U.S. patent application number 17/497182 was filed with the patent office on 2022-03-31 for agitator for a surface treatment apparatus and a surface treatment apparatus having the same.
The applicant listed for this patent is SHARKNINJA OPERATING LLC. Invention is credited to Xavier F. CULLERE, Daniel R. DER MARDEROSIAN, Steven GACIN, Vignesh GNANASEKARAN, Nathan HERRMANN, Adam UDY, Kai XU.
Application Number | 20220095864 17/497182 |
Document ID | / |
Family ID | 1000006064084 |
Filed Date | 2022-03-31 |
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United States Patent
Application |
20220095864 |
Kind Code |
A1 |
DER MARDEROSIAN; Daniel R. ;
et al. |
March 31, 2022 |
AGITATOR FOR A SURFACE TREATMENT APPARATUS AND A SURFACE TREATMENT
APPARATUS HAVING THE SAME
Abstract
An agitator for a vacuum cleaner including an elongated main
body extending along a pivot axis and having first and second
opposite lateral ends, one or more soft cleaning elements extending
from elongated main body between the first and second opposite
lateral ends, one or more channels formed within the one or more
soft cleaning elements and disposed between the first and second
opposite lateral ends, and one or more deformable flaps disposed
within the one or more channels and extending from the elongated
main body.
Inventors: |
DER MARDEROSIAN; Daniel R.;
(Westwood, MA) ; HERRMANN; Nathan; (Cambridge,
MA) ; GACIN; Steven; (Needham, MA) ; CULLERE;
Xavier F.; (Newton, MA) ; UDY; Adam; (Sutton,
GB) ; GNANASEKARAN; Vignesh; (Needham, MA) ;
XU; Kai; (Suzhou, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SHARKNINJA OPERATING LLC |
Needham |
MA |
US |
|
|
Family ID: |
1000006064084 |
Appl. No.: |
17/497182 |
Filed: |
October 8, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17466242 |
Sep 3, 2021 |
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17497182 |
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16656930 |
Oct 18, 2019 |
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17466242 |
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63089376 |
Oct 8, 2020 |
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63074719 |
Sep 4, 2020 |
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63077386 |
Sep 11, 2020 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 9/0477
20130101 |
International
Class: |
A47L 9/04 20060101
A47L009/04 |
Claims
1. An agitator for a vacuum cleaner comprising: an elongated main
body extending along a pivot axis and having first and second
opposite lateral ends; one or more soft cleaning elements extending
from elongated main body between the first and second opposite
lateral ends; one or more channels formed within the one or more
soft cleaning elements and disposed between the first and second
opposite lateral ends; and one or more deformable flaps disposed
within the one or more channels and extending from the elongated
main body.
2. The agitator of claim 1, wherein the one or more channels is
configured to allow the one or more deformable flaps to move
forward and backward as the agitator rotates about the pivot
axis.
3. The agitator of claim 2, wherein the one or more channels have a
width proximate an opening of the one or more channel that is 3-20
mm wide.
4. The agitator of claim 1, wherein the one or more soft cleaning
elements extend over a substantial portion of a generally
cylindrical portion of the elongated main body.
5. The agitator of claim 4, wherein the one or more soft cleaning
elements extend over the entire generally cylindrical portion of
the elongated main body except where the at least one channel is
formed.
6. The agitator of claim 1, wherein the one or more channels
includes a first and a second channel and wherein the one or more
deformable flaps includes a first and a second deformable flap
disposed within the first and second channel, respectively, the
first channel extending from the first lateral end to a central
region of the agitator and the second channel extending from the
second lateral end to the central region of the agitator.
7. The agitator of claim 1, wherein the one or more channels
extends from the first lateral end to the second lateral end of the
agitator.
8. The agitator of claim 1, wherein the one or more channels have a
generally "U" cross-sectional shape.
9. The agitator of claim 1, wherein the one or more channels have a
generally "V" cross-sectional shape.
10. The agitator of claim 1, wherein the one or more deformable
flaps have a height extending radially outward from the elongated
main body that is equal to a height of the one or more soft
cleaning elements.
11. The agitator of claim 1, wherein the one or more deformable
flaps have a height extending radially outward from the elongated
main body that is less than a height of the one or more soft
cleaning elements.
12. The agitator of claim 1, wherein the one or more deformable
flaps have a height extending radially outward from the elongated
main body that is greater than a height of the one or more soft
cleaning elements.
13. The agitator of claim 1, further comprising one or more bristle
strips disposed within the one or more channels.
14. The agitator of claim 13, wherein the one or more bristle
strips is disposed rotationally before the one or more deformable
flaps.
15. The agitator of claim 13, wherein the one or more bristle
strips is disposed rotationally after the one or more deformable
flaps.
16. The agitator of claim 13, wherein the one or more bristle
strips has a height extending radially outward from the elongated
main body that is greater than a height of the one or more soft
cleaning elements.
17. The agitator of claim 1, further comprising one or more rows of
tufts disposed within the one or more channels.
18. The agitator of claim 17, wherein the one or more rows of tufts
is disposed rotationally before the one or more deformable
flaps.
19. The agitator of claim 17, wherein the one or more rows of tufts
is disposed rotationally after the one or more deformable
flaps.
20. The agitator of claim 17, wherein the one or more bristle
strips has a height extending radially outward from the elongated
main body that is greater than a height of the one or more soft
cleaning elements.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Application Ser. No. 63/089,376 filed on Oct. 8, 2020,
which is fully incorporated herein by reference. The present
application also is a continuation-in-part of U.S. patent
application Ser. No. 17/466,242, filed on Sep. 3, 2021, which
claims the benefit of U.S. Provisional Application Ser. No.
63/074,719 filed on Sep. 4, 2020, and U.S. Provisional Application
Ser. No. 63/077,386 filed on Sep. 11, 2020, all of which are fully
incorporated herein by reference. The present application is also a
continuation-in-part of U.S. application Ser. No. 16/656,930 filed
on Oct. 18, 2019, which is fully incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to a vacuum
cleaner, and more particularly, to a vacuum cleaner including a
system to migrate and/or remove debris from an agitator.
BACKGROUND
[0003] A vacuum cleaner may be used to clean a variety of surfaces.
Some vacuum cleaners include a rotating agitator (e.g., brush
roll). While the known vacuum cleaners are generally effective at
collecting debris, some debris (for example, elongated debris such
as hair, fur, or the like) may become entangled in the agitator.
The entangled debris may reduce the efficiency of the agitator, and
may cause damage to the motor, bearings, support structure, and/or
drive train that rotates the agitator. Moreover, it may be
difficult to remove the entangled debris from the agitator because
it is entangled in the bristles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Embodiments are illustrated by way of example in the
accompanying figures, in which like reference numbers indicate
similar parts, and in which:
[0005] FIG. 1 is a bottom view of one embodiment of a vacuum
cleaner, consistent with embodiments of the present disclosure;
[0006] FIG. 2 is a cross-sectional view of the vacuum cleaner of
FIG. 1 taken along line II-II, consistent with embodiments of the
present disclosure;
[0007] FIG. 3 generally illustrates one example of a hair migration
system, consistent with embodiments of the present disclosure;
[0008] FIG. 4 generally illustrates a perspective cross-sectional
view of one embodiment of a combing unit taken along lines IV-IV of
FIG. 1;
[0009] FIG. 5 generally illustrates a cross-sectional view of the
combing unit of FIG. 4 taken along lines IV-IV of FIG. 1;
[0010] FIG. 6 generally illustrates a cross-sectional view of the
combing unit of FIG. 4 taken along lines VI-VI of FIG. 2;
[0011] FIG. 7 generally illustrates a cross-sectional view of
another embodiment of the combing unit taken along lines VI-VI of
FIG. 2;
[0012] FIG. 7A shows a perspective view of an example of a combing
unit having teeth in a central region with a length that measures
greater than teeth in a lateral (or end) region, consistent with
embodiments of the present disclosure;
[0013] FIG. 8 generally illustrates a cross-sectional view of one
embodiment of a plurality of sectioned agitator chambers of the
vacuum cleaner of FIG. 1 taken along line II-II;
[0014] FIG. 9 is a side schematic view of an agitator capable of
being used with the vacuum cleaner of FIG. 1, consistent with
embodiments of the present disclosure;
[0015] FIG. 10 shows a schematic view of a plurality of ribs
configured to engage (e.g., contact) the agitator of FIG. 9,
consistent with embodiments of the present disclosure;
[0016] FIG. 11 shows a schematic view of a plurality of ribs
configured to engage (e.g., contact) an agitator, consistent with
embodiments of the present disclosure;
[0017] FIG. 12 shows a schematic cross-sectional end view of a
surface cleaning head, consistent with embodiments of the present
disclosure;
[0018] FIG. 13 shows a cross-sectional perspective view of the
surface cleaning head of FIG. 12, consistent with embodiments of
the present disclosure;
[0019] FIG. 14 shows a perspective view of a surface cleaning head,
consistent with embodiments of the present disclosure;
[0020] FIG. 14A shows a perspective view of an example of an
agitator cover, consistent with embodiments of the present
disclosure;
[0021] FIG. 14B shows a perspective view of a portion of a robotic
cleaner having the agitator cover 14A coupled thereto, consistent
with embodiments of the present disclosure;
[0022] FIG. 15 shows a perspective view of an agitator cover which
is capable of being used with the surface cleaning head of FIG. 14,
consistent with embodiments of the present disclosure;
[0023] FIG. 16 shows a bottom view of the agitator cover of FIG.
15, consistent with embodiments of the present disclosure;
[0024] FIG. 17 shows a perspective view of an agitator cover which
is capable of being used with the surface cleaning head of FIG. 14,
consistent with embodiments of the present disclosure;
[0025] FIG. 18 shows a bottom view of the agitator cover of FIG.
17, consistent with embodiments of the present disclosure;
[0026] FIG. 19 shows a side view of a rib, consistent with
embodiments of the present disclosure;
[0027] FIG. 20 shows a schematic view of an agitator having flaps
and bristles, consistent with embodiments of the present
disclosure;
[0028] FIG. 21 shows a schematic view of an agitator having
bristles, consistent with embodiments of the present
disclosure;
[0029] FIG. 22 shows a schematic cross-sectional view of an
agitator having end caps, consistent with embodiments of the
present disclosure;
[0030] FIG. 23 shows a schematic cross-sectional view of an example
of the agitator of FIG. 22 having ribs extending along a portion of
the agitator and disposed between the end caps, consistent with
embodiments of the present disclosure;
[0031] FIG. 24 shows a perspective view of an end cap for an
agitator, consistent with embodiments of the present
disclosure;
[0032] FIG. 25 shows another perspective view of the end cap of
FIG. 24, consistent with embodiments of the present disclosure;
[0033] FIG. 26 shows a perspective view of an end cap, consistent
with embodiments of the present disclosure;
[0034] FIG. 27 shows another perspective view of the end cap of
FIG. 26, consistent with embodiments of the present disclosure;
[0035] FIG. 27A shows a perspective view of an end cap, consistent
with embodiments of the present disclosure;
[0036] FIG. 27B shows a perspective view of a surface cleaning head
having the end cap of FIG. 27A coupled thereto, consistent with
embodiments of the present disclosure;
[0037] FIG. 28 is a front view of another example of an agitator,
consistent with the present disclosure;
[0038] FIG. 29 is a cross-sectional view of the agitator of FIG. 29
taken along line 29-29, consistent with embodiments of the present
disclosure;
[0039] FIG. 30 shows one example of the elongated main body of the
agitator of FIG. 29 without the flaps, consistent with embodiments
of the present disclosure;
[0040] FIG. 31A shows another example of an elongated main body of
the agitator of FIG. 30, consistent with embodiments of the present
disclosure;
[0041] FIG. 31B shows a close-up of an end of the flap of FIG. 31A,
consistent with embodiments of the present disclosure;
[0042] FIG. 32 shows one example of the flap of FIG. 29 without the
elongated main body, consistent with embodiments of the present
disclosure;
[0043] FIG. 33 shows another example of the flap of FIG. 32,
consistent with embodiments of the present disclosure;
[0044] FIG. 34 shows one example of a flap with a portion removed
to form a taper, consistent with embodiments of the present
disclosure;
[0045] FIG. 35 shows another example of a flap with having a base
configured to form a taper, consistent with embodiments of the
present disclosure;
[0046] FIG. 36 shows one example of an agitator having a flap
disposed at a non-perpendicular angle with respect to the agitator
body, consistent with embodiments of the present disclosure;
[0047] FIG. 37 shows another example of an end cap having a
plurality of ribs for engaging with a distal end of a flap,
consistent with embodiments of the present disclosure;
[0048] FIG. 37A shows a perspective view of an agitator, consistent
with embodiments of the present disclosure;
[0049] FIG. 37B shows a cross-sectional view of an agitator having
passively angled bristles and aggressively angled flaps, consistent
with embodiments of the present disclosure;
[0050] FIG. 37C shows a perspective view of an agitator, consistent
with embodiments of the present disclosure;
[0051] FIG. 37D shows a perspective view of a debrider having
bristle combs, consistent with embodiments of the present
disclosure;
[0052] FIG. 37E shows a cross-sectional view of a vacuum cleaner
including a leading roller and an agitator consistent with
embodiments of FIGS. 37A-D, consistent with embodiments of the
present disclosure;
[0053] FIG. 38 shows another example of a vacuum cleaner,
consistent with embodiments of the present disclosure;
[0054] FIG. 39 shows one example of a hand vacuum of FIG. 38
including a trigger, consistent with embodiments of the present
disclosure;
[0055] FIG. 40 shows one example of a hand vacuum of FIG. 38
including an air flow pathway extending therethrough, consistent
with embodiments of the present disclosure;
[0056] FIG. 41 generally shows one example of a close-up of the
debris collection chamber secured to the may body of the hand
vacuum, consistent with embodiments of the present disclosure;
[0057] FIG. 42 generally shows one example of a close-up of the
debris collection chamber unsecured to the may body of the hand
vacuum, consistent with embodiments of the present disclosure;
[0058] FIG. 43 generally shows one example of the debris collection
chamber and the primary filter, consistent with embodiments of the
present disclosure;
[0059] FIG. 44 generally shows one example of the debris collection
chamber of FIG. 43 with a lid open and the primary filter,
consistent with embodiments of the present disclosure;
[0060] FIG. 45 generally shows one example of the second stage
filter, consistent with embodiments of the present disclosure;
[0061] FIG. 46 generally shows one example of the pre-motor filter,
consistent with embodiments of the present disclosure;
[0062] FIG. 47 generally shows one example of the post motor
filter, consistent with embodiments of the present disclosure;
[0063] FIG. 48 generally illustrates one embodiment of a robot
vacuum cleaner which may include one or more of the features
described in the present disclosure;
[0064] FIG. 49 generally illustrates another embodiment of a vacuum
cleaner which may include one or more of the features described in
the present disclosure;
[0065] FIG. 50 generally illustrates a front perspective view of
the cleaning head of FIG. 49 including one or more of the features
described in the present disclosure;
[0066] FIG. 51 generally illustrates a front view of the cleaning
head of FIG. 49 including one or more of the features described in
the present disclosure;
[0067] FIG. 52 generally illustrates a front perspective view of a
portion of the cleaning head of FIG. 49 including one or more of
the features described in the present disclosure;
[0068] FIG. 53 generally illustrates a cross-sectional view of the
cleaning head of FIG. 49 take generally perpendicular to the pivot
axis including one or more of the features described in the present
disclosure;
[0069] FIG. 54 generally illustrates a bottom view of the cleaning
head of FIG. 49 including one or more of the features described in
the present disclosure;
[0070] FIG. 55 generally illustrates a partial exploded front
perspective view of the cleaning head of FIG. 49 with the cover
plate and a portion of the cleaning head body not shown;
[0071] FIG. 56 generally illustrates a cross-sectional view of the
cleaning head of FIG. 49 generally taken along the pivot axis;
[0072] FIG. 57 shows a deformable flap including holes; and FIG. 58
shows bristle filament shapes.
DETAILED DESCRIPTION
[0073] While the making and using of various embodiments of the
present disclosure are discussed in detail below, it should be
appreciated that the present disclosure provides many applicable
inventive concepts that can be embodied in a wide variety of
specific contexts. The specific embodiments discussed herein are
merely illustrative of specific ways to make and use the disclosure
and do not limit the scope of the disclosure.
[0074] The present disclosure is generally directed to an agitator
for a surface treatment apparatus. The agitator includes a body and
a deformable flap that extends from the body. The deformable
includes one or more tapers that extend within a corresponding end
region of the deformable flap. The agitator is configured to be
received within an agitator chamber of the surface treatment
apparatus such that the agitator can be rotated within the agitator
chamber. Rotation of the agitator causes the deformable flap to
engage a surface to be cleaned (e.g., a floor) such that debris
deposited thereon can be disturbed by the deformable flap. In
operation, the one or more tapers may encourage a migration of
fibrous debris (e.g., hair) along a longitudinal axis of the body
towards a common location (e.g., a removal location).
[0075] Turning now to FIGS. 1 and 2, one embodiment of a vacuum
cleaner 10 is generally illustrated. The term vacuum cleaner 10 is
intended to refer to any type of vacuum cleaner including, but not
limited to, hand-operated vacuum cleaners and robot vacuum
cleaners. Non-limiting examples of hand-operated vacuum cleaners
include upright vacuum cleaners, canister vacuum cleaners, stick
vacuum cleaners, and central vacuum systems. Thus, while various
aspects of the present disclosure may be illustrated and/or
described in the context of a hand-operated vacuum cleaner or a
robot vacuum cleaner, it should be understood the features
disclosed herein are applicable to both hand-operated vacuum
cleaners and robot vacuum cleaners unless specifically stated
otherwise.
