 26 are
used, the brushrolls 26 being connected together with a mounting
portion that receives the drive belt.
[0025] The brushroll 26 may be constructed from wood, or any other
durable and sturdy material, as described above. It is also
contemplated that brushroll 26 may vary in thickness throughout the
span of brushroll 26. It may be tapered at certain portions or it
may have a uniform thickness throughout.
[0026] In the embodiment shown in FIG. 2, attached to distal ends
36 of brushroll 26 are spindles 42. Spindles 42 receive rotary
belts 44 that also attach to nozzle brushes 20 to promote rotation
of nozzle brush 20 when brushroll 26 rotates. More specifically,
spindles 42 support and stabilize rotary belt 44. Each rotary belt
44 wraps around a base of a nozzle brush 20, which may also be
configured with a mounting groove (not shown) formed thereon to
secure rotary belt 44 during rotation about a vertical axis. As
depicted in one exemplary embodiment, nozzle brushes 20 are
positioned rearward of the brushroll 26. However, it is understood
that nozzle brush 20 may also be positioned forward of brushroll
26.
[0027] In one exemplary embodiment, vacuum cleaner base 10 may be
configured with an air flow groove 53 (shown in phantom in FIG. 1).
Air flow groove 53 may be formed through a portion of a vacuum
cleaner and leads into cavity 28 so as to be in fluid communication
with a recess formed in vacuum cleaner base 10, adjacent brushroll
26 and the air channel formed therein. Generally, air flow groove
53 is positioned adjacent to nozzle brush 20 and particularly close
to a pathway where nozzle brush 20 may direct dirt and debris
to.
[0028] Air flow groove 53 is configured to have a predetermined
size to create a low pressure area inside vacuum base 10. Such a
low pressure area assists in creating a relatively high air flow
rate through cavity 28, the recess and aperture formed within
vacuum cleaner base 10 (described in further detail in connection
with the embodiment shown in FIGS. 3-5), and into the air channel.
The high air flow forces dirt and debris (including hard objects)
that may be continuously rotating about brushroll 26 due to
centripetal forces generated thereby, to be directed into the air
channel 32. Thus, the relatively high air flow allows a vacuum
cleaner effectively direct dirt and debris loosened up or pushed
into the air channel of the vacuum system by brushroll 126 and
nozzle brush 120.
[0029] FIG. 3 illustrates a perspective view of an alternative
embodiment of a vacuum cleaner base 100 and FIG. 4 illustrates the
underside thereof. Vacuum cleaner base 100 includes an outer
portion 112, a panel cover 114, one or more wheels 116, a
projection portion 118, and at least one nozzle brush 120. A light
158 may also be attached to outer portion 112. As may be seen, in
this embodiment, nozzle brushes 120 are positioned adjacent a
forward edge 121 of vacuum cleaner base 100.
[0030] Referring to FIG. 4, it can be seen that panel cover 114
substantially covers and at least partially seals off the
structures within and contents of vacuum base 100. Panel cover 114
is depicted in FIG. 4 as one continuous piece but it is
contemplated that panel cover 114 may be made up of more than one
piece. Panel cover 114 is relatively flat as it engages with a
targeted surface. However, panel cover 114 may include varying
shaped depressions and extrusions depending on what structure it is
covering. Panel cover 114 may be held in position by any number of
fasteners suitable to secure panel cover 114 in position during use
and at rest. It is contemplated that panel cover 114 will vary in
shape and design depending on the shape and design of the
corresponding base. Panel cover 114 may be made from the same or
similar materials as the outer portion.
[0031] A substantial portion of a cavity 128 is exposed through an
opening 130 formed in the panel cover 114. A rotating brushroll 126
is positioned within cavity 128. Brushroll 126 is configured to
carry bristles 127. Bristles 127 may be attached directly to an
outer surface 129 of brushroll 126, or, alternatively, indirectly
to brushroll 126. More specifically, bristles 127 may be mounted to
a substrate that is removably received within brushroll such that
bristle 127 may extend outwardly from a channel formed through
outer surface 129 of brushroll.
[0032] Cavity 128 may be formed in part by a casing 152 as depicted
in FIG. 7 or upper casing 152a and lower casing 152b as depicted in
FIG. 8. Casing 152 may be made of one piece or multiple pieces and
out of a variety of materials including metals and plastics. Casing
152 may also be formed out of a portion of outer portion 12 or may
be independently attached to vacuum base 100.