[0076] With this in mind, FIG. 1 generally illustrates a bottom
view of a vacuum cleaner 10 and FIG. 2 generally illustrates a
cross-section of the vacuum cleaner 10 taken along lines II-II of
FIG. 1. It should be understood that the vacuum cleaner 10 shown in
FIGS. 1 and 2 is for exemplary purposes only and that a vacuum
cleaner consistent with the present disclosure may not include all
of the features shown in FIGS. 1 and 2, and/or may include
additional features not shown in FIGS. 1 and 2. For exemplary
purposes only, a vacuum cleaner 10 may include a cleaning head
(which may also be referred to as a nozzle and/or cleaning nozzle)
12 and optionally a handle 14. In the illustrated embodiment, the
handle 14 is pivotally coupled to the cleaning head 12 such that
the user may grasp the handle 14 while standing to move the
cleaning head 12 on a surface to be cleaned 114 (e.g., a floor)
using one or more wheels 16. It should be appreciated; however,
that the cleaning head 12 and the handle 14 may be an integrated or
unitary structure (e.g., such as a handleheld vacuum cleaner).
Alternatively, the handle 14 may be eliminated (e.g., such as in a
robot vacuum cleaner).
[0077] The cleaning head 12 includes a cleaning head body or
housing 13 that at least partially defines/includes one or more
agitator chambers 22. The agitator chambers 22 include one or more
openings (or air inlets) 23 defined within and/or by a portion of
the bottom surface/plate 25 of the cleaning head 12/cleaning head
body 13. At least one rotating agitator or brush roll 18 is
configured to be coupled to the cleaning head 12 (either
permanently or removably coupled thereto) and is configured to be
rotated about a pivot axis 20 (e.g., in the direction and/or
reverse direction of arrow A, FIG. 2) within the agitator chambers
22 by one or more rotation systems 24. The rotation systems 24 may
be at least partially disposed in the vacuum head 12 and/or handle
14, and may one or more motors 26 (either AC and/or DC motors)
coupled to one or more belts and/or gear trains 28 for rotating the
agitators 18.
[0078] The vacuum cleaner 10 includes a debris collection chamber
30 in fluid communication with the agitator chamber 22 such that
debris collected by the rotating agitator 18 may be stored. The
agitator chamber 22 and debris chamber 30 may be fluidly coupled to
a vacuum source 32 (e.g., a suction motor or the like) for
generating an airflow (e.g., partial vacuum) in the agitator
chamber 22 and debris collection chamber 30 and to suck up debris
proximate to the agitator chamber 22 and/or agitator 18. As may be
appreciated, the rotation of the agitator 18 may aid in
agitating/loosening debris from the cleaning surface. Optionally,
one or more filters 34 may be provided to remove any debris (e.g.,
dust particles or the like) entrained in the vacuum air flow. The
debris chamber 30, vacuum source 32, and/or filters 34 may be at
least partially located in the cleaning head 12 and/or handle 14.
Additionally, one or more suction tubes, ducts, or the like 36 may
be provided to fluidly couple the debris chamber 30, vacuum source
32, and/or filters 34. For example, the suction tube 36 may include
a suction inlet and/or suction opening 33, FIG. 2, which separates
the suction tube 36 from the agitation chamber 22 (e.g., which is
the entrance of the suction tube 36 from the agitation chamber 22).
The vacuum cleaner 10 may include and/or may be configured to be
electrically coupled to one or more power sources such as, but not
limited to, an electrical cord/plug, batteries (e.g., rechargeable,
and/or non-rechargeable batteries), and/or circuitry (e.g., AC/DC
converters, voltage regulators, step-up/down transformers, or the
like) to provide electrical power to various components of the
vacuum cleaner 10 such as, but not limited to, the rotation systems
24 and/or the vacuum source 32.
[0079] The agitator 18 includes an elongated agitator body 40 that
is configured to extend along and rotate about a longitudinal/pivot
axis 20. The agitator 18 (e.g., but not limited to, one or more of
the ends of the agitator 18) is permanently or removably coupled to
the vacuum head 12 and may be rotated about the pivot axis 20 by
the rotation system 24. In the illustrated embodiment, the
elongated agitator body 40 has a generally cylindrical
cross-section, though other cross-sectional shapes (such as, but
not limited to, oval, hexagonal, rectangular, octagonal, concaved,
convex, and the like) are also possible. The agitator 18 may have
bristles, fabric, felt, nap, pile, and/or other cleaning elements
(or any combination thereof) 42 around the outside of the elongated
agitator body 40. Examples of brush rolls and other agitators 18
are shown and described in greater detail in U.S. Pat. No.
9,456,723 and U.S. Patent Application Pub. No. 2016/0220082, which
are fully incorporated herein by reference.
[0080] As the agitator 18 rotates within the agitation chamber 22,
the agitator 18 may come into contact with elongated (or fibrous)
debris such as, but not limited to, hair, string, and the like. The
fibrous debris 44 may have a length that is much longer than the
diameter of the agitator 18. By way of a non-limiting example, the
fibrous debris 44 may have a length that is 2-10 times longer than
the diameter of the agitator 18. Because of the rotation of the
agitator 18 as well as the length and flexibility of the fibrous
debris 44, the fibrous debris 44 will tend to wrap around the
diameter of the agitator 18.
[0081] As may be appreciated, an excessive amount of fibrous debris
44 building up on the agitator 18 may reduce the efficiency of the
agitator 18 and/or cause damage to the vacuum cleaner 10 (e.g., the
rotation systems 24 or the like). To address the problem of fibrous
debris 44 wrapping around the agitator 18, the vacuum cleaner 10
may include one or more hair migration systems 49 and/or one or
more combing units 50 (also referred to as a debrider) disposed at
least partially within the agitation chamber 22. As explained
herein, the hair migration system 49 may be configured to cause at
least some of the fibrous debris 44 wrapped around the agitator 18
to move along the agitator 18 (and optionally be removed from the
agitator 18) as the agitator 18 rotates about the pivot axis 20.
The combing unit 50 (which may optionally be used in combination
with the hair migration system 49) may be configured to dislodge at
least some of the fibrous debris 44 that is wrapped around the
agitator 18, wherein the dislodged fibrous debris 44 may be
entrained into the suction air flow, through the suction tube 36,
and ultimately to the debris collection chamber 30. The hair
migration system 49 may include one or more ribs 116, bristles 60,
and/or sidewalls 62 (e.g., resiliently deformable sidewalls/flaps).
At least one rib 116 (shown in hidden lines) can extend within the
surface cleaning head 12 and can be configured to engage (e.g.,
contact) the agitator 18 such that fibrous debris can be urged
towards one or more predetermined locations on the agitator 18. For
example, the at least one rib 116 can extend transverse (e.g., at a
non-perpendicular angle) to a longitudinal axis L of the agitator
18 such that, as fibrous debris becomes entangled around the
agitator 18, the fibrous debris engages (e.g., contacts) the rib
116 and is urged towards a predetermined location along the
agitator 18. While the vacuum cleaner 10 is illustrated with both
the hair migration system 49 and combing unit 50, it should be
appreciated that some examples of the vacuum cleaner 10 may include
only the hair migration system 49 or combing unit 50.
[0082] Turning now to FIG. 3, one example of a hair migration
system 49 is generally illustrated. The hair migration system 49
may include a plurality of bristles 60 on the agitator 18 aligned
in one or more rows or strips. Alternatively (or in addition), the
hair migration system 49 may include one or more sidewalls and/or
continuous sidewalls (which in some examples may be referred to as
a flap or resiliently deformable flap) 62 adjacent to at least one
row of bristles 60. The rows of bristles 60 and/or continuous
sidewall 62 are configured to reduce hair from becoming entangled
in the bristles 60 of the agitator 18. Optionally, the combination
of the bristles and sidewall 62 may be configured to generate an
Archimedes screw force that urges/causes the hair to migrate
towards one or more collection areas of the agitator 18 (e.g., but
not limited to, a central region 41 of the agitator 18). The
bristles 60 may include a plurality of tufts of bristles 60
arranged in rows and/or one or more rows of continuous bristles
60.
[0083] The plurality of bristles 60 extend outward (e.g., generally
radial outward) from the elongated agitator body 40 (e.g., a base
portion) to define one or more continuous rows. One or more of the
continuous rows of bristles 60 may be coupled (either permanently
or removably coupled) to the elongated agitator body 40 using one
or more form locking connections (such as, but not limited to, a
tongue and groove connection, a T-groove connection, or the like),
interference connections (e.g., interference fit, press fit,
friction fit, Morse taper, or the like), adhesives, fasteners
overmoldings, or the like.
[0084] The rows of bristles 60 at least partially revolve around
and extend along at least a portion of the longitudinal axis/pivot
axis 20 of the elongated agitator body 40 of the agitator 18. As
defined herein, a continuous row of bristles 60 is defined as a
plurality of bristles 60 in which the spacing between adjacent
bristles 60 along the axis of rotation 20 is less than or equal to
3 times the largest cross-sectional dimension (e.g., diameter) of
the bristles 60.
[0085] As mentioned above, the plurality of bristles 60 are aligned
in and/or define at least one row that at least partially revolves
around and extends along at least a portion of the longitudinal
axis/pivot axis 20 of the elongated agitator body 40 of the
agitator 18. For example, at least one of the rows of bristles 60
may be arranged in a generally helical, arcuate, and/or chevron
configuration/pattern/shape. Optionally, one or more of the rows of
bristles 60 (e.g., the entire row or a portion thereof) may have a
constant pitch (e.g., constant helical pitch). Alternatively (or in
addition), one or more of the rows of bristles 60 (e.g., the entire
row or a portion thereof) may have a variable pitch (e.g., variable
helical pitch). For example, at least a portion of the row of
bristles 60 may have a variable pitch that is configured to
accelerate the migration of hair and/or generally direct debris
towards a desired location (e.g., the central region 41 of the
agitator 18 and/or towards the primary inlet 33 of the suction tube
36).
[0086] In one example, at least one row of bristles 60 may be
arranged proximate to (e.g., immediately adjacent to) at least one
sidewall 62. The sidewall 62 may be disposed as close as possible
to the nearest row of bristles 60, while still allowing the
bristles 60 to bend freely left-to-right. For example, one or more
of the sidewalls 62 may extend substantially continuously along the
row of bristles 60. In one embodiment, the sidewall 62 may have a
length at least as long as the length of the adjacent row of
bristles 60. The sidewall 62 may extend substantially parallel to
at least one of the rows of bristles 60. As used herein, the term
"substantially parallel" is intended to mean that the separation
distance between the sidewall 62 and the row of bristles 60 remains
within 25% of the greatest separation distance along the entire
longitudinal length of the row of bristles 60, for example, within
20% of the greatest separation distance along the entire
longitudinal length of the row of bristles 60 and/or within 15% of
the greatest separation distance along the entire longitudinal
length of the row of bristles 60. Also, as used herein, the term
"immediately adjacent to" is intended to mean that no other
structural feature or element having a height greater than the
height of the sidewall 62 is disposed between the sidewall 62 and a
closest row of bristles 60, and that the separation distance D
between the sidewall 62 and the closest row of bristles 60 is less
than, or equal to, 5 mm (for example, less than or equal to 3 mm,
less than or equal to 2.5 mm, less than or equal to 1.5 mm, and/or
any range between 1.5 mm to 3 mm).
[0087] One or more of the sidewalls 62 may therefore at least
partially revolve around and extend along at least a portion of the
longitudinal axis/pivot axis 20 of the elongated agitator body 40
of the agitator 18. For example, at least one of the sidewalls 62
may be arranged in a generally helical, arcuate, and/or chevron
configuration/pattern/shape. Optionally, one or more of the
sidewalls 62 (e.g., the entire row or a portion thereof) may have a
constant pitch (e.g., constant helical pitch). Alternatively (or in
addition), one or more of the sidewalls 62 (e.g., the entire row or
a portion thereof) may have a variable pitch (e.g., variable
helical pitch).
[0088] While the agitator 18 is shown having a row of bristles 60
with a sidewall 62 arranged behind the row of bristles 60 as the
agitator 18 rotates about the pivot axis 20, the agitator 18 may
include one or more sidewalls 62 both in front of the row of
bristles 60, behind the row of bristles 60, and/or without the rows
of bristles 60. As noted above, one or more of the sidewalls 62 may
extend outward from a portion of the elongated agitator body 40 as
generally illustrated in FIG. 3. For example, one or more of the
sidewalls 62 may extend outward from a base of the elongated
agitator body 40 from which the row of bristles 60 is coupled
and/or may extend outward from a portion of an outer periphery of
the elongated agitator body 40. Alternatively (or in addition), one
or more of the sidewalls 62 may extend inward from a portion of the
elongated agitator body 40. For example, the radially distal-most
portion of the sidewall 62 may be disposed at a radial distance
from the pivot axis 20 of the elongated agitator body 40 that is
within 20 percent of the radial distance of the adjacent,
surrounding periphery of the elongated agitator body 40, and the
proximal-most portion of the sidewall 62 (i.e., the portion of the
sidewall 62 which begins to extend away from the base) may be
disposed at a radial distance that is less than the radial distance
of the adjacent, surrounding periphery of the elongated agitator
body 40. As used herein, the term "adjacent, surrounding periphery"
is intended to refer to a portion of the periphery of the elongated
agitator body 40 that is within a range of 30 degrees about the
pivot axis 20.
[0089] In some examples, the agitator 18 may include at least one
row of bristles 60 substantially parallel to at least one sidewall
62. According to one embodiment, at least a portion (e.g., all) of
the bristles 60 in a row may have an overall height Hb (e.g., a
height measured from the pivot axis 20) that is longer than the
overall height Hs (e.g., a height measured from the pivot axis 20)
of at least one of the adjacent sidewalls 62. Alternatively (or in
addition), at least a portion (e.g., all) of the bristles 60 in a
row may have a height Hb that is 2-3 mm (e.g., but not limited to,
2.5 mm) longer than the height Hs of at least one of the adjacent
sidewalls 62. Alternatively (or in addition), the height Hs of at
least one of the adjacent sidewalls 62 may be 60 to 100% of the
height Hb of at least a portion (e.g., all) of the bristles 60 in
the row. For example, the bristles 60 may have a height Hb in the
range of 12 to 32 mm (e.g., but no limited to, within the range of
18 to 20.5 mm) and the adjacent sidewall 62 may have a height Hs in
the range of 10 to 29 mm (e.g., but no limited to, within the range
of 15 to 18 mm).
[0090] The bristles 60 may have a height Hb that extends at least 2
mm beyond the distal-most end of the sidewall 62. The sidewall 62
may have a height Hs of at least 2 mm from the base, and may have a
height Hs that is 50% or less of the height Hb of the bristles 60.
At least one sidewall 62 may be disposed close enough to the at
least one row of bristles 60 to increase the stiffness (e.g.,
decrease the range or motion) of the bristles 60 in at least one
front-to-back direction as the agitator 18 is rotated during normal
use. The sidewall 62 may therefore allow the bristles 60 to flex
much more freely in at least one side-to-side direction compared to
a front-to-back direction. For example, the bristles 60 may be
25%-40% (including all values and ranges therein) stiffer in the
front-to-back direction compared to side-to-side direction.
According to one embodiment, the sidewall 62 may be located
adjacent to (e.g., immediately adjacent to) the row of bristles 60.
For example, the distal most end of the sidewall 62 (i.e., the end
of the sidewall 62 furthest from the center of rotation PA) may be
0-10 mm from the row of bristles 60, such as 1-9 mm from the row of
bristles 60, 2-7 mm from the row of bristles 60, and/or 1-5 mm from
the row of bristles 60, including all ranges and values
therein.
[0091] In another example, at least a portion (e.g., all) of the
bristles 60 in a row may have an overall height Hb that is shorter
than the overall height Hs of at least one of the adjacent
sidewalls 62. Alternatively (or in addition), at least a portion
(e.g., all) of the bristles 60 in a row may have a height Hb that
is 2-3 mm (e.g., but not limited to, 2.5 mm) shorter than the
height Hs of at least one of the adjacent sidewalls 62.
Alternatively (or in addition), the height Hb of at least a portion
(e.g., all) of the bristles 60 in the row may be 60 to 100% of the
Height Hs of at least one of the adjacent sidewalls 62. For
example, the bristles 60 may have a height Hb in the range of 10 to
29 mm (e.g., but no limited to, within the range of 15 to 18 mm)
and the adjacent sidewall 62 may have a height Hs in the range of
12 to 32 mm (e.g., but no limited to, within the range of 18 to
20.5 mm). The sidewall 62 may have a height Hs that extends at
least 2 mm beyond the distal-most end of the bristles 60. The
bristles may have a height Hb of at least 2 mm from the base, and
may up a height Hb that is 50% or less of the height Hs of the
sidewall 62.