[0033] Turning now to FIG. 5, the underside of vacuum cleaner base
100 with panel cover 114 removed is shown. An air channel 132 is
positioned within vacuum cleaner base 100. Air channel 132 is
fluidly connected with an opening of a vacuum chamber (not shown)
that is generally located in the body of the vacuum cleaner (not
shown). The opening of the vacuum chamber may be partially formed
from projection portion 118 of vacuum cleaner base 100, although it
may alternatively be formed separately from the projection portion
118. Air channel 132 may also be formed partially from projection
portion 118.
[0034] Also contained within vacuum cleaner base 100 is a motor
140. In one exemplary arrangement, motor 140 is at least partially
covered by both outer portion 112 and panel cover 114 (removed).
Motor 140 is connected to a motor arm 136. In one exemplary
arrangement, motor arm 136 extends axially into air channel 132.
Many variations of motors are suitable for use in the vacuum
cleaner; especially those used and sold by Rexair, Inc., the
assignee of the present disclosure. Two examples of suitable motors
are described in the U.S. Pat. Nos. 5,949,175 and 6,777,844, each
incorporated herein by reference in their entirety.
[0035] Brushroll 126 is generally cylindrically-shaped but may
include various grooves or channels formed in external surface 129
to facilitate mechanical communication with other structures within
vacuum cleaner base 100. For example, a center portion 133 of
brushroll 126 may be configured with a groove 134 to which a drive
belt 138 is mounted to facilitate mechanical communication between
motor 140 and brushroll 126. In one particular arrangement,
disposed on either side of groove 134 is a retaining flange 135
that assists with retaining drive belt 138 on brushroll 126. In
another embodiment, a pair of brushrolls 126 are used, the
brushrolls 126 being connected together with a mounting portion
that receives drive belt 138.
[0036] In one embodiment, brushroll 126 may be constructed from
wood. However, it is also contemplated that brushroll 126 may be
made from any number of durable and sturdy materials previously
described above. It is also contemplated that brushroll 126 may
vary in thickness throughout the span of brushroll 126. It may be
tapered at certain portions or it can have a uniform thickness
throughout.
[0037] In one embodiment, bristles 127 attached to brushroll 126
are arranged in a spiral pattern. More specifically, bristles 127
on brushroll 126 are depicted in FIG. 5 as two spiral-patterned
rows integrated into brushroll 126. However, it is contemplated
that more bristle rows may be present on brushroll 126 and that the
pattern with which the rows are arranged may vary from the depicted
spiral design to a chevron design or other arrangements.
[0038] As discussed above, in some embodiments the bristles 127 are
removably attached or replaceable as illustrated in FIG. 8. It is
desirable to have bristles 127 that are sturdy enough to loosen
debris and dirt from the targeted surface without causing damage to
the surface such as unnecessary scratching, scuffing or snagging of
the surface. Any number of suitable materials that are well known
in the art can be used for this purpose.
[0039] In addition, bristles 170 on nozzle brush 120 may be
removably attached or replaceable. Bristles 170 of both nozzle
brush 120 and the elongate brushroll 126 may be made of various
materials exhibiting a variety of properties, wherein some are
thicker, coarser, and stiffer in nature while others are finer,
softer, and less stiff. A variety of types and materials the
bristles are made of such as plastics, acrylics, resins, goat hair
and so forth, that exist are known in the art and made to be
adaptable to a particular surface that is to be cleaned. Bristles
170 of the nozzle brush 120 shown in FIG. 7 ideally exhibit the
same sturdy qualities as those bristles 127 on brushroll 126.
Bristles 170 may be arranged in rows, bunches, partially or
completely covering the outermost surface of the power nozzle brush
120. A bristle-less brushroll or nozzle brush is also conceivable
wherein the material used is designed to facilitate the uptake of
dirt and debris.