[0092] According to one embodiment, the sidewall 62 includes
flexible and/or elastomeric materials, and may be generally
referred to as flaps and/or resiliently deformable flaps. Examples
of a flexible and/or elastomeric material include, but are not
limited to, rubber, silicone, and/or the like. The sidewall 62 may
include a combination of a flexible material and fabric. The
combination of a flexible material and fabric may reduce wear of
the sidewall 62, thereby increasing the lifespan of the sidewall 62
as well as providing an additional method for cleaning and
agitation. The rubber may include natural and/or synthetic, and may
be either a thermoplastic and/or thermosetting plastic. The rubber
and/or silicone may be combined with polyester fabric and/or nylon
fabric (e.g. PA66). In one embodiment, sidewall 62 may include cast
rubber and fabric (e.g., polyester fabric). The cast rubber may
include natural rubber cast with a polyester fabric. Alternatively
(or in addition), the cast rubber may include a polyurethane (such
as, but not limited to, PU 45 Shore A) and cast with a polyester
fabric.
[0093] Because the sidewall 62 may be assembled on a helical path,
there may be a need for the top edge and bottom edge of the
sidewall 62 to follow different helices each with a different
helical radius. When a flexible material with reinforcement is
selected to pass life requirements, the stretch required along
these edges should be accounted for in order for the as-assembled
sidewall 62 position to agree with the different helical radius and
helical path of each edge (because the fiber materials of the
composite sidewall 62 can reduce the flexibility of the sidewall
62). If this is not met, then the distal end of the sidewall 62 may
not be positioned at a constant distance from the bristles 60
(e.g., within 10 mm as described herein). Therefore, the sidewall
62 geometry and the material choices may be selected to satisfy the
spatial/positional requirements of the sidewall 62, the flexibility
required to perform the anti-wrap function, and the durability to
withstand normal use in a vacuum cleaner. The addition of a fabric
may be useful in higher agitator rotation speed applications (e.g.,
but not limited to, upright vacuum applications).
[0094] The agitator 18 (e.g., the bristles 60 and/or sidewall 62)
should be aligned within the agitator chamber 22 such that the
bristles 60 and/or sidewall 62 are able to contact the surface to
be cleaned. The bristles 60 and/or sidewall 62 should be stiff
enough in at least one of the directions to engage the surface to
be cleaned (e.g., but not limited to, carpet fibers) without
undesirable bending (e.g., stiff enough to agitate debris from the
carpet), yet flexible enough to allow side-to-side bending. Both
the size (e.g., height Hs) and location of the sidewalls 62
relative to the row of bristles 60 may be configured to generally
prevent and/or reduce hair from becoming entangled around the base
or bottom of the bristles 60. The bristles 60 may be sized so that
when used on a hard floor, it is clear of the floor in use.
However, when the surface cleaning apparatus 10 is on carpet, the
wheels will sink in and the bristles 60 and/or sidewall 62 will
penetrate the carpet. The length of bristles 60 and/or sidewall 62
may be chosen so that it is always in contact with the floor,
regardless of floor surface. Additional details of the agitator 18
(such as, but not limited to, the bristles 60 and/or sidewall 62)
are described in U.S. Patent Application Publication Number
2018/0070785 filed on Sep. 8, 2017, entitled "Agitator with Hair
Removal," which is fully incorporated herein by reference.
[0095] As noted herein, the hair migration system 49 (e.g., the
combination of the bristles 60 and/or the sidewall 62) may be
configured to migrate fibrous debris 44 in a desired and/or target
direction and/or to a desired location. In accordance with at least
one aspect of the present disclosure, the hair migration system 49
is configured to migrate the fibrous debris 44 towards the combing
unit 50 and/or towards a region of the agitator 18 which is
proximate to an inlet of the suction tube 36 which is fluidly
coupled to the agitation chamber 22. In the illustrated embodiment,
the hair migration system 49 is configured to migrate the fibrous
debris 44 towards a central region 41 of the agitator 18 (e.g.,
which may be proximate to the combing unit 50) and the primary
inlet 33 of the suction tube 36 (FIGS. 4-6) when the agitator 18 is
rotating within the agitation chamber 22. For example, the hair
migration system 49 may be configured to migrate the fibrous debris
44 along the agitator 18 towards the combing unit 50 to allow the
combing unit 50 to remove the fibrous debris 44 from the agitator
18, whereupon the fibrous debris 44 may be entrained in the suction
air flow into the suction tube 36.
[0096] In at least one example, the hair migration system 49 may
include a first and at least a second (e.g., a left and a right)
hair migration sections 66, 67. Each hair migration section 66, 67
may include one or more sidewalls 62 and/or the bristles 60 as
generally described herein. The sidewalls 62 and/or the bristles 60
of one or more of the hair migration sections 66, 67 may have a
generally helical pattern and/or a generally chevron pattern.
According to one aspect, at least a portion of the hair migration
sections 66, 67 may partially overlap in an overlap region 69. In
the illustrated example, only the sidewalls 62 overlap; however, it
should be appreciated that only the bristles 60 may overlap and/or
both the sidewalls 62 and the bristles 60 may partially overlap. As
used herein, the hair migration sections 66, 67 are considered to
overlap if the sidewalls 62 and/or the bristles 60 of the adjacent
hair migration sections 66, 67 pass through the radial
cross-section as the agitator 18 rotates about the pivot axis 20
within the agitator chamber 22. The amount and/or degree of overlap
(i.e., the size of the overlap region 69) may vary depending upon
the intended application. For example, the size of the overlap
region 69 may vary depending upon the length of the combing unit
50, the overall length of the agitator 18, the rotational speed of
the agitator 18, or the like. According to one embodiment, the size
of the overlap region 69 may be 10-30 mm, and the agitator 18 may
have a length of 225 mm. According to another embodiment, the size
of the overlap region 69 may be 4-20% of the length of the agitator
18. Of course, these are merely examples.
[0097] Optionally, the height of one or more of the sidewalls 62
and/or the bristles 60 may taper in at least a portion of the
overlap region 69. The reduction in the height of the sidewalls 62
and/or the bristles 60 in the overlap region 69 may facilitate
removal of fibrous debris 44 from the agitator 18 by reducing the
compressive force that the fibrous debris 44 applies to the
agitator 18.
[0098] While the hair migration system 49 is shown having two
adjacent hair migration sections 66, 67 which each extend across
only a portion of the length of the agitator 18, it should be
appreciated that the hair migration system 49 may have greater than
or less than two migration sections 66, 67. For example, the hair
migration system 49 may include one or more continuous hair
migration sections that extend substantially along the entire
length of the agitator 18. In particular, the elongated hair
migration section may have a generally helical and/or generally
chevron pattern that may change direction at the target location in
order to migrate towards the target location from both ends of the
agitator 18.
[0099] Turning now to FIGS. 4-6, one example of the combing unit 50
is generally illustrated. In particular, FIG. 4 generally
illustrates a perspective cross-sectional view taken along lines
IV-IV of FIG. 1 without the agitator 18 for clarity, FIG. 5
generally illustrates a cross-sectional view taken along lines
IV-IV of FIG. 1, and FIG. 6 generally illustrates a cross-sectional
view taken along lines VI-VI of FIG. 2 without the agitator 18 for
clarity. While only a single combing unit 50 is shown, it should be
appreciated that the vacuum cleaner 10 may include a plurality of
combing units 50.
[0100] The combing unit 50 may be at least partially disposed in
the agitator chamber 22 and may include a plurality of fingers,
ribs, and/or teeth 52 forming a comb-like structure that is
configured to contact a portion of the length of the agitator 18
(e.g., the bristles 60 and/or sidewalls 62 as discussed herein).
The fingers 52 are configured to extend (e.g., protrude) from a
portion of the vacuum cleaner 10 (such as, but not limited to, the
body 13, agitator chamber 22, bottom surface 25, and/or debris
collection chamber 30) generally towards the agitator 18 such that
at least a portion of the fingers 52 contact an end portion of the
bristles 60 and/or one or more of the sidewalls 62. Rotation of the
agitator 18 causes the fingers 52 of the combing unit 50 to pass
between the plurality of bristles 60 and/or contact one or more of
the more of the sidewalls 62, thereby preventing hair from becoming
entangled on the agitator 18. It should be appreciated that the
shape or the fingers, ribs, and/or teeth 52 are not limited to
those shown and/or described in the instant application unless
specifically claimed as such.
[0101] According to one embodiment, at least some of the fingers 52
(e.g., all of the fingers 52) extend generally towards the agitator
18 such that a distal most end of the fingers 52 is within 2 mm of
the sidewall 62 as the sidewall 62 rotates past the fingers 52. As
such, the fingers 52 may or may not contact the sidewall 62.
[0102] Alternatively (or in addition), at least some of the fingers
52 (e.g., all of the fingers 52) extend generally towards the
agitator 18 such that a distal most end of the fingers 52 contact
(e.g., overlap) the sidewall 62 as the sidewall 62 rotates past the
fingers 52. For example, the distal most end of the fingers 52 may
contact up to 3 mm of the distal most end of the sidewall 62, for
example, 1-3 mm of the distal most end of the sidewall 62, 0.5-3 mm
of the distal most end of the sidewall 62, up to 2 mm of the distal
most end of the sidewall 62, and/or 2 mm of the sidewall 62,
including all ranges and values therein.
[0103] The fingers 52 may be placed along all or a part of the
longitudinal length L of the combing unit 50, for example, either
evenly or randomly spaced along longitudinal length L. According to
one embodiment, the density of the fingers 52 (e.g., number of
fingers 52 per inch) may be in the range of 0.5-16 fingers 52 per
inch such as, but not limited to, 1-16 fingers 52 per inch, 2-16
fingers 52 per inch, 4 to 16 fingers 52 per inch and/or 7-9 fingers
52 per inch, including all ranges and values therein. For example,
the fingers 52 may have a 2-5 mm center to center spacing, a 3-4 mm
center to center spacing, a 3.25 mm center to center spacing, a
1-26 mm center to center spacing, up to a 127 mm center to center
spacing, up to a 102 mm center to center spacing, up to a 76 mm
center to center spacing, up to a 50 mm center to center spacing, a
2-26 mm center to center spacing, a 2-50.8 mm center to center
spacing, and/or a 1.58-25.4 mm center to center spacing, including
all ranges and values therein.
[0104] The width of the fingers 52 (e.g., also referred to as
teeth) may be configured to occupy a minimum width subject to
manufacturing and strength requirements. The reduced width of the
fingers 52 may minimize wear on the agitator 18 and facilitate
airflow between the fingers 52 for clearing of hair. The collective
widths of the plastic fingers 52 may be 30% or less than the total
width of the combing unit 50, particularly when the combing unit 50
is plastic.
[0105] The width of the fingers 52 along the profile and brush roll
axis 20 may be based on structural and molding requirements. The
profile of the distal end of the fingers 52 may be arcuate (e.g.,
rounded) or may form a sharp tip (e.g., the leading edge and the
trailing edge may intersect at the inflection point to form an
acute angle). According to one embodiment, the profile of the
distal end of the fingers 52 may be rounded and smooth, based on
material and production factors. For example, the profile of the
distal end of the fingers 52 may be 0.6-2.5 mm in diameter (such
as, but not limited to, 1-2 mm in diameter and/or 1.6 mm in
diameter) for a 28 mm diameter agitator 18.
[0106] The root gap of the fingers 52 (e.g., the transition between
adjacent fingers 52) may have a radial gap clearance that is from 0
to 25% of the major diameter of the agitator 18. For example, the
root gap of the fingers 52 may be between 2-7% of the major
diameter of the agitator 18 such as, but not limited to, 3-6% of
the major diameter of the agitator 18 and/or 5.4% of the major
diameter of the agitator 18. By way of a non-limiting example, the
root gap of the fingers 52 may be a 1.5 mm gap for a 28 mm agitator
18.
[0107] While the fingers 52 are illustrated being spaced in a
direction extending along a longitudinal length L of the combing
unit 50 that is generally parallel to the pivot axis 20 of the
agitator 18, it should be appreciated that all or a portion of the
fingers 52 may extend along one or more axes (e.g., a plurality of
axes) in one or directions that are transverse to the pivot axis 20
(e.g., but not limited to, a V shape).
[0108] The combing unit(s) 50 extends across only a portion of the
length of the agitation chamber 22, for example, the portion
corresponding to the primary suction inlet 33 of the suction tube
36. At least one combing unit 50 may be disposed proximate to the
primary suction inlet 33 of the suction tube 36. As used herein,
the phrase "proximate to the primary suction inlet 33 of the
suction tube 36" and the like is intended to mean that the combing
unit 50 is disposed within and/or upstream of the primary suction
inlet 33 at a distance less than 20% of the cross-sectional area of
the primary suction inlet 33 of the suction tube 36.
[0109] In the illustrated example, the vacuum cleaner 10 is shown
having a primary suction inlet 33 (best seen in FIG. 6) and two
adjacent secondary suction inlets 71 which extend laterally (e.g.,
left and right) from the primary suction inlet 33 along the length
of the agitation chamber 22. The primary suction inlet 33 and the
secondary suction inlets 71 of the suction tube 36 are defined as
the transitional areas between the agitation chamber 22 and the
suction tube 36 which defines the beginning of the suction path
from the agitation chamber 22. While the vacuum cleaner 10 is shown
having only a single primary suction inlet 33 and two adjacent
secondary suction inlets 71, it should be understood that the
vacuum cleaner 10 may have less or greater than two secondary
suction inlets 71 and/or more than one primary suction inlet 33. In
an embodiment having more than one primary suction inlet 33, the
vacuum cleaner 10 may optionally include more than one combing unit
50. In addition, the vacuum cleaner 10 may not have any secondary
suction inlets 71.
[0110] The primary suction inlet 33 of the suction tube 36 is
defined as having a height which is larger than the height of the
adjacent secondary suction inlets 71. As such, the primary suction
inlet 33 may have a larger pressure (but lower velocity) compared
to the secondary suction inlets 71. For example, the secondary
suction inlets 71 may have a height which is less than 25% of the
height of the primary suction inlet 33, e.g., the secondary suction
inlets 71 may have a height which is less than 20% of the height of
the primary suction inlet 33; the secondary suction inlets 71 may
have a height which is less than 15% of the height of the primary
suction inlet 33; and/or the secondary suction inlets 71 may have a
height which is less than 10% of the height of the primary suction
inlet 33, including all values and ranges therein. The primary
suction inlet(s) 33 collectively have a length that is less than
the length of the agitation chamber 22. For example, the collective
length of the primary suction inlet(s) 33 is less than 80% of the
length of the agitation chamber 22, e.g., the collective length of
the primary suction inlet(s) 33 may be less than 60% of the length
of the agitation chamber 22; the collective length of the primary
suction inlet(s) 33 may be less than 50% of the length of the
agitation chamber 22; the collective length of the primary suction
inlet(s) 33 may be less than 40% of the length of the agitation
chamber 22; and/or the collective length of the primary suction
inlet(s) 33 may be less than 30% of the length of the agitation
chamber 22, including all values and ranges therein.
[0111] According to one aspect, the upper surface of the secondary
suction inlets 71 may be disposed 3-5 mm from the surface to be
cleaned when the vacuum cleaner 10 is disposed on the surface to be
cleaned. The secondary suction inlets 71 may be configured to
extend from the primary suction inlet 33 across substantially the
entire length of the agitation chamber 22. This configuration may
enhance suction of the vacuum cleaner 10 by reducing and/or
eliminating dead spots within the agitation chamber 22 in which the
air flow is too low to entrain debris. Additionally (or
alternatively), the upper surface of the primary suction inlet 33
may be 12-18 mm (e.g., 15 mm) from the upper surface of the
secondary suction inlets 71 (e.g., 15-21 mm from the floor).
[0112] As discussed herein, the fingers 52 of the combing unit 50
may be configured to contact the agitator 18, e.g., the bristles 60
and/or sidewall 62. According to one aspect, the fingers 52 of the
combing unit 50 may all have substantially the same height as
generally illustrated in FIGS. 4-6. According to one aspect, the
fingers 52 may have a height of 8-10 mm, and the combing unit 50
may have an overall length of 30-40 mm (e.g., but not limited to,
35 mm). The plurality of fingers 52 of the combing unit 50 may
extend across the entire length of the upper portion of the primary
suction inlet 33. Alternatively, one or more of the fingers 52 may
have a different length. For example, one or more of the fingers
52' on the lateral region 73 may have a longer length as generally
illustrated in FIG. 7. In other words, the one or more fingers 52'
corresponding to the lateral region 73 may have a length that
measures greater than the teeth 52 which correspond to a central
region 77. By way of further example, one or more of the fingers
52' within the lateral region 73 may have a length that measures
less than the one or more fingers 52 within the central region 77.
An example of a combing unit 93 having a plurality of fingers 94,
wherein the portion of the plurality of fingers 94 corresponding to
a central region 95 of the combing unit 93 have a length 96 that
measures greater than the length 96 of the portion of the plurality
of finger 94 corresponding to lateral regions 97, is shown in FIG.
7A. As shown in FIG. 7A, the central region 95 extends between each
of the lateral regions 97. A length 98 of the central region 95 may
measure in a range of 20% to 60% of a length 99 of the combing unit
93.
[0113] Turning now to FIG. 8, the present disclosure may also
feature a plurality of sectioned agitator chambers 80. In
particular, the sectioned agitator chambers 80 may extend between
the agitator 18 and an inner wall 82 defining the agitation chamber
22. The pressure within the sectioned agitator chambers 80 may be
higher and/or lower compared to the pressure within the remaining
sections of the agitation chamber 22 (e.g., the pressure of the
agitation chamber 22 proximate to the opening 23) and/or the
suction tube 36. The sectioned agitator chambers 80 may be defined
by the bristles 60 and/or sidewalls 62 extending from the agitator
body 40 and contacting against the inner wall 82 of the agitation
chamber 22. In particular, the bristles 60 and/or sidewalls 62 may
create localized sealing with the inner wall 82. The shape, size,
and pattern of the bristles 60 and/or sidewalls 62 may be used to
adjust the pressure within the sectioned agitator chambers 80 as
the agitator 18 rotates about the pivot axis 20. While the
illustrated example is shown having four sectioned agitator
chambers 80, it should be appreciated that the vacuum cleaner 10
may have greater than or less than four sectioned agitator chambers
80.
[0114] Turning now to FIG. 9, a schematic view of an agitator 200,
which may be an example of the agitator 18 of FIG. 1, is generally
illustrated. As shown, the agitator 200 includes at least one
resiliently deformably flap 202 (which may be an example of the
sidewall 62) extending helically around an elongated main body 203
of the agitator 200 in a direction along a longitudinal axis 204 of
the agitator 200. As discussed herein, the agitator 200 may not
include any bristles; however, it should be appreciated that the
agitator 200 may optionally include bristles in addition to (or
without) the flaps 202.
[0115] The flap 202 may generally be described as a continuous
strip that extends longitudinally along at least a portion of and
in a direction away from the elongated main body 203 of the
agitator 200. In some instances, the flap 202 can extend
longitudinally along the elongated main body 203 for a substantial
portion (e.g., at least 30%, at least 40%, at least 50%, at least
60%, at least 70%, at least 80%, at least 90%, at least 95%, or at
least 99%) of a length 205 the elongated main body 203. The flap
202 is configured to engage (e.g., contact) a surface to be cleaned
as the agitator 200 is rotated such that debris is urged in a
direction of, for example, the opening/air inlet 23 of the vacuum
cleaner 10 of FIG. 1.
[0116] In some instances, the flap 202 can extend helically around
the main body 203 of the agitator 200 according to a first
direction. In other instances, the flap 202 can extend helically
around the main body 203 of the agitator 200 according to a first
and a second direction such that at least one chevron shape is
formed.
[0117] The helical shape of the flap 202, as the flap 202 extends
around the elongated main body 203 of the agitator 200, can be
configured to urge fibrous debris towards one or more predetermined
locations along the agitator 200. For example, when fibrous debris,
such as hair, becomes entangled around the agitator 200, engagement
(e.g., contact) of the flap 202 with the surface to be cleaned
and/or the rib 116 of FIG. 1 can cause the fibrous debris to be
urged along the agitator 200 in accordance with a helical shape of
the flap 202.
[0118] FIG. 10 shows a schematic example of a plurality of ribs
300, which may be examples of the rib 116, engaging (e.g.,
contacting) the agitator 200. As shown, each of the ribs 300 extend
transverse to the longitudinal axis 204 of the agitator 200 at a
non-perpendicular angle and are configured to engage (e.g.,
contact) at least a portion of the flap 202. For example, a rib
angle .alpha. formed between the longitudinal axis 204 and a
respective one or more of the ribs 300 may measure in range of
about 30.degree. to about 60.degree.. As the number of ribs 300 is
increased and the rib angle .alpha. is decreased, the rate at which
fibrous debris is urged along the agitator 200 may be
increased.
[0119] In some instances, the ribs 300 can be configured to extend
at least partially around the agitator 200. As such, the ribs 300
can have an arcuate shape. Such a configuration may increase the
amount of engagement (e.g., contact) between the flaps 202 and the
ribs 300. The ribs 300 are configured to cause the flap 202 to
deform in response to the flap 202 engaging (e.g., contacting) the
ribs 300. For example, the ribs 300 may be made of a plastic (e.g.,
acrylonitrile butadiene styrene), a metal (e.g., an aluminum or
steel alloy), and/or any other suitable material and the flap 202
may be made of a rubber (e.g., a natural or synthetic rubber)
and/or any other suitable material.
[0120] In some instances, each of the ribs 300 can extend parallel
to each other. In other instances, one or more of the ribs 300 may
not extend parallel to at least one other of the ribs 300 (e.g., at
least one rib 300 may extend transverse to at least one other rib
300). As shown, in some instances, each of the ribs 300 may be
evenly spaced. In other instances, the ribs 300 may not be evenly
spaced. For example, a separation distance 301 extending between
the ribs 300 may decrease or increase in a migration direction 304
that extends along the longitudinal axis 204 of the agitator 200.
The migration direction 304 may generally be described as the
direction in which the fibrous debris is urged.
[0121] As shown, each of the ribs 300 can be oriented such that at
least a portion of at least one rib 300 overlaps at least a portion
of at least one other rib 300 (e.g., a longitudinal location along
a first rib corresponds to a longitudinal location along an
adjacent rib). As a result, an overlap region 303 can extend
between two adjacent ribs 300. The overlap region 303 may result in
a substantially continuous urging of fibrous debris along the
migration direction 304.
[0122] As the agitator 200 is rotated according to a rotation
direction 302, the flap 202 engages (e.g., contacts) a portion of
at least one of the ribs 300 and moves along a peripheral edge of
the ribs 300. The inter-engagement between the ribs 300 and the
flap 202 urges fibrous debris in the migration direction 304.
[0123] In some instances, there may be a plurality of migration
directions 304. For example, the agitator 200 can be configured to
urge fibrous debris towards opposing ends of the agitator 200. The
migration direction 304 may be based, at least in part, on a
helical pitch of the flap 202, the rotation direction 302, and/or
the rib angle .alpha..
[0124] FIG. 11 shows a schematic example of a plurality of ribs
400, which may be examples of the rib 116, engaging (e.g.,
contacting) an agitator 401, which may be an example of the
agitator 200 of FIG. 9. As shown, a rotation direction 402 and a
migration direction 404 are opposite that of FIG. 10. As such, the
migration directions 304 and 404 may generally be described as
being based, at least in part, on an orientation of the ribs 300
and 400.
[0125] FIG. 12 shows a schematic cross-sectional end view of a
surface cleaning head 500, which may be an example of the surface
cleaning head 12 of FIG. 1. As shown, the surface cleaning head 500
includes an agitator chamber 502 configured to receive an agitator
504, which may be an example of the agitator 200 of FIG. 9. The
agitator 504 includes a plurality of flaps 506 and the surface
cleaning head 500 includes at least one rib 508 configured to
engage (e.g., contact) the plurality of flaps 506. As shown, the at
least one rib 508 extends from an inner surface 501 of the agitator
chamber 502. For example, the at least one rib 508 may be formed
from or coupled to at least a portion of the surface cleaning head
500.
[0126] An overlap distance 512 between the rib 508 and the flap 506
may be measured from an engaging surface 516 of the at least one
rib 508 to a distal most portion of the flap 506 adjacent the rib
508 when the flap 506 is engaging (e.g., contacting) the at least
one rib 508. For example, the overlap distance 512 may measure, at
its maximum, in a range of about 1 millimeter (mm) to about 3 mm.
By way of further example, the overlap distance 512 may measure, at
its maximum, in a range of about 1 mm to about 2 mm.
[0127] In instances having a plurality of ribs 508, a measure of a
height 514 of one or more ribs 508 may differ from at least one
other rib 508. As such, the overlap distance 512 can be configured
to vary between ribs 508. Additionally, or alternatively, a measure
of a length 510 of the engaging surface 516 may differ from at
least one other rib 508. Alternatively, a measure of the height 514
and/or a measure of the length 510 of the engaging surface 516 may
be substantially the same for each of the ribs 508.
[0128] In some instances, a friction increasing material may be
coupled to at least a portion of the engaging surface 516. For
example, a rubber (e.g., natural or synthetic rubber) may extend
along at least a portion of the engaging surface 516. Such a
configuration may improve the rate at which fibrous materials are
urged along the agitator 504.
[0129] FIG. 13 shows a schematic cross-sectional perspective view
of a surface cleaning head 500. As shown, the surface cleaning head
500 may include a plurality of ribs 508 that are each configured to
engage (e.g., contact) a flap 506. As shown, the ribs 508 are
configured to extend at least partially around at least a portion
of the agitator 504.
[0130] FIG. 14 shows a perspective view of a surface cleaning head
700, which may be an example of the surface cleaning head 12 of
FIG. 1. The surface cleaning head 700 may include an agitator cover
702 having a plurality of ribs 704 (shown in hidden lines)
extending therefrom. The agitator cover 702 may be coupled to or
integrally formed from the surface cleaning head 700 such that the
agitator cover 702 defines at least a portion of an agitator
chamber within which an agitator (e.g., the agitator 18) rotates.
In some instances, the agitator cover 702 may not be visible to a
user of the surface cleaning head 700 and may have length that
measures less than that of the agitator. For example, the surface
cleaning head 700 may include a plurality of agitator covers 702,
wherein each agitator cover 702 corresponds to a respective distal
end of the agitator and the combined length of the agitator covers
702 measures less that a total length of the agitator. FIG. 14A
shows an example of an agitator cover 710 that has a length that
measures less than a total length of the agitator and FIG. 14B
shows an example of an agitator chamber 712 of a robotic cleaner
having a plurality of agitator covers 710 disposed therein at
opposing distal ends of the agitator chamber 712. The agitator
covers 710 include ribs 714 and may be coupled to or integrally
formed from the agitator chamber 712 such that the ribs 714 are
positioned to engage at least a portion of an agitator. In other
words, the agitator chamber 712 includes ribs at opposing distal
ends of the agitator chamber 712. By positioning the agitator
covers 710 at opposing distal ends of the agitator chamber 712,
migration of fibrous debris over the ends of the agitator (e.g.,
into the bearings and/or axle) may be reduced and/or prevented
while mitigating wear to the agitator.
[0131] The ribs 704 are configured to engage (e.g., contact) an
agitator (e.g., the agitator 18) disposed within the surface
cleaning head 700 such that fibrous debris (e.g., hair) entangled
around the agitator can be urged towards one or more locations
along the agitator at least in part by the ribs 704.
[0132] In some instances, the ribs 704 may extend along only a
portion of the agitator cover 702. For example, the ribs 704 may
extend along a central portion of the agitator cover 702 (e.g., a
portion corresponding to 20% to 60% of the length of the agitator
cover 702 that is substantially centrally located between distal
ends of the agitator cover 702). By way of further example, the
ribs 704 may extend along one or more distal end portions of the
agitator cover 702 (e.g., a portion corresponding to 15% to 40% of
the length of the agitator cover 702 that is proximate to or extend
from a distal end of the agitator cover 702).
[0133] While the ribs 704 are shown as being disposed along the
agitator cover 702, the ribs 704 may be disposed elsewhere within
the surface cleaning head 700. As such, the ribs 704 can generally
be described as being disposed within the surface cleaning head 700
such that the ribs 704 are stationary relative to the agitator when
the agitator is rotated. For example, the ribs 704 may be disposed
along a sidewall of the surface cleaning head 700. In these
instances, the ribs 704 may not obscure a view of the agitator
through the agitator cover 702, when the agitator cover 702 is
transparent and visible to a user.
[0134] FIGS. 15 and 16 show a bottom perspective view and a bottom
view of the agitator cover 702 of FIG. 14, respectively. As shown,
the plurality of ribs 704 each extend parallel to each other and
transverse (e.g., at a non-perpendicular angle) to a longitudinal
axis 800 of the agitator cover 702. The ribs 704 may generally be
described as being oriented to urge fibrous debris towards a single
distal end of the agitator.
[0135] FIGS. 17 and 18 show a perspective view and a bottom view of
an agitator cover 1000 that may be used with the surface cleaning
head 700 of FIG. 14. As shown, the agitator cover 1000 includes a
plurality of ribs 1002. The ribs 1002 are configured to engage
(e.g., contact) an agitator (e.g., the agitator 18) such that
fibrous debris is urged towards at least one predetermined location
between distal ends of the agitator (e.g., towards the center of
the agitator). As shown, at least one of the ribs 1002 extends
transverse to at least one other of the ribs 1002. As such, the
transverse ribs 1002 can generally be described as collectively
defining a chevron shape. In some instances, the agitator may
include one or more flaps that extend helically around an elongated
main body of the agitator according to a first and a second
direction such that the one or more flaps define a chevron
shape.
[0136] FIG. 19 shows a side view of a rib 1200, which may be an
example of the rib 116 of FIG. 1. The rib 116 can have an arcuate
shape that extends at least partially around an agitator (e.g., the
agitator 18) in a direction transverse (e.g., at a
non-perpendicular angle) to a longitudinal axis of the agitator. As
such, the rib 1200 may generally be described as extending
helically around the elongated main body of the agitator. In some
instances, the rib 1200 can be coupled to a surface cleaning head
(e.g., the surface cleaning head 12) such that the rib 1200 is
stationary relative to the agitator and urges fibrous debris
towards a predetermined location.
[0137] FIG. 20 shows a schematic example of an agitator 1300, which
may be an example of the agitator 18 of FIG. 1. As shown, the
agitator 1300 includes a plurality of flaps 1302 and a plurality of
bristle strips 1304 extending substantially parallel to a
corresponding flap 1302. The bristle strips 1304 may include a
plurality of individual bristles extending from an elongated main
body 1305 of the agitator 1300.
[0138] A bristle height 1306 may measure less than a flap height
1308. For example, the bristle height 1306 may be such that, when
the agitator 1300 is rotated within a surface cleaning head, such
as the surface cleaning head 12 of FIG. 1, the bristles strips 1304
do not engage (e.g., contact) one or more ribs configured to urge
fibrous debris along the agitator 1300. By way of further example,
in some instances, the bristle strip height 1306 may measure such
that the portion of bristles engaging (e.g., contacting) the one or
more ribs measures less than the portion of the flap 1302 engaging
(e.g., contacting) the one or more ribs. Alternatively, the bristle
height 1306 may measure greater than the flap height 1308. As such,
the bristle strips 1304 may come into engagement (e.g., contact)
with one or more ribs configured to urge fibrous debris along the
agitator 1300. In some instances, the bristle height 1306 may
measure substantially equal to the flap height 1308. As such, both
the bristle strips 1304 and the flaps 1302 may come into engagement
(e.g., contact) with one or more ribs configured to urge fibrous
debris along the agitator 1300. In some instances, the agitator
1300 may not include the bristle strips 1304 (for example, as
shown, in FIG. 9). In some examples, the bristle height 1306 and/or
the flap height 1308 may be measured from the axis of rotation of
the agitator 1300.
[0139] FIG. 21 shows a schematic example of an agitator 1500, which
may be an example of the agitator 18 of FIG. 1. As shown, the
agitator 1500 includes a plurality of bristle strips 1502 extending
helically around an elongated main body 1504 of the agitator 1500.
The bristle strips 1502 may include a plurality of individual
bristles extending from an elongated main body 1504 of the agitator
1500.
[0140] FIG. 22 shows a schematic cross-sectional view of an
agitator 1600, which may be an example of the agitator 18 of FIG.
1. As shown, the agitator 1600 includes an elongated main body 1602
having one or more flaps 1604 extending therefrom. The flaps 1604
are configured to engage a surface to be cleaned (e.g., a floor).
The elongated main body 1602 is configured to rotate about a
rotation axis 1606 that extends longitudinally through the
elongated main body 1602. One or more axles 1608 can be disposed
along the rotation axis 1606 and be coupled to the elongated main
body 1602. For example, a plurality of axles 1608 can be coupled to
the elongated main body 1602 at opposing ends of the main body
1602.
[0141] A first and a second end cap 1610 and 1612 can be disposed
at opposing distal ends of the elongated main body 1602. The end
caps 1610 and 1612 may generally be described as an agitator cover,
wherein at least a portion the agitator cover extends completely
around an axis of rotation of an agitator. The first and second end
caps 1610 and 1612 are configured to be fixed relative to elongated
main body 1602 such that the elongated main body 1602 rotates
relative to the first and second end caps 1610 and 1612. For
example, the first and second end caps 1610 and 1612 can be coupled
to a portion of a surface cleaning head (e.g., the surface cleaning
head 12 of FIG. 1).
[0142] The first and second end caps 1610 and 1612 can define
respective end cap cavities 1614 and 1616 having cavity sidewalls
1615 and 1617. At least a portion of the elongated main body 1602
and at least a portion of one or more of the flaps 1604 are
received within respective ones of the end cap cavities 1614 and
1616. When the elongated main body 1602 and the one or more flaps
1604 are received within respective end cap cavities 1614 and 1616,
the cavity sidewalls 1615 and 1617 extend longitudinally along the
elongated main body 1602 and the one or more flaps 1604 by an
extension distance 1619 and 1621. The extension distance 1619 and
1621 may measure, for example in a range of 1% to 25% of a total
length 1623 of the elongated main body 1602. By way of further
example, the extension distance 1619 and 1621 may measure in a
range of 5% and 15% of the total length 1623 of the elongated main
body 1602. By way of still further example, the extension distance
1619 and 1621 may measure 10% of the total length 1623 of the
elongated main body 1602. By way of still further example, the
extension distance 1619 and 1621 may measure in a range of 1.3
centimeters (cm) to 5 cm. In some instances, the extension distance
1619 and 1621 may measure differently for each of the first and
second end caps 1610 and 1612.