[0040] A recess 154 may be formed in vacuum cleaner base 100, as
shown in FIG. 7. Recess 154 aides in facilitating uptake of debris
that contains small hard objects that would otherwise spit back
out. Recess 154, as shown, has an angled surface 155. Angled
surface 155 is oriented so as to have a first end 157 that is
positioned axially lower than a second end 159. With this
configuration dirt and debris is directed upwardly in recess 154
from brushroll 120, along angled surface 155 to cause such dirt and
debris to move towards an aperture 156 that opens into air channel
132, shown in FIG. 5. Hard objects are either directed into air
channel 132 or contained in recess 154 until they are drawn into
air channel 132. In one embodiment recess 154 is configured to
create a vortex-like tunnel that pulls dirt and debris caught in
the recess 154 from outer edges of casing 152 into a center portion
where aperture 156 fluidly communicates with air channel 132.
Recess 154 may span the length of the casing 152, enclosing
brushroll 126 or may vary in length. In some arrangements, recess
154 may even be comprised of sections.
[0041] In some arrangements, as best seen in FIGS. 6-7, an air flow
groove 153 is formed through a portion of a vacuum cleaner into
cavity 128. More specifically, in one particular arrangement, air
flow groove 153 is formed through an outer portion of gear housing
150 or vacuum base 100 and extends into cavity 128. Thus, air flow
groove 153 is in fluid communication with recess 154, aperture 156
and air channel 132. Generally, air flow groove 153 is positioned
adjacent to nozzle brush 120 and particularly close to the path
that nozzle brush 120 may direct dirt and debris to. In one
exemplary arrangement, air flow groove 153 is arranged so as to be
adjacent to a dust pan region 161. Dust pan region 161 cooperates
with air flow groove 153 to retain dirt and debris within recess
154 until such dirt and debris may be drawn through aperture 156 of
air channel 132.
[0042] Air flow groove 153 is configured to have a predetermined
size to create a low pressure area inside vacuum base 100. In one
exemplary arrangement, air flow groove 153 is approximately 1/4
inches wide and 1/8 inches in height. Such a low pressure area
assists in creating a relatively high air flow rate through cavity
128, recess 154 and aperture 156, into air channel 132. The high
air flow forces dirt and debris (including hard objects) that may
be continuously rotating about brushroll 126, due to centripetal
forces, to be directed into air channel 132. Thus, the relatively
high air flow allows a vacuum cleaner to effectively direct dirt
and debris loosened up or pushed into the air channel 132 of the
vacuum system by brushroll 126 and nozzle brush 120.
[0043] In one arrangement, positioned at each end of brushroll 126
are worm gears 124, seen best in FIG. 6. In an alternative
embodiment, a bearing housing 130 is positioned adjacent to each
worm gear 124, between the end of brushroll 126 and worm gears 124,
best seen in FIG. 5. In both of these embodiments, worm gears 124
and the bearing housings 130 rotate in sync with brushroll 126,
about a first axis. Specifically, motor 140 positioned within
vacuum base 100 rotates motor arm 136. Drive belt 138 is positioned
such that it is wrapped around both motor arm 136 and a portion of
brushroll 126. As motor 140 axially rotates motor arm 136 about an
axis, drive belt 138 rotates around both motor arm 136 and
brushroll 126, facilitating continuous revolutions about a first
axis. Worm gears 124, and if applicable, adjacent bearing housings
130, also rotate about the first axis, in sync with elongate
brushroll 126.
[0044] In another embodiment (not shown), a motor 140 operatively
communicates with brushroll 126 and may be attached to a drive
shaft (not shown) that causes brushroll 126 to rotate about the
first axis, which may be oriented to be generally horizontal with
respect to an engaged surface or ground. Additionally, in one
embodiment, (not shown) a motor may be positioned externally of
vacuum base 100 and in operative communication with brushroll 127
through a turbine system. The motor draws in air which in turn
causes rotational movement of brushroll 127 through a turbine
driven system. This particular embodiment may be incorporated into
a handheld version of a vacuum base wherein at least one nozzle
brush is rotated through brushroll 127 driven by a turbine motor
system.
[0045] Referring specifically to the arrangements depicted in FIGS.
3-6 and 8, rotatable nozzle brush 120 is depicted as positioned on
a forward outer edge 141 of vacuum base 100 so as to extend
outwardly from the vacuum base 100. In an exemplary embodiment, a
pair of rotatable nozzle brushes 120 are partially situated in gear
housings 150 (best seen in FIG. 6) adjacent each end of the
elongate brushroll 126. Each gear housing 150 contains a worm gear
124 and spur gear 148 as shown in FIG. 6. The outer circumference
of nozzle brush 120 may carry a gear having a plurality of gripping
teeth protruding radially outwardly there from such as those
adapted for various types of gears including spur, worm, hypoid,
bevel and any type of system having a driving portion attached to
brushroll 126 and a driven portion attached to nozzle brush 120.