[0143] Each of the end caps 1610 and 1612 can include one or more
ribs 1618 and 1620 extending within the end cap cavities 1614 and
1616. The one or more ribs 1618 and 1620 extend toward the
elongated main body 1602 in a radial direction such that the one or
more ribs 1618 and 1620 engage (e.g., contact) one or more of the
flaps 1604. As shown, at least a portion of the one or more flaps
1604 overlap with one or more of the ribs 1618 and 1620. For
example, a measure of an overlap between the ribs 1618 and 1620 and
one or more of the flaps 1604 may measure in a range of 1% and 99%
of a rib thickness 1625. By way of further example, a measure of an
overlap between the ribs 1618 and 1620 and one or more of the flaps
1604 may measure in a range of 10% and 75% of the rib thickness
1625. By way of still further example, a measure of an overlap
between the ribs 1618 and 1620 and one or more of the flaps 1604
may measure greater than 0% and less than 99% of the rib thickness
1625. Reducing an amount of overlap between the ribs 1618 and 1620
and one or more of the one or more flaps 1604 may reduce the amount
of wear experienced by the one or more flaps 1604, increasing the
longevity of the one or more flaps 1604.
[0144] The one or more ribs 1618 and 1620 can be configured to urge
fibrous debris (e.g., hair) in a direction away from the distal
ends of the elongated main body 1602 (e.g., in a direction of a
central portion of the elongated main body 1602). The interaction
between the ribs 1618, 1620 and the flaps 1604 can mitigate and/or
prevent fibrous debris from becoming entangled about the one or
more axles 1608 and/or entrapped within one or more bearings
supporting the one or more axles 1608.
[0145] The one or more flaps 1604 can be configured to cooperate
with the one or more ribs 1618 and 1620 to urge fibrous debris in a
direction away from the distal ends of the elongated main body
1602. For example, the one or more flaps 1604 may extend helically
around at least a portion of the elongated main body 1602. In some
instances, the one or more flaps 1604 may extend helically around
at least a portion of the elongated main body 1602 according to two
or more directions such that one or more chevron shapes are formed.
In some instances, the one or more flaps 1604 can be configured to
urge fibrous debris in a direction away from the distal ends of the
elongated main body 1602 after the fibrous debris is spaced apart
from the end caps 1610 and 1612. In these instances, the one or
more flaps 1604 can urge the fibrous debris to a common location
along the elongated main body 1602 such that the fibrous debris can
be removed therefrom (e.g., using a combing unit/debriding rib that
engages the one or more flaps 1604 and removes fibrous debris
therefrom as a result of the rotation of the elongated main body
1602).
[0146] As shown in FIG. 23, one or more ribs 1700 can extend
between the end caps 1610 and 1612. The ribs 1700 can be coupled to
and/or integrally formed from, for example, a portion of a surface
cleaning head (e.g., the surface cleaning head 12 of FIG. 1) and/or
one or more of the end caps 1610 and 1612. The ribs 1700 may
cooperate with the ribs 1618 and 1620 of the end caps 1610 and 1612
to urge fibrous debris (e.g., hair) towards one or more common
locations along the elongated main body 1602. When the elongated
main body 1602 includes one or more bristles (e.g., in addition to
or in the alternative to the one or more flaps 1604) the ribs 1700
may improve the migration of fibrous debris towards one or more
locations along the elongated main body 1602.
[0147] FIG. 24 shows a perspective view of an end cap 1800, which
may be an example of the end cap 1610 of FIG. 22. As shown, the end
cap 1800 defines a cavity 1802 for receiving at least a portion of
an agitator (e.g., the agitator 18 of FIG. 1). The cavity 1802 is
defined by a cavity sidewall 1804 extending from a cavity base
1806. The cavity sidewall 1804 may extend from the cavity base 1806
by an extension distance 1805. The extension distance 1805 extends
from the cavity base 1806 to a distal surface 1810 of the cavity
sidewall 1804, the distal surface 1810 being spaced apart from the
cavity base 1806. A measure of the extension distance 1805 can vary
along a perimeter of the cavity base 1806. For example, the end cap
1800 can be configured such that a measure of the extension
distance 1805 increases with increasing distance from a surface to
be cleaned when the end cap 1800 is coupled to a surface cleaning
head (e.g., the surface cleaning head 12 of FIG. 1). As shown, a
measure of the extension distance 1805 corresponding to a floor
facing portion 1807 of the end cap 1800 measures less than a
measure of the extension distance 1805 corresponding to a surface
cleaning head facing portion 1809 of the end cap 1800. Such a
configuration may increase the effective cleaning width of the
agitator while still mitigating and/or preventing hair migration
into the axles and/or bearings by leaving a greater portion of the
agitator exposed on the floor facing portion 1807 when compared to
the surface cleaning head facing portion 1809.
[0148] The cavity sidewall 1804 can include one or more ribs 1808
that extend from the cavity sidewall 1804 and into the cavity 1802.
As shown, the ribs 1808 can extend from the cavity base 1806 along
the cavity sidewall 1804 in a direction of the distal surface 1810
of the cavity sidewall 1804. The ribs 1808 can form a rib angle
.beta. with the cavity base 1806. The rib angle .beta. may measure
greater than or less than 90.degree.. As such, in some instances,
the one or more ribs 1808 may extend helically along the cavity
sidewall 1804.
[0149] As shown, the ribs 1808 extend from the cavity base 1806 to
the distal surface 1810 of the cavity sidewall 1804. In some
instances, a plurality of ribs 1808 extend from the cavity sidewall
1804. When a plurality of ribs 1808 extend from the cavity sidewall
1804, a measure of a rib length 1812 corresponding to each rib 1808
may be different. For example, a measure of the rib length 1812 may
be based, at least in part, on a measure of the extension distance
1805 of the cavity sidewall 1804 at a location along the perimeter
of the cavity base 1806 where the corresponding rib 1808
terminates. As shown, a measure of the rib length 1812
corresponding to ribs 1808 proximate the floor facing portion 1807
of the end cap 1800 measures less than a measure of the rib length
1812 corresponding to ribs 1808 proximate the surface cleaning head
facing portion 1809 of the end cap 1800.
[0150] FIG. 25 shows another perspective view of the end cap 1800.
As shown, the end cap 1800 can include an axle opening 1902 through
which at least a portion of an axle (e.g., the axle 1608 of FIG.
22) can extend. A protrusion 1903 can extend from the cavity base
1806 and extend around the axle opening 1902. As also shown, one or
more rib openings 1904 can extend along the cavity base 1806. The
rib openings 1904 can have a rib opening length 1906 that generally
corresponds to a measure of a distance over which a corresponding
rib 1808 extends along the cavity base 1806. As such, a measure of
the rib opening length 1906 may be less than a measure of the rib
length 1812 for a corresponding rib 1808.
[0151] The cavity sidewall 1804 can also define an engagement
region 1908 that extends on an outer surface 1910 of the cavity
sidewall 1804. The outer surface 1910 faces in a direction away
from the cavity 1802. The engagement region 1908 is configured to
engage, for example, at least a portion of a surface cleaning head
(e.g., the surface cleaning head 12 of FIG. 1) such that the end
cap 1800 is retained within the surface cleaning head. For example,
the engagement region 1908 can include a raised portion 1911 and a
recessed portion 1912 that collectively define a portion of a
snap-fit joint.
[0152] FIGS. 26 and 27 show perspective views of an end cap 2000,
which may be an example of the end cap 1612 of FIG. 22. As shown,
the end cap 2000 includes a cavity 2002 defined by a cavity base
2004 and a cavity sidewall 2006 extending from the cavity base
2004. One or more ribs 2008 can extend from the cavity sidewall
2006 and into the cavity 2002. As shown, the one or more ribs 2008
have a helical shape. In other words, the cavity base 2004, the
cavity sidewall 2006, and the ribs 2008 can be similar to the
cavity base 1806, the cavity sidewall 1804, and the ribs 1808
described in relation to FIGS. 24 and 25.
[0153] As shown, the end cap 2000 can include an engagement region
2010. The engagement region 2010 can be configured to engage, for
example, at least a portion of a surface cleaning head (e.g., the
surface cleaning head 12 of FIG. 1) such that the end cap 2000 is
retained within the surface cleaning head. For example, the
engagement region 2010 can define a portion of a snap-fit joint. As
also shown, the cavity base 1806 can be substantially planar and
include one or more rib openings 2012 and an axle opening 2014 for
receiving at least a portion of an axle (e.g., the axle 1608 of
FIG. 22).
[0154] While the end caps 1800 and 2000 have been illustrated as
being separate components from the housing/body of the vacuum
cleaner 10, it should be appreciated that any one or more of the
end caps described herein may be integrally formed as part of the
housing/body of the vacuum cleaner 10. Any one or more of the end
caps described herein may be formed as separate components from the
agitator 18, such that removal of the agitator 18 does not result
in the removal of the end cap. Alternatively, one or more of the
end caps may form part of an agitator assembly, wherein removal of
the agitator 18 results in the removal of at least one of the end
caps.
[0155] In some instances, one or more openings may extend through
at least a portion of the cavity sidewalls 1804 and 2006. For
example, FIG. 27A shows an example of an end cap 2750 having one or
more openings 2752 extending through a cavity sidewall 2754. As
shown, the one or more openings 2752 extend between adjacent ribs
2756. For example, and as shown, a collective area of each of the
one or the one or more openings 2752 may measure greater than a
surface area of the cavity sidewall 2754. When the end cap 2750 is
coupled to a surface cleaning head, a portion of the surface
cleaning head extends over the one or more openings 2752. An
example of the end cap 2750 in a surface cleaning head 2758 is
shown in FIG. 27B. As shown, the end cap 2750 is coupled to an
inner surface of the surface cleaning head 2758. For example, the
end cap 2750 can be coupled to the surface cleaning head 2758 such
that the end cap 2750 extends around at least a portion of a top
portion of an agitator 2760. In some instances, at least a portion
of the surface cleaning head 2758 may be transparent to visible
light such that at least a portion of the agitator 2760 and/or the
end caps 2750 are visible.
[0156] Turning now to FIGS. 28 and 29, another example of an
agitator 2800 is generally illustrated, which may be an example of
the agitator 18 of FIG. 1. In particular, FIG. 28 is a front view
of the agitator 2800 and FIG. 29 is a cross-sectional view of the
agitator 2800 of FIG. 29 taken along line 29-29. The agitator 2800
may include at least one resiliently deformable flap 2802 (which
may be an example of the sidewall 62) extending helically around at
least a portion of an elongated main body 2804 of the agitator 2800
in a direction along a longitudinal axis 2806 of the agitator 2800.
For example, the agitator 2800 may include a plurality of
deformable flaps 2802, wherein a length of each of the deformable
flaps 2802 measures less than a length of the main body 2804. As
shown, the agitator 2800 includes a plurality of deformable flaps
2802 that extend from end regions 3000, 3002 of the main body 2804
to a central region 3004 of the main body 2804. As discussed
herein, the agitator 2800 may not include any bristles; however, it
should be appreciated that the agitator 2800 may optionally include
bristles in addition to (or without) the flaps 2802.
[0157] FIG. 30 shows one example of the elongated main body 2804 of
the agitator 2800 of FIG. 29 without the flaps 2802 and/or
bristles. The elongated main body 2804 of the agitator 2800 may
have a generally circular cross-section (taken along a
cross-section that is generally transverse to the longitudinal axis
2806). As used herein, the phrase "generally circular
cross-section" is intended to mean that the radius R of the
elongated main body 2804 at any point within a circular
cross-section is within 25% of the maximum radius of the elongated
main body 2804 within the circular cross-section. In the
illustrated example, the circular cross-section of the elongated
main body 2804 is larger in the proximate end regions 3000, 3002
than in the central region 3004. As such, the circular
cross-section of the elongated main body 2804 may be said to taper
from the proximate end regions 3000, 3002 to the central region
3004. The taper of the proximate end regions 3000, 3002 may be
constant (e.g., linear) and/or nonlinear. In at least one example,
the middle 3008 of the elongated main body 2804 may have the
smallest circular cross-section. The taper of a first proximate end
region 3000 may be the same as or different than the taper of the
second end region 3002.
[0158] The taper of the elongated main body 2804 may increase the
stiffness of the resiliently deformable flap 2802 in the proximate
end regions 3000, 3002, while increasing the flexibility of the
resiliently deformable flap 2802 in the central region 3004. The
reduced cross-section of the central region 3004 may also increase
debris (e.g., hair) removal by allowing the combing unit 50 (e.g.,
the teeth 52) to extend further into the resiliently deformable
flap 2802 and/or bristles (e.g., further towards the center of the
agitator 2800), thereby increasing the contact between the combing
unit 50 and the resiliently deformable flap 2802 and/or bristles.
As such, the teeth 52 may have a greater length in the central
region 3004 when compared to teeth 52 located outside of the
central region 3004.
[0159] With reference to FIGS. 31A-B, another example of an
elongated main body 2804 of the agitator 2800 of FIG. 30 is shown.
Similar to FIG. 30, the elongated main body 2804 may have a
generally circular cross-section, wherein the circular
cross-section of the proximate end regions 3000, 3002 is greater
than in a central region 3004. In at least one embodiment, a first
end region 3000 may have a length extending along the longitudinal
axis 2806 that is 10% to 40% of the total length 3100 of the
elongated main body 2804. For example, the length of the first end
region 3000 may be 25% to 30% of the total length 3100 of the
elongated main body 2804 and/or 20% of the total length 3100 of the
elongated main body 2804.
[0160] The length of the second end region 3002 along the
longitudinal axis 2806 may be the same as the first end region
3000. Alternatively, the length of the second end region 3002 may
be shorter than the first end region 3000. In at least one example,
the second end region 3002 may have a length extending along the
longitudinal axis 2806 that is 8% to 30% of the total length 3100
of the elongated main body 2804. For example, the length of the
second end region 3002 may be 10% to 20% of the total length 3100
of the elongated main body 2804, for example, 17% of the total
length 3100 of the elongated main body 2804. By way of a
non-limiting example, the overall length 3100 of the elongated main
body 2804 may be 222.2 mm, the first end region 3000 may have a
length of 45.7 mm, and the second end region 3002 may have a length
of 36.9 mm.
[0161] As discussed herein, the proximate end regions 3000, 3002
may have a radius R that tapers. The taper may be linear or
non-linear (e.g., curvilinear). In at least one embodiment, the
radius R of the inner end region 3102 of the proximate end regions
3000, 3002 (e.g., the region 3102 of the proximate end regions
3000, 3002 adjacent to the central region 3004) may be 3-15% less
than the radius R of the distal end region 3104 of the proximate
end regions 3000, 3002 (e.g., the region 3104 of the proximate end
regions 3000, 3002 adjacent to the end caps). For example, the
radius R of the inner end region 3102 may be 5-10% less than the
radius R of the distal end region 3104 and/or 8.6% less than the
radius R of the distal end region 3104. The difference in the
radius of the end regions of the first proximate end region 3000
may be the same or different than the difference in the radius of
the end regions of the second proximate end region 3002.
[0162] By way of a non-limiting example, the radius R of the inner
end region 3102 may be 21.25 mm and the radius R of the distal end
region 3104 maybe 23.25 mm. The taper of the end regions 3000, 3002
may promote hair migration by tapering stiffness of the ribs/flaps
and/or bristles. To this end, increasing the length of the
free/unsupported portion of the ribs/flaps and/or bristles will
result in a decrease in the effective stiffness of the ribs/flaps
and/or bristles, thereby enhancing hair migration.
[0163] Turning now to FIGS. 32-33, one example of the flap 2802 of
FIG. 29 without the elongated main body 2804 is generally
illustrated. As described herein, the flap 2802 may extend
generally helically around at least a portion of the elongated main
body 2804 and may be formed of a resiliently deformable material.
One or more of the end regions 3200, 3202 of the flap 2802 may
include a chamfer or taper (e.g., the flap may include a taper in
only one or each end region 3200, 3202). As such, the height 3204
of the flap 2802 in at least a portion of the end regions 3200,
3202 may be less than the height 3204 of the flap 2802 in a central
region 3206. In other words, the taper may cause a cleaning edge
3201 of the flap 2802 to approach the elongated main body 2804.
According to one example, the height 3204 of the flap 2802 may be
measured from a base 3208 of the flap 2802 to the cleaning edge
3201 of the flap 2802, where the base 3208 is configured to be
secured to the agitator 2800 (e.g., the elongated main body 2804).
Alternatively, the height 3204 of the flap 2802 may be measured
from the axis of rotation of the agitator 2800 to the cleaning edge
3201 of the flap 2802. The taper of the end regions 3200, 3202 may
be constant (e.g., linear) and/or nonlinear. In at least one
example, the middle 3210 of the flap 2802 may have the largest
height 3204. The taper of a first end region 3200 may be the same
as or different than the taper of the second end region 3202.
[0164] With additional reference to FIG. 28, the first end region
3200 may be arranged within one of the proximate end regions 3000,
3002 of the elongated main body 2804 and the second end region 3202
may be arranged within the central region 3004 of the elongated
main body 2804. The taper of the first end region 3200 may be
configured to be at least partially received in an end cap, for
example, a migrating hair end cap such as the end caps described in
FIGS. 22-27. The taper of the first end region 3200 may reduce wear
and/or friction between the flap 2802 and the end caps, thereby
enhancing the lifespan of the flap 2802 and the end caps. In at
least some examples, the taper of the first end region 3200 may
reduce fold-over of flap 2802 (both within the end cap and the
portion of the flap 2802 disposed proximate to and outside of the
end cap) as the flap 2802 rotates within the end cap. Reducing
fold-over of the flap 2802 may increase contact between the flap
2802 and the surface to be cleaned, thereby enhancing the cleaning
performance.
[0165] With reference to FIG. 33, the taper of the first end region
3200 may have a length 3304 and a height 3306. The length 3304 may
be selected based on the dimensions of the end cap to which it is
received. For example, the length 3304 may be same as the insertion
distance of the flap 2802 in the end cap, shorter than the
insertion distance of the flap 2802 in the end cap, or longer than
the insertion distance of the flap 2802 in the end cap. The taper
of the first end region 3200 helps relieve the bend of the flap
2802 as it is tucked into the end cap. By way of example, the taper
of the first end region 3200 may have a length 3304 of between 5-9
mm, and a height 3306 of between 1-3 mm and/or a length 3304 of 7
mm and a height 3306 of 2 mm.
[0166] The taper of the second end region 3202 may be configured to
enhance hair migration along the agitator 2800. In particular, the
taper may enhance hair migration since hair will tend to migrate to
smallest diameter. Thus, the taper of the second end region 3202
may allow hair to be more effectively migrated towards a specific
location. In addition, the taper of the second end region 3202 may
function as a hair storage area. To this end, the central region
3004 of the agitator 2800 may have a smaller overall diameter
compared to the overall diameter of the proximate end regions 3000,
3002. As such, hair may build up and wrap around the central region
3004 of the agitator 2800. As generally illustrated in FIGS. 29-30,
the taper of the second end region 3202 of a first flap 2802 may
partially overlap with the taper of the second end region 3202 of
an adjacent flap 2802 within the central region 3004. When the flap
2802 is optionally used in combination with a debrider unit 50
and/or ribs 116, the teeth of the debrider unit 50 and/or ribs 116
may optionally be longer in a region proximate the second end
region 3202 of the flap 2802.
[0167] Turning back to FIG. 33, the dimensions of the taper of the
flap 2802 can impact the performance and/or lifespan of the flaps
2802. Increasing the taper (e.g., length 3300 and/or height 3302)
can improve hair migration; however, too large of a taper can
negatively impact cleaning performance. For example, a taper of the
second end region 3202 that is too large can result in a gap
wherein the flap 2802 does not sufficiently contact the surface to
be cleaned. On the other hand, too small of a taper in the second
end region 3202 (e.g., length 3300 and/or height 3302) may not
result in sufficient hair migration.
[0168] Experimentation has shown that eliminating the inside
chamfer (e.g., eliminating the taper of the second end region 3202)
may eliminate the middle gap, which may result in an improved
cleaning performance and aesthetic appearance (no chamfer with a
kink); however, elimination of the middle gap, may cause hair build
up on the agitator 2800 due to insufficient hair migration. A taper
in the second end region 3202 having a length 3300 that is too
short may mitigate and/or eliminate the detrimental effects caused
by the middle gap and may encourage migration of hair; however,
such a configuration, may result in too steep of a chamfer and may
cause a bad kink. For example, experimentation has shown that a
taper in the second end region 3202 having a length 3300 of 5 mm
and a height 3302 of 7 mm results in a taper that causes a kink
that has an aesthetically displeasing appearance to users and can
cause the flap 2802 to fold backwards, which may hurt cleaning/hair
removal.
[0169] A taper in the second end region 3202 having a length 3300
that is too long may improve migration of hair and may not kink the
flap 2802; however, it may result in a large middle gap. For
example, experimentation has shown that a taper in the second end
region 3202 having a length 3300 of 30 mm and a height 3302 of 7 mm
results in a taper having a large cleaning gap that is potentially
detrimental to the overall cleaning performance.
[0170] The inventors of the instant application have unexpectedly
found that a taper in the second end region 3202 having a length
3300 of 15-25 mm and a height 3302 of 5-12 mm allows hair to
migrate, while minimizing the middle cleaning gap and a size of any
resulting a kink (e.g., the resulting kink is generally not visible
and does not substantially impact performance). By way of
non-limiting examples, the taper in the second end region 3202 may
have a length 3300 of 17-23 mm and a height 3302 of 6-10 mm, for
example, a length 3300 of 20 mm and a height 3302 of 7 mm. Put
another way, the taper in the second end region 3202 may have a
length 3300 and a height 3302 having a slope of 1 to 0.3, for
example, a slope of 0.28 to 0.42, a slope of 0.315 to 0.0385,
and/or a slope of 0.35.
[0171] One or more of the tapers in the first and/or second end
regions 3200, 3202 may be formed by removing a portion 3400 of the
outer, cleaning edge 3201 of the flap 2802 (e.g., the edge that
contacts the surface to be cleaned), for example, as generally
illustrated in FIG. 34. This is particularly useful when the flap
2802 is formed from a non-woven material (such as, but not limited
to rubber, plastic, silicon, or the like).
[0172] In embodiments where the flap 2802 is formed, at least in
part, from a woven material, it may be desirable to maintain a
selvedge in one or more of the first and/or second end regions
3200, 3202. The selvedge extends along the cleaning edge 3201 of
the flap 2802 and the selvedge may improve wear resistance of the
flap 2802 when to a portion of the cleaning edge 3201 of the flap
2802 that the does not include a selvedge (e.g., if a portion of
the flap 2802 were removed to create the taper). In at least one
example, a manufacturer's selvedge is maintained, and one or more
of the tapers in the first and/or second end regions 3300, 3202 may
be formed modifying the mounting edge of the flap 2802. One example
of the selvedge 3500 is generally illustrated in FIG. 35. In
particular, the cleaning edge 3201 of the flap 2802 may be
substantially linear prior to mounting to the agitator, and the
mounting edge 3402 (which may also be the base 3208) of the flap
2802, in the regions of the first and/or second end regions 3200,
3202, may have a reduced length 3502 compared to the length 3504 of
the flap 2802 in the central region 3206 (e.g., the middle 3210).
In at least one example, the mounting edge 3402 may include a
plurality of segments 3506 (e.g., a plurality of contoured "T"
segments produced in a mold) that straighten out when the flap 2802
is installed in the agitator body 2804, thereby resulting in a
contoured (e.g., tapered) selvedge 3500 in the first and/or second
end regions 3200, 3202. In other words, the flap 2802 may generally
be described as including the plurality of segment 3506 along the
mounting edge 3402 that, when mounted to the body 2804, cause a
taper to be formed within the flap 2802.
[0173] Turning now to FIG. 36, another example of an agitator 3600
is generally illustrated, which may be an example of the agitator
18 of FIG. 1. The agitator 3600 may include an agitator body 3602
which includes a plurality of channels 3604 configured to receive a
mounting edge 3606 of a flap 3608, e.g., as generally described
herein. The plurality of channels 3604 and/or mounting edge 3606 of
the flap 3608 may be configured to align the flap 3608 at a
mounting angle 3610. The mounting angle 3610 may be defined as an
angle between a line 3612 extending along the radius of the
agitator body 3602 and a line 3614 extending along the length of
the flap 3608. The lines 3612, 3614 may intersect at the outer edge
3615 of the agitator body 3602. The mounting angle 3610 may be
angled towards the rotation direction (e.g., the line 3614 may
contact the surface to be cleaned prior to the line 3612 when the
agitator 3600 is rotated). The mounting angle 3610 may be any angle
within the range of 10-45 degrees, for example, 15-30 degrees,
30-25 degrees, and/or 22.53 degrees. An aggressive mounting angle
3610 may improve cleaning and help prevent hair from bending the
flaps 3608 back and wrapping around the agitator 3600. However, if
the mounting angle 3610 is too aggressive, excessive noise and/or
wear may be generated.
[0174] With reference now to FIG. 37, a cross-sectional view of
another example of an end cap 3700 is generally illustrated. The
end cap 3700 may be similar to the end cap 1610 of FIG. 22. As
such, like reference numerals refer to similar features unless
noted otherwise, and for the sake of brevity, will not be repeated.
Similar to end cap 1610, end cap 3700 may include a plurality of
ribs 3702-3712. For example, a plurality of ribs 3702-3708 may
extend from an inner surface 3714 of the end cap 3700, e.g.,
proximate a top region 3716 of the end cap 3700. The plurality of
ribs 3702-3708 may have different heights 3718. The different
heights of the ribs 3702-3708 may help reduce noise and/or wear on
the flap 2802.
[0175] The heights 3718 of the plurality of ribs 3702-3708 may
generally inversely correspond to the taper of the flap 2802 (e.g.,
the taper of the first end region 3200). In at least one example,
the different heights 3718 of the plurality of ribs 3702-3708 may
have different amounts of rib/flap engagement 3720. For example,
ribs closest to the distal-most end 3722 of the agitator 2800
(e.g., but not limited to, rib 3702) may have a larger rib/flap
engagement 3720 compared to ribs furthest away from the end 3722 of
the agitator 2800 (e.g., but not limited to, rib 3708). In at least
one example, the end cap 3700 may include one or more ribs that
engage and/or are close to the flap 2802 but are not within the
taper of the first end region 3200. For illustrative purposes, the
rib/flap engagement 3720 of the closest rib (e.g., but not limited
to, rib 3702) and the further rib (e.g., but not limited to, rib
3708) may taper between 2.0 mm to 0 mm, for example, 1.5 mm to 0
mm. The spacing between adjacent ribs 3702-3712 may be constant or
varied. For example, the spacing between adjacent ribs 3702-3712
may be 2-4 mm, for example, 2-3 mm, 2.5-2.75 mm, and/or 2.75 mm.
Close proximity of the ribs/teeth 3702-3712 may prevent hair from
continuously spinning between two adjacent ribs/teeth. The
ribs/teeth 3702-3712 may have a tooth width of 1-3 mm, for example,
1-2 mm, 1.5-1.75 mm, and/or 1.75 mm.
[0176] In at least one example, the bottom region 3724 of the end
cap 3700 (e.g., a region of the end cap 3700 closest to the surface
to be cleaned) may have a different configuration of ribs 3710-3712
compared to the top end region 3716. For example, the bottom region
3724 of the end cap 3700 may have fewer ribs compared to the top
end region 3716. The ribs 3710-3712 may also extend across a
smaller area of the flap 2802. For example, the ribs 3710-3712 may
be disposed only in the taper of the first end region 3200.
[0177] FIG. 37A shows a perspective view of an example of an
agitator 3750 having a plurality of deformable flaps 3752 (which
may be an example of the sidewall 62) and a plurality of bristle
strips and/or a plurality of tufts arranged in a row 3754. The
bristle strips and/or rows of tufts 3754 extend along and generally
parallel to at least a portion of a corresponding deformable flap
3752. As shown, a length of the bristle strips and/or rows of tufts
3754 measures less than a length of a corresponding deformable flap
3752. In other words, the bristles strips and/or rows of tufts 3754
extend along only a portion of a corresponding deformable flap
3752. For example, a measure of a length of a bristle strip and/or
row of tufts 3754 may be less than half of a measure of a length of
a corresponding deformable flap 3752.
[0178] One or more of the bristle strips and/or rows of tufts 3754
may be arranged in front of a corresponding deformable flap 3752
(e.g., from a rotational perspective, the bristle strip and/or row
of tufts 3754 contact the surface to be cleaned prior to the
corresponding deformable flap 3752 immediately adjacent to the
bristle strip and/or row of tufts 3754 as the agitator rotates).
Alternatively (or in addition), one or more of the bristle strips
and/or rows of tufts 3754 may be arranged behind a corresponding
deformable flap 3752 (e.g., from a rotational perspective, the
bristle strip and/or row of tufts 3754 contact the surface to be
cleaned after the corresponding deformable flap 3752 immediately
adjacent to the bristle strip and/or row of tufts 3754 as the
agitator rotates).
[0179] As shown, the deformable flaps 3752 each include a taper
3753 at central end regions 3756. The taper 3753 of the central end
region 3756 for at least one deformable flap 3752 may be different
from a taper 3753 of the central end region 3756 for at least one
other deformable flap 3752. For example, a first group of
deformable flaps 3752 may have a first taper 3753a having a first
slope and the second group of deformable flaps 3752 may have a
second taper 3753b having a second slope, the second slope
measuring differently from the first. In some instances, the first
and second groups of deformable flaps 3752 may be arranged around a
body 3758 of the agitator 3750 in a generally alternating fashion.
For example, a deformable flap 3752 having the first taper 3753a
may be positioned such that the next immediate deformable flap 3752
on one side has the second taper 3753b and the next immediate
deformable flap 3752 on the other side includes the first taper
3753a. By way of further example, a deformable flap 3752 having the
first taper 3753a, may be positioned such that the next immediate
deformable flap 3752 on either side has the second taper 3753b.
[0180] In some instances, the body 3758 of the agitator 3750 may
narrow and/or taper towards a central portion of the body 3758. The
taper may extend from the distal ends of the body 3758. In some
instances, the taper may extend from end regions of the body 3758
such that the taper begins at location spaced apart from a distal
end of the body 3758.
[0181] With reference to FIG. 37B, the bristle strip and/or row of
tufts 3754 may be arranged at a passive angle as the agitator
rotates. As used herein, a passive angle means that the base of the
bristle strip and/or row of tufts 3754 is arranged normal to the
surface to be cleaned prior to the tip of the bristle strip and/or
row of tufts 3754 being arranged normal to the surface to be
cleaned as the agitator rotates. The corresponding deformable flap
3752 may be arranged an aggressive angle as the agitator rotates.
As used herein, an aggressive angle means that the tip of the
deformable flap 3752 is arranged normal to the surface to be
cleaned prior to the base of the deformable flap 3752 being
arranged normal to the surface to be cleaned as the agitator
rotates. In FIG. 37B, the bristle strip and/or row of tufts 3754 is
shown on the left and the deformable flap 3752 is shown on the
right as the agitator rotates clockwise.
[0182] As noted herein, an agitator may include one or more bristle
strips and/or rows of tufts 3754 that extend along and generally
parallel to at least a portion of one or more corresponding
deformable flaps 3752 (collectively referred to as bristle/flap
arrangement 5000, FIG. 37C). The length of the bristle strips
and/or rows of tufts 3754 may be the same as, less than, or longer
than a length of a corresponding deformable flap 3752. In one
example, a first bristle/flap arrangement 5000a may extend from a
first lateral end region 5051 of the agitator towards a central
region 5052 of the agitator, and a second bristle/flap arrangement
5000b may extend from a second lateral end region 5053 of the
agitator towards the central region 5052 of the agitator. The
second bristle/flap arrangement 5000b may be
rotationally/circumferentially offset relative to the first
bristle/flap arrangement 5000a such that the first bristle/flap
arrangement 5000a initially comes into contact with the surface to
be cleaned prior to the second bristle/flap arrangement 5000b as
the agitator rotates. This arrangement of the first and second
bristle/flap arrangement 5000a,b may repeat around the
agitator.
[0183] In at least one example, an agitator consistent with the
present disclosure may include one or more first and second
bristle/flap groups 5050a,b that are rotationally/circumferentially
offset relative to each other. In other words, the first
bristle/flap group 5050a initially comes into contact with the
surface to be cleaned prior to the second bristle/flap group 5050b
as the agitator rotates. This arrangement of the first and second
bristle/flap groups 5050a,b may repeat around the agitator.
[0184] The first bristle/flap group 5050a may extend from the first
lateral end region 5051 of the agitator towards the central region
5052 of the agitator, the first bristle/flap group 5050a may
include at least two bristle/flap arrangements 5000 and/or at least
one bristle/flap arrangement 5000 and one or more bristle strips
and/or row of tufts 3754 or deformable flaps 3752. In at least one
example, the bristle/flap arrangements 5000 bristle strips and/or
row of tufts 3754 or deformable flaps 3752 within the first
bristle/flap group 5050a may be spaced apart from each other by a
circumferential distance that is no more than 20% of the
circumference of the agitator body, for example, no more than 15%
of the circumference of the agitator body, no more than 10% of the
circumference of the agitator body, and/or no more than 5% of the
circumference of the agitator body.
[0185] The second bristle/flap group 5050b may extend from the
second lateral end region 5053 of the agitator towards the central
region 5052 of the agitator, the second bristle/flap group 5050b
may include at least two bristle/flap arrangements 5000 and/or at
least one bristle/flap arrangement 5000 and one or more bristle
strips and/or row of tufts 3754 or deformable flaps 3752. In at
least one example, the bristle/flap arrangements 5000, bristle
strips and/or row of tufts 3754 or deformable flaps 3752 within the
second bristle/flap group 5050b may be spaced apart from each other
by a circumferential distance that is no more than 20% of the
circumference of the agitator body, for example, no more than 15%
of the circumference of the agitator body, no more than 10% of the
circumference of the agitator body, and/or no more than 5% of the
circumference of the agitator body.
[0186] Optionally, the central end regions 3756 of the deformable
flap 3752 and/or bristle strips and/or rows of tufts 3754 of one or
more of the bristle/flap arrangements 5000 of the first
bristle/flap group 5050a may partially overlap the same area on the
surface to be cleaned the central end regions 3756 of the
deformable flap 3752 and/or bristle strips and/or rows of tufts
3754 of one or more of the bristle/flap arrangements 5000 of the
second bristle/flap group 5050b when the agitator rotates. In one
example, the length of the bristle strips and/or rows of tufts 3754
in the central region of the agitator may be shorter than its
corresponding deformable flap 3752 and/or eliminated.