For instance in FIG. 6, a worm gear 124 mechanically engages the
plurality of gripping teeth of spur gear 148 on the corresponding
nozzle brush 120, as shown. As worm gear 124 rotates about its
axis, spur gear 148 causes nozzle brush 120 to rotate about a
second axis with each revolution of worm gear 124. The driving
portion of gear 124 is contemplated to be made of a metallic
material such as stainless steel, a plastic or polymer based
material including, but not limited to, Entech nylon66 and Ashland
Zytel WRF 500, or other suitable resin material. Likewise, the
driven portion may also be made of similar materials as to that of
the driving portion. Any combination of the materials mentioned
above or those having similar characteristics as recognized by
those skilled in the art are conceivable.
[0046] One particular embodiment using a gear system to
mechanically rotate a nozzle brush 120 through a brushroll 126
comprises using a bath of grease such as Molbilux EP 023 to ensure
adequate lubrication and prevent wearing. However, in one
particular embodiment a gear system devoid of any grease is
possible. More specifically, where the driving portion is made of a
stainless steel while the driven portion is made of plastic
material. Such an arrangement of a greaseless or tubeless system is
advantageous when cleaning floors as such lubricants may soil the
engaged surface if they were to leak out of the system.
[0047] One particular advantage of a gear system driving nozzle
brushes 120 through brushroll 126 is the ability to adjust the
torque and speed relationships between brushroll 126 and the power
nozzle brush 120. It has been found that rotating brushroll 126 at
higher speeds tend to loosen dirt and debris caused by the rotating
beating action of bristles 127. However, rotating nozzle brush 120
at a lower rotational speed than brushroll 126 has been found to be
more effective than rotating nozzle brush 120 at a high rotational
speed as too high of a speed tends to project dirt and debris
beyond the intended intake of vacuum base 100. The ratio of the
speeds of nozzle brush 120 to brushroll 126 may be of the range
1:1. 1:5, 1:10 and 1:20 wherein brushroll 126 rotates 20 times
faster than nozzle brush 120. Other non-gear systems are also
conceived to adjust the ratio of speed as discussed below.
[0048] Nozzle brush 120 may be secured to vacuum base 100 or gear
housing 150 within vacuum base by a suitable fastener 122 such as a
stud, pin or a screw, traversing the center of nozzle brush 120, so
as not to hinder rotation about the second axis. Plain or ball
bearings (not shown) may be press fit onto or otherwise attached to
122 facilitating rotational movement. A gear such as spur gear 148
may be press fit, pinned or molded onto fastener 122. Other
fastening means may be contemplated as alternatives for attaching
nozzle brush 120 to vacuum base 100 as well. More particularly,
those that may be easily removed and allow nozzle brush 120 to be
selectively detached. Nozzle brush 120 is generally circular in
shape with bristles 170 protruding from the outermost surface of
nozzle brush 120; specifically, they protrude from the surface that
engages the targeted surface.
[0049] It is further contemplated that additional nozzle brushes
120 may be added to vacuum cleaner base 100 in alternate
embodiments. It is also contemplated that nozzle brush 120 may be
positioned on the outer edges of vacuum cleaner base 100 or
positioned more internally, for example, near the air channel 132
of the base 100. FIGS. 1-2 show embodiments where nozzle brush 20
is placed on an outer edge of vacuum cleaner base 10 behind
brushroll 26. FIGS. 3-5 illustrate embodiments where nozzle brush
120 is placed on a forward corner of vacuum cleaner base 100,
adjacent brushroll 126. FIG. 9 illustrates a specific operation of
the embodiments shown in FIGS. 3-5. More specifically, as nozzle
brush 120 engages a target surface 200 to be cleaned, nozzle brush
120 is able to reach debris 204 deposited adjacent a wall 202.
[0050] As previously stated, it is contemplated that the number and
position of nozzle brushes 20, 120 may vary between embodiments. It
is contemplated that some nozzle brushes 20, 120 are powered by
alternative means, other than through the operation of brushroll
26, 126. For instance, nozzle brushes 20, 120 may be directly
powered by motor 140. It is also contemplated that nozzle brushes
20, 120 may be used to drive brushroll 26, 126. Other power
mechanisms operatively communicating between brushroll 26, 126 and
nozzle brush 20, 120 using a flex shaft, and magnetic clutches.