[0187] The second bristle/flap group 5050b may be rotationally
offset relative to the first bristle/flap group 5050a such that the
first bristle/flap group 5050a initially comes into contact with
the surface to be cleaned prior to the second bristle/flap group
5050b as the agitator rotates. This configuration of the first and
second bristle/flap arrangement 5000a,b may repeat around the
agitator. In other words, the first and second bristle/flap groups
5050a,b may generally be described as being staggered about the
circumference of the agitator (e.g., a staggered configuration). In
some instances, there may be some overlap between the first and
second bristle/flap groups 5050a,b. For example, when extending
helically around in a staggered configuration, portions of the
first and second bristle/flap groups 5050a,b may simultaneously
contact the surface to be cleaned. In at least one example, no
portion of either bristle/flap group 5050a,b intersects or extends
into the other bristle/flap group 5050a,b (e.g., no portion of the
bristle/flap arrangements 5000 of either bristle/flap group 5050a,b
is disposed between the bristle/flap arrangements 5000 of the other
bristle/flap group 5050a,b).
[0188] It should be appreciated that in any of the embodiments
described herein, the deformable flaps, row of bristle strips,
and/or row of tufts may contact the teeth of the debrider.
Alternatively (or in addition), any of the embodiments described
herein may include deformable flaps, row of bristle strips, and/or
row of tufts that are clearanced (i.e., spaced apart) from the
teeth of the debrider such that deformable flaps, row of bristle
strips, and/or row of tufts do not contact the teeth of the
debrider. In particular, the deformable flaps, row of bristle
strips, and/or row of tufts and the teeth of the debrider may be
spaced apart from each other such that one or more layers of hair
(e.g., two or more layers, three or more layers, or the like) on
the agitator may contact the debrider as the agitator rotates. In
addition, the teeth of any of the debriders described herein may
include either rigid teeth and/or flexible teeth (e.g., bristles of
a bristle comb 5060 as generally illustrated in FIG. 37D) that may
deflect when in contact with the deformable flaps, row of bristle
strips, row of tufts, and/or hair on the agitator.
[0189] The agitator 3750 may be used in any vacuum cleaner known to
those skilled in the art. One example of a vacuum cleaner including
dual agitators, consistent with an embodiment of the present
disclosure, is shown in FIG. 37E. The vacuum cleaner includes a
surface cleaning head 100 having a housing 110 with a front side
112, and a back side 113, left and right sides 116a, 116b, an upper
side 118, and a lower or under side 120. The housing 110 defines a
suction conduit 128 having an opening 127 on the underside 120 of
the housing 110. The suction conduit 128 is fluidly coupled to a
dirty air inlet, which leads to a suction motor (not shown) either
in the surface cleaning head 100 or another location in the vacuum
cleaner. The suction conduit 128 is the interior space defined by
interior walls in the housing 110, which receives and directs air
drawn in by suction, and the opening 127 is where the suction
conduit 128 meets the underside 120 of the housing 110. Although an
embodiment of the housing 110 is described herein for illustrative
purposes, the housing 110 and components thereof may have other
shapes and configurations.
[0190] The surface cleaning head 100 includes dual rotating
agitators 122, 124, for example, a brush roll 122 and a leading
roller 124. The brush roll 122 and leading roller 124 may be
configured to rotate about first and second rotating axes (RA1,
RA2), respectively, that generally extend perpendicular to a
longitudinal axis LA of the surface cleaning head 100 (e.g.,
generally perpendicular to the intended direction of the vacuuming
movement of the surface cleaning head 100 and/or generally parallel
to the front side 112). The rotating brush roll 122 and/or the
leading roller 124 may be coupled to, and rotated about the
rotating axes, by one or more motors.
[0191] The rotating brush roll 122 (which may include the agitator
3750 as shown in FIG. 37A-D) may be at least partially disposed
within the suction conduit 128 (shown schematically in broken lines
in FIG. 37E). The leading roller 124 is positioned in front of and
spaced from the brush roll 122 and at least substantially outside
the suction conduit 128. As shown in FIG. 37E, at least an inside
upper portion (e.g., at least an inside upper half) of the leading
roller 124 may not be exposed to the flow path into the opening 127
of the suction conduit 128 while at least an inside of the bottom
portion of the leading roller 124 may be exposed to the flow path
into the opening 127 of the suction conduit 128. The leading roller
124 may be received in a leading roller chamber 126, which may
prevent the inside upper half of the leading roller 124 from being
exposed to the flow path. Other variations are possible with
different portions of the leading roller 124 being exposed and not
exposed to the flow path. A space between lower portions of the
leading roller 124 and the brush roll 122 forms an inter-roller air
passageway 146 that may provide at least a portion of the flow path
into the opening 127 of the suction conduit 128 and allow debris to
be carried into the suction conduit 128.
[0192] As shown, the brush roll 122 may be disposed in front of one
or more wheels 130 for supporting the housing 110 on the surface 10
to be cleaned. For example, one or more larger wheels may be
disposed along the back side 114 and/or one or more smaller middle
wheels (not shown) may be provided at a middle section on the
underside of the housing 110 and/or along the left and right sides
116a, 116b. Other wheel configurations may also be used. The wheels
130 facilitate moving the surface cleaning head 100 along the
surface 10 to be cleaned, and may also allow the user to easily
tilt or pivot the surface cleaning head 100 (e.g., brush roll 122
and/or the leading roller 124) off of the surface 10 to be cleaned.
The rear wheel(s) 130 and the middle wheel(s) may provide the
primary contact with the surface being cleaned and thus primarily
support the surface cleaning head 100. When the surface cleaning
head 100 is positioned on the surface 10 being cleaned, the leading
roller 124 may also rest on the surface 10 being cleaned. In other
embodiments, the leading roller 124 may be positioned such that the
leading roller 124 sits just above the surface being cleaned.
[0193] One or more combing unit, debriding protrusions, and/or ribs
may contact a surface of the leading roller 124 and/or the brush
roll 122 to facilitate debris removal and/or migrate hair to a
desired location. The combing unit, debriding protrusions, and/or
ribs may include any combing unit, debriding protrusions, and/or
ribs known to those skilled in the and/or described herein
including, but not limited to, the combing unit, debriding
protrusions, and/or ribs include combing unit 50, 93, debriding
protrusions 150, and ribs 508, 704, 1002, 1200, 1700, 1808, 2008,
3702.
[0194] According to an embodiment, one or more sealing strips 170,
172 may be located along the rear and left and right sides of the
opening 127 to the suction conduit 128. The sealing strips 170, 172
may contact the surface 10 being cleaned to seal against the
surface together with the leading roller 124 contacting the surface
10 in front of the roller. Side edge vacuum passageways may be
formed between the side sealing strips 172 and the leading roller
124 to direct air into the inter-roller air passageway 146 and back
towards the opening 127 of the suction conduit 128. As such, the
side edge vacuum passageways and the inter-roller air passageway
146 provide at least a portion of the air flow path to the suction
conduit 128.
[0195] The housing 110 may be open at the front side 112 such that
a front portion of the leading roller 124 is exposed to facilitate
edge cleaning. According to an embodiment, the housing 110 may
include a front bumper 160 that extends from the front side 112 of
the housing 110 just beyond (or at least as far as) a front contact
surface of the leading roller 124 such that the bumper 160 first
contacts a vertical surface 12 to prevent damage to the leading
roller 124. The bumper 160 may be sufficiently resilient to bend or
compress to allow the leading roller 124 to contact the vertical
surface 12 for edge cleaning.
[0196] The rotating brush roll 122 may have bristles, fabric, or
other cleaning elements, or any combination thereof around the
outside of the brush roll 122. For example, the rotating brush roll
122 may include the agitator 3750. The agitator 3750 may further
two deformable flaps 3752 in front of each row of bristle strips
3754. As such, two deformable flaps 3752 may be disposed in front
of (e.g., immediately in front of) each bristle strip 3754 and two
deformable flaps 3752 may be disposed behind (e.g., immediately
behind) each bristle strip 3754 as the agitator 3750 rotates.
Having two deformable flaps 3752 disposed in front of each bristle
strip 3754 and two deformable flaps 3752 may be disposed behind
each bristle strip 3754 may increase the number of agitating
interactions, thereby improving carpet cleaning. One or more of the
deformable flaps 3752 may include holes (for example, as shown in
FIG. 57) that may decrease the stiffness of the deformable flaps
3752, thereby reducing noise.
[0197] In addition, the harness (#4) of the deformable flaps 3752
may be decreased, thereby decreasing the flap impact force and snap
back force and reducing the noise. The flap tip OD/flap engagement
with the floor (#3) may be decreased, which may increase
deep-carpet agitation and reduce noise. Optionally, the bristle
strip 3754 may be replaced with a row of bristle tufts. The bristle
tufts may increase deep-carpet agitation, thereby improving carpet
cleaning. The bristle strip 3754 may be aggressively angled, which
may increase deep-carpet and abrasive agitation and enhance carpet
cleaning and pet hair pickup. The bristle filament length
diameter/stiffness may be increased to improve deep-carpet
agitation and carpet cleaning. Alternatively, the bristle filament
length diameter/stiffness may be reduced to decrease human hair
wrap and improve hair migration capabilities (e.g., hair migration
to the center). The bristle filament shape may be changed to one of
more as shown in FIG. 58.
[0198] The change in bristle shape may increase cleaning or
pet-hair pickup. A soft material may be added between the
deformable flaps 3752 to increase fine scrubbing/wiping of hard
floors and increase stuck-on-dust pickup. The rotation speed of the
agitator 3750 may be decreased to reduce the number of total
interactions, thereby reducing noise.
[0199] Other examples of brush rolls and agitators are shown and
described in greater detail in U.S. Pat. No. 9,456,723 and U.S.
Patent Application Pub. No. 2016/0220082, which are fully
incorporated herein by reference.
[0200] The leading roller 124 may include a relatively soft
material (e.g., soft bristles, fabric, felt, nap or pile) arranged
in a pattern (e.g., a spiral pattern) to facilitate capturing
debris, as will be described in greater detail below. The leading
roller 124 may be selected to be substantially softer than that of
the brush roll 122. The softness, length, diameter, arrangement,
and resiliency of the bristles and/or pile of the leading roller
124 may be selected to form a seal with a hard surface (e.g., but
not limited to, a hard wood floor, tile floor, laminate floor, or
the like), whereas the bristles of the brush roll 122 may selected
to agitate carpet fibers or the like. For example, the leading
roller 124 may be at least 25% softer than the brush roll 122,
alternatively the leading roller 124 may be at least 30% softer
than the brush roll 122, alternatively the leading roller 124 may
be at least 35% softer than the brush roll 122, alternatively the
leading roller 124 may be at least 40% softer than the brush roll
122, alternatively the leading roller 124 may be at least 50%
softer than the brush roll 122, alternatively the leading roller
124 may be at least 60% softer than the brush roll 122. Softness
may be determined, for example, based on the pliability of the
bristles or pile being used.
[0201] The size and shape of the bristles and/or pile may be
selected based on the intended application. For example, the
leading roller 124 may include bristles and/or pile having a length
of between 5 to 15 mm (e.g., 7 to 12 mm) and may have a diameter of
0.01 to 0.04 mm (e.g., 0.01-0.03 mm). According to one embodiment,
the bristles and/or pile may have a length of 9 mm and a diameter
of 0.02 mm. The bristles and/or pile may have any shape. For
example, the bristles and/or pile may be linear, arcuate, and/or
may have a compound shape. According to one embodiment, the
bristles and/or pile may have a generally U and/or Y shape. The U
and/or Y shaped bristles and/or pile may increase the number of
points contacting the floor surface 10, thereby enhancing sweeping
function of leading roller 124. The bristles and/or pile may be
made on any material such as, but not limited to, Nylon 6 or Nylon
6/6.
[0202] The leading roller 124 may have an outside diameter Dlr that
is smaller than the outside diameter Dbr of the brush roll 122. For
example, the diameter Dlr may be greater than zero and less than or
equal to 0.8 Dbr, greater than zero and less than or equal to 0.7
Dbr, or greater than zero and less than or equal to 0.6 Dbr.
According to example embodiments, the diameter Dlr may be in the
range of 0.3 Dbr to 0.8 Dbr, in the range of 0.4 Dbr to 0.8 Dbr, in
the range of 0.3 Dbr to 0.7 Dbr, or in the range of 0.4 Dbr to 0.7
Dbr. As an illustrative example, the brush roll 122 may have an
outside diameter of 48 mm and the leading roller 124 may have an
outside diameter of 30 mm. While the leading roller 124 may have an
outside diameter Dlr that is smaller than the outside diameter Dbr
of the brush roll 122, the brush roll 122 may have bristles that
are longer than the bristle and/or pile of the leading roller
122.
[0203] Positioning a leading roller 124 (having a diameter Dlr that
is smaller than the diameter Dbr of the brush roll 122) in front of
the brush roll 122 provides numerous benefits. For example, this
arrangement decreases the height Hf (see, e.g., FIG. 1) of the
front side 112 of the surface cleaning head 100 (e.g., the housing
110) from the surface 10 to be cleaned. The decreased height Hf of
the front of the surface cleaning head 100 provides a lower profile
that allows the surface cleaning head 100 to fit under objects
(e.g., furniture and/or cabinets). Moreover, the lower height Hf
allows for the addition of one or more light sources 111 (such as,
but not limited to, LEDs), while still allowing the surface
cleaning head 100 to fit under objects.
[0204] Additionally, the smaller diameter Dlr of the leading roller
124 allows the rotating axis of the leading roller 124 to be placed
closer to the front side 112 of the surface cleaning head 100. When
rotating, the leading roller 124 forms a generally cylindrical
projection having a radius that is based on the overall diameter of
the leading roller 124. As the diameter of the leading roller 124
decreases, the bottom contact surface 140 (FIG. 1) of the leading
roller 124 moves forward towards the front side 112 of the surface
cleaning head 100. In addition, when the surface cleaning head 100
contacts a vertical surface 12 (e.g., but not limited to, a wall,
trim, and/or cabinet), the bottom contact surface 140 of the
leading roller 124 is also closer to the vertical surface 12,
thereby enhancing the front edge cleaning of the surface cleaning
head 100 compared t o a larger diameter leading roller. Moreover,
the smaller diameter Dlr of the leading roller 124 also reduces the
load/drag on the motor driving the leading roller 124, thereby
enhancing the lifespan of the motor and/or allowing a smaller motor
to be used to rotate both the brush roll 122 and leading roller
124.
[0205] With reference to FIG. 38, another example of a vacuum
cleaner 3800 is generally illustrated. The vacuum cleaner 3800 may
include a head 3802 (which may optionally include one or more
agitators as described herein), a wand 3804 (which may optionally
include one or more joints 3806 configured to allow the wand 3804
to bend, e.g., between an extended position as shown, and a bent
position), and a hand vacuum 3808. The hand vacuum 3808 may include
a debris collection chamber 3810 and a vacuum source 3812 (e.g., a
suction motor or the like) for generating an airflow (e.g., partial
vacuum) in the head 3802, wand 3804, and debris collection chamber
3810 to suck up debris proximate to the head 3802. The wand 3804
may define a wand longitudinal axis 3814 extending between a first
end 3816 configured to be coupled to the head 3802, and a second
end 3818 configured to be coupled to the hand vacuum 3808. One or
more of the first and second ends 3816, 3818 may be removably
coupled to the head 3802 and hand vacuum 3808, respectively.
[0206] Turning now to FIG. 39, the hand vacuum 3808 of FIG. 38 is
shown in more detail. In particular, the hand vacuum 3808 may
include a wand connector 3900 having a first end region 3902 that
is fluidly coupled to the second end 3818 of the wand 3804, and a
second end region 3904 that is coupled to a handle body 3906
forming a portion of the main body 3908 of the hand vacuum 3808.
The wand connector 3900 includes a longitudinal wand axis 3910 that
extends through the first end region 3902 to the second end region
3904, and through at least a portion of the handle body 3906. The
longitudinal wand axis 3910 may be parallel to the wand
longitudinal axis 3814. For example, the longitudinal wand axis
3910 may be colinear with the wand longitudinal axis 3814.
[0207] The handle body 3906 may further include a handle 3912, for
example, in the form of a pistol grip or the like, which the user
can grasp to manipulate the hand vacuum 3808. The handle body 3906
may optionally include one or more actuators (e.g., buttons) 3914.
The actuator 3914 may be located anywhere on the hand vacuum 3808
(such as, but not limited to, on the handle body 3906). The
actuator 3914 may be configured to adjust one or more parameters of
the hand vacuum 3808 and/or the head 3802. For example, the
actuator 3914 may turn on power to the suction motor 3812 and/or to
one or more rotatable agitators located in the head 3802.
[0208] Alternatively, or in addition to the actuators 3914, the
handle body 3906 may include a trigger 3916 configured to adjust
one or more parameters of the hand vacuum 3808 and/or the head
3802. The trigger 3916 may be at least partially located between
the handle 3912 and the wand connector 3900, and may move along a
trigger direction 3918. The trigger direction 3918 may be linear or
non-linear (e.g., arcuate or the like). In at least one example,
the trigger direction 3918 may be parallel to the longitudinal wand
axis 3910 and/or the wand longitudinal axis 3814. For example, the
trigger direction 3918 may be colinear with the longitudinal wand
axis 3910 and/or the wand longitudinal axis 3814. The trigger
direction 3918 may extend through at least a portion of the wand
connector 3900 and/or the wand 3804. The trigger 3916 may be
particularly suited for adjusting the suction force of the suction
motor 3812 and/or for adjusting the rotational speed of one or more
of the rotatable agitators located in the head 3802. The
positioning of the trigger 3916 may provide an ergonomically
friendly design that facilitates use of the vacuum cleaner
3800.