[0051] In all of the described embodiments, as vacuum cleaner base
10, 100 engages a targeted surface, the combination of rotation of
brushroll 26, 126, and nozzle brush 20, 120, create a powerful
source of agitation that promotes and enhances the loosening,
collection and uptake of dirt and debris from the surface. Nozzle
brush 20, 120 increases the area of the targeted surface that can
be reached and cleared of dirt and debris by adding a substantial
amount of spinning power that can grab more dirt and debris as
compared to a vacuum cleaner without a nozzle brush 20, 120
configuration.
[0052] Rotation and beating of bristles 27, 127 of brushroll 26,
126 onto an engaged surface, mixed with the rotation and vibrations
of the spinning bristles 170 on nozzle brush 20, 120, facilitate
the uptake of dirt and debris particles as they are drawn into
cavity 28, 128. The dirt and debris then pass through an opening or
aperture 156 as shown in FIG. 7. Bristles 27, 127 of brushroll 26,
126 may be configured to direct dirt and debris toward the center
of brushroll 26, 126 where they are then pushed or drawn through
aperture 156 into air channel 132 that may be formed, in part, by
projection portion 18, 118 of vacuum cleaner base 10, 100 and
continuously drawn through the opening of the vacuum chamber (not
shown). From there it passes to the body of the vacuum cleaner (not
shown) where the dirt and debris may run through a filtering
process and eventually end up in a receptacle (not shown) where it
is stored until it is discarded. It is contemplated that these
events can occur within many types of vacuums including a standard
upright vacuum.
[0053] In one exemplary embodiment, the height and position of
vacuum cleaner base 10, 100 in relation to the surface to be
cleaned may be selectively adjustable, such as raised away from the
surface, to allow for thicker surfaces such as carpeting, or
lowered to be closer to more planar-like surfaces such as wood
floors. Additionally, it is contemplated the height of brushroll
26, 126 and nozzle brush 20, 120 may also be selectively adjusted
with respect to the engaged surface. It is also contemplated that
the angle of the second axis about which nozzle brush 20, 120
rotates may be selectively adjusted with respect to the engaged
surface.
[0054] The appended claims have been particularly shown and
described with reference to the foregoing embodiments, which are
merely illustrative of the best modes for carrying out the
invention defined by the appended claims. It should be understood
by those skilled in the art that various alternatives to the
embodiments described herein may be employed in practicing the
invention defined by the appended claims without departing from the
spirit and scope of the invention as defined in claims. The
embodiments should be understood to include all novel and
non-obvious combinations of elements described herein, and claims
may be presented in this or a later application to any novel and
non-obvious combination of these elements. Moreover, the foregoing
embodiments are illustrative, and no single feature or element is
essential to all possible combinations that may be claimed in this
or a later application.
[0055] With regard to the processes, methods, heuristics, etc.
described herein, it should be understood that although the steps
of such processes, etc. have been described as occurring according
to a certain ordered sequence, such processes could be practiced
with the described steps performed in an order other than the order
described herein. It further should be understood that certain
steps could be performed simultaneously, that other steps could be
added, or that certain steps described herein could be omitted. In
other words, the descriptions of processes described herein are
provided for illustrating certain embodiments and should in no way
be construed to limit the appended claims.
[0056] Accordingly, it is to be understood that the above
description is intended to be illustrative and not restrictive.
Many embodiments and applications other than the examples provided
would be apparent to those of skill in the art upon reading the
above description. The scope of the invention should be determined,
not with reference to the above description, but should instead be
determined with reference to the appended claims, along with the
full scope of equivalents to which such claims are entitled. It is
anticipated and intended that future developments will occur in the
arts discussed herein, and that the disclosed systems and methods
will be incorporated into such future embodiments. In sum, it
should be understood that the invention is capable of modification
and variation and is limited only by the following claims.
[0057] All terms used in the claims are intended to be given their
broadest reasonable constructions and their ordinary meanings as
understood by those skilled in the art unless an explicit
indication to the contrary is made herein. In particular, use of
the singular articles such as "a," "the," "said," etc. should be
read to recite one or more of the indicated elements unless a claim
recites an explicit limitation to the contrary.
* * * * *