[0209] With reference to FIGS. 40-47, further details of one
example of the hand vacuum 3808 of FIGS. 38-39 are shown. In
particular, an air pathway 4000 may extend from the wand 3804 (not
shown), through the wand connector 3900 (for example, through the
first end region 3902) and into the debris collection chamber 3810.
At least some of the debris may be collected in the debris
collection chamber 3810, for example, through an inlet 4001 (FIGS.
43-44) of the debris collection chamber 3810 which is coupled the
second end region 3904 of the wand connector 3900. The air pathway
4000 may extend from the debris collection chamber 3810 and through
one or more primary filters 4002 (see, e.g., FIGS. 43-44). In at
least one example, the primary filter 4002 may include one or more
cyclonic filters 4004 as generally illustrated, though it should be
appreciated that any filter may be used. Optionally, the air
pathway 4000 may extend through one or more secondary (e.g., second
stage) filters 4006 (see, e.g., FIG. 45). The secondary filters
4006 may include any known filter such as, but not limited to, a
plurality of cyclones 4008. The plurality of second stage cyclones
4008 may be smaller than the primary filter 4002, and may be
configured to separate smaller debris particles from the air
pathway 4000 than the primary filter 4002. The secondary filters
4006 may be located in the air pathway 4000 between the primary
filter 4002 and the vacuum source 3812.
[0210] Optionally, one or more pre-motor filters 4010 may be
provided (see, e.g., FIG. 46). The pre-motor filters 4010 may be
located in the air pathway 4000 between the primary filter 4002 and
the vacuum source 3812, for example, between the secondary filter
4006 and the vacuum source 3812. The pre-motor filters 4010 may be
configured to separate smaller debris particles from the air
pathway 4000 than the primary filter 4002 and/or the secondary
filter 4006. In at least one example, the pre-motor filters 4010
may include one or more foam layers, cloth and/or woven layers, or
the like. Optionally, the exhaust air in the air pathway 4000 may
exit the vacuum source 3812 through one or more post motor filters
4012 (see, e.g., FIG. 47). The post motor filters 4012 may include
a high-efficiency particulate air (HEPA) filter or the like.
[0211] While various features disclosed herein have been
illustrated in combination with a hand-operated vacuum cleaner, any
one or more of these features may be incorporated into a robot
vacuum cleaner as generally illustrated in FIG. 48. It should be
understood that the robotic vacuum cleaner shown is for exemplary
purposes only and that a robotic vacuum cleaner may not include all
of the features shown in FIG. 48 and/or may include additional
features not shown in FIG. 48. The robotic vacuum cleaner may
include an air inlet 23 fluidly coupled to a debris compartment 30
and a suction motor 32. The suction motor 32 causes debris to be
suctioned into the air inlet 23 and deposited into the debris
compartment 30 for later disposal. The robotic vacuum cleaner may
optionally include one or more agitators 18 at least partially
disposed within the air inlet 23. The agitator 18 may be driven by
one or more motors disposed within the robotic vacuum cleaner. By
way of a non-limiting example, the agitator 18 may include a
rotatable bush bar having a plurality of bristles and/or sidewalls
62 (e.g., resiliently deformable flaps). The robotic vacuum cleaner
may include one or more wheels 16 coupled to a respective drive
motor 910. As such, each wheel 16 may be generally described as
being independently driven. The robotic vacuum cleaner can be
steered by adjusting the rotational speed of one of the plurality
of wheels 16 relative to the other of the plurality of wheels 16.
One or more side brushes 918 can be positioned such that a portion
of the side brush 918 extends at least to (e.g., beyond) the
perimeter defined by a vacuum housing 13 of the robotic vacuum
cleaner. The side brush 918 can be configured to urge debris in a
direction of the air inlet 23 such that debris located beyond the
perimeter of the vacuum housing 13 can be collected. For example,
the side brush 918 can be configured to rotate in response to
activation of a side brush motor 920.
[0212] A user interface 922 can be provided to allow a user to
control the robotic vacuum cleaner. For example, the user interface
922 may include one or more push buttons that correspond to one or
more features of the robotic vacuum cleaner. The robotic vacuum
cleaner may optionally include a power source (such as one or more
batteries) and/or one or more displaceable bumpers 912 disposed
along a portion of the perimeter defined by a vacuum housing 13 of
the robotic vacuum cleaner. The displaceable bumper 912 may
displaced in response to engaging (e.g., contacting) at least a
portion of an obstacle that is spaced apart from the surface to be
cleaned. Therefore, the robotic vacuum cleaner may avoid becoming
trapped between the obstacle and the surface to be cleaned. The
robotic vacuum cleaner may include any one or more of the various
features disclosed herein.
[0213] Turning now to FIGS. 49-54, yet another example of a vacuum
cleaner 10 consistent with the present disclosure is generally
illustrated. As noted herein, the vacuum cleaner 10 is intended to
refer to any type of vacuum cleaner including, but not limited to,
hand-operated vacuum cleaners and robot vacuum cleaners.
Non-limiting examples of hand-operated vacuum cleaners include
upright vacuum cleaners, canister vacuum cleaners, stick vacuum
cleaners, and central vacuum systems. Thus, while various aspects
of the present disclosure may be illustrated and/or described in
the context of a hand-operated vacuum cleaner or a robot vacuum
cleaner, it should be understood the features disclosed herein are
applicable to both hand-operated vacuum cleaners and robot vacuum
cleaners unless specifically stated otherwise.
[0214] The vacuum cleaner 10 may include a cleaning head (which may
also be referred to as a nozzle and/or cleaning nozzle) 12 and
optionally a handle 14. In the illustrated embodiment, the handle
14 is pivotally coupled to the cleaning head 12, e.g., by way of a
wand or the like, such that the user may grasp the handle 14 while
standing to move the cleaning head 12 on a surface to be cleaned
114 (e.g., a floor) using one or more wheels 16. It should be
appreciated; however, that the cleaning head 12 and the handle 14
may be an integrated or unitary structure (e.g., such as a
handleheld vacuum cleaner). Alternatively, the handle 14 may be
eliminated (e.g., such as in a robot vacuum cleaner).
[0215] The cleaning head 12 includes a cleaning head body or
housing 13 that at least partially defines/includes one or more
agitator chambers 22 (best seen in FIG. 53). The agitator chambers
22 include one or more openings (or air inlets) 23 defined within
and/or by a portion of the bottom surface/plate 25 of the cleaning
head 12/cleaning head body 13. At least one rotating agitator or
brush roll 18 is configured to be coupled to the cleaning head 12
(either permanently or removably coupled thereto) and is configured
to be rotated about a pivot axis 20 (e.g., in the direction and/or
reverse direction of arrow A, FIG. 50) within the agitator chamber
22 by one or more rotation systems.
[0216] The cleaning head 12 may optionally include a cover plate
4901. The cover plate 4901 (which may be formed, at least in part,
by a transparent and/or semi-transparent material) may be removably
coupled to the cleaning head body 13 or may be permanently coupled
to the cleaning head body 13 (and as such, may be considered part
of the cleaning head body 13). In any event, the cover plate 4901
may form at least part of the agitator chamber 22. The transparent
and/or semi-transparent cover plate 4901 may allow the user to see
the agitator 18 rotating within the agitator chamber 22. The
agitator cover 4901 may include any agitator cover known to those
skilled in the art such as, but not limited to, agitator cover 702,
710, 1000 optionally including ribs 704, 714, 1002.
[0217] The cleaning head 12 may include an exposed front edge 4902.
The exposed front edge 4902 may be formed by a portion of the cover
plate 4901 and/or the cleaning head body 13 and may be configured
to allow large debris and/or piles of debris to come into direct
contact with the agitator 18, rather come into contact with the
cleaning head 12 (e.g., the cover plate 4901 and/or the cleaning
head body 13). In particular, the height H1 (see, e.g., FIG. 51) of
the exposed front edge 4902 from the surface to be cleaned 114 may
be between 25-150% (e.g., 50-125%) of the height H2 of the pivot
axis 20 from the surface to be cleaned 114. In at least one
example, the height H1 of the exposed front edge 4902 may be
greater than or equal to the height H2 of the pivot axis 20 from
the surface to be cleaned 114. The exposed front edge 4902 may
extend along substantially the entire length L of the agitator 18
(e.g., greater than 75% of the length L of the agitator 18) and/or
along only a portion (e.g., 50-75% of the length L of the agitator
18).
[0218] The cleaning head 12 may include one or more end caps 5001.
One or more of the end caps 5001 may be formed, at least in part,
and/or extend along a portion of the cleaning head body 13 and/or
the cover plate 4901 which is exposed to the agitator chamber 22.
The end caps 5001 may include any end cap design known to those
skilled in the art and/or any of the end caps described herein such
as, but not limited to, end caps 1610, 1612, 1800, 2000, and 2750.
The end caps 5001 may include one or more ribs 5002 (for example,
but not limited to, ribs 1618, 1620, 1808, 2008, 2756) configured
to contact a portion of the agitator 18 (such as, but not limited
to, the soft material, bristle strips, and/or flaps of the agitator
18) as the agitator 18 rotates within the agitator chamber 22. In
at least one example, the end caps 5001 may extend along one or
more of the lateral end regions of the agitator 18 and contact up
to 25% of the length L of the agitator 18; however, it should be
appreciated that the end caps 5001 may extend across substantially
the entire length L of the agitator 18. The end caps 5001 may
extend radially around the entire circumference of the agitator 18.
For example, the ribs 5002 of the end caps 5001 may extend and/or
contact the agitator 360 degrees around the outer surface of the
agitator 18.
[0219] The end caps 5001 may disposed proximate to and/or define
the lateral ends (e.g., left and right sides) of the cleaning head
12 and/or agitator chamber 22. For example, a first and a second
end cap 5001 can be disposed at opposing distal ends of the
elongated main body of the agitator 18 and either end cap 5001 may
be removably coupled to the cleaning head 12 or permanently coupled
to the cleaning head 12. Removal of an end cap 5001 may result in
all the ribs 5002 associated with the end cap 5001 being
simultaneously removed along with the end cap 5001. Alternatively,
all or a portion of the ribs 5002 may remain within the agitator
chamber 22 when the end cap 5001 is removed. In this example, all
or some of the ribs 1618, 1620, 1808, 2008, 2756 disposed within
the agitator chamber 22 after the end cap 4904 has been removed may
be separately removed from the agitator chamber 22 or may be
permanently disposed within the agitator chamber 22. With reference
to FIGS. 52 and 55, a first portion/subset 5201 of the ribs 5002
may be formed by the agitator cover 4901 and/or the cleaning head
body 13, while a second portion/subset 5202 of the ribs 5002 may be
part of the removable end cap 5001a (note, the agitator cover 4901
and/or the cleaning head body 13 forming the first portion/subset
5201 of the ribs 5002 is not shown in FIG. 55, and the second
portion/subset 5202 of the ribs 5002 are disposed in the inner
surface of the removable end cap 5001 in FIG. 55). As such, removal
of the end cap 5001a will result in second portion/subset 5202 of
the ribs 5002 being simultaneously removed with the end cap 5001a,
while the first portion/subset 5201 of the ribs 5002 remains within
the agitator chamber 22.
[0220] The end caps 5001 may be removably secured to the cleaning
head 12 (e.g., the cleaning head body 13) using any mechanism known
to those skilled in the art such as, but not limited to, one or
more fasteners, screws, bolts, biased tabs, detents, clips, locks,
nuts, or the like. Optionally, one or more sealing strips may be
disposed along a rear portion of the opening 23 of the agitator
chamber 22 and/or along all or a portion of the lateral (e.g., left
and right) sides of the opening 23 of the agitator chamber 22. The
side sealing strips may extend from the end caps 5001. The end caps
5001 may optionally include and/or define side edge air passageways
configured to direct vacuum air flow from the side edges of the
cleaning head 12 towards the opening 23 of the agitator chamber
22.
[0221] The cleaning head 12 and/or agitator chamber 22 may include
one or more combing units/debriders 5400 (best seen in FIG. 54).
The combing unit/debrider 5400 may include any combing
unit/debrider known to those skilled in the art and/or described
herein. For example, the combing unit 5400 may include a combing
unit 50 as generally described herein with reference to FIGS. 1-7.
In at least one example, the combing unit 50 may be configured to
contact a portion of the agitator 18 (such as, but not limited to,
the soft material, bristle strips, and/or flaps of the agitator 18)
as the agitator 18 rotates within the agitator chamber 22.
[0222] With reference now to FIGS. 52 and 53, one example of an
agitator 5210 consistent with the agitator 18 is generally
illustrated. The agitator 5210 may be used within any vacuum
cleaner 10 known to those skilled in the art including any vacuum
cleaner described herein such as, but not limited to, the vacuum
cleaner of FIGS. 49-60 and/or robot vacuum cleaner. The agitator
5210 may be alone or in combination with one or more additional
agitators 18. When used in combination with one or more additional
agitators 18, the agitator 5210 may be the leading roller, the rear
roller, and/or an intermediate roller (i.e., between the leading
roller and the rear roller).
[0223] The agitator 5210 may include an elongated main body or core
5300 (see, e.g., FIG. 53) having a long axis LA extending along the
pivot axis 20 of the agitator 5210. The elongated body or core 5300
may be formed from a substantially rigid material configured to
allow the agitator 5210 to be rotated within the agitator chamber
22. The elongated body or core 5300 may have a generally
cylindrical shape (see, e.g., FIG. 53) or may have a tapered design
as described in U.S. Ser. No. 16/656,930, filed Oct. 18, 2019,
which is fully incorporated herein by reference. As can be seen,
the agitator 5210 includes at least one soft cleaning feature 5302
and at least one resiliently deformable flap 5304 (which may be an
example of a sidewall) and/or at least one continuous row of
bristles 5305 substantially adjacent to the flaps 5304 (note, the
continuous row of bristles 5305 may be replaced by a row of a
plurality of adjacent tufts) disposed within at least one channel
5310 and extending helically around and radially outward from at
least a portion of an elongated main body/core 5300 of the agitator
5210 in a direction along a longitudinal axis LA of the agitator
5210. As described herein, the agitator 5210 may generally be
regarded as a fuzzy roller with a soft material forming at least
one channel 5310 and at least one resiliently deformable flap 5304
and/or row of bristles 5305 disposed therein.
[0224] The soft cleaning feature 5302 may include a plush, dense
pile formed from relatively flexible filaments/material (e.g., but
not limited to, a velvet or velvet-like material). The pile may be
similar to the raised or fluffy surface of a carpet, rug or cloth,
and comprises filaments woven on to a fabric carrier member (not
shown) attached to the elongated main body 5300, for example using
an adhesive. The length of the filaments of the pile may be in the
range from 5 to 30 mm, for example, 5 to 25 mm, 5 to 15 mm, and/or
5 to 10 mm (including all ranges and values therein). The fabric
carrier may be in the form of a strip wound on to the elongated
main body 5300 so that the pile is substantially continuous,
substantially covering the outer surface of the elongated main body
5300 as described herein. Alternatively, the carrier member may be
in the form of a cylindrical sleeve into which the elongated main
body 5300 is inserted.
[0225] The pile material may include synthetic fibers such as
nylon, polyester, petroleum-based acrylic or acrylonitrile, natural
fibers (such as wool or animal fur), or wood pulp-based rayon,
and/or from blended fibers. The nap or pile of the soft cleaning
feature 5302 may be configured to agitate and/or transport debris
towards the opening 23 of the cleaning head 12 and/or generally
form a seal with the surface being cleaned 114. Due to the softness
of the pile/nap, the soft cleaning feature 5302 may dampen
vibration, absorb sound, and/or reduce damage (e.g., scratching) to
the floor surface (e.g., but not limited to, hardwood floors or the
like). By way of non-limiting examples, the soft cleaning feature
5302 may have a density of 5001-8250 grams/cm, for example, 6600
grams/cm. The pile of the soft cleaning feature 5302 may extend
approximately 2-25 cm from the elongated body or core 5300, for
example, 2-15 cm, 2-10 cm, and/or 7 mm (including all ranges and
values therein). The filament density and diameter may be adjusted
to provide the desired soften and deformability, as well as to
generally form a seal with the surface being cleaned 114.
[0226] The agitator 5210 may include one or more channels 5310 with
at least one resiliently deformable flap 5304 and/or row of
bristles 5305 at least partially disposed therein. The channels
5310 may be configured to allow the resiliently deformable flap
5304 and/or row of bristles 5305 to move forward and backwards as
the agitator 5210 rotates. In at least one example, the channel
5310 may have width proximate the opening that is approximately
3-20 mm wide (front to back), for example, 5-15 mm wide, 6-12 mm
wide, and/or approximately 8 mm, including all ranges and values
therein.
[0227] The channels 5310 may be at least partially formed and/or
defined by the soft cleaning feature 5302. In at least one example
(see, e.g., FIGS. 25-27), the channel 5310 may have a "U"
cross-sectional shape including a base 5312 (which may be formed by
the elongated main body 5300) and two sidewalls 5314, 5316 (which
may be formed by the soft cleaning feature 5302). The sidewalls
5314, 5316 may be substantially normal to the surface of the
elongated main body 5300 and/or may extend at an obtuse and/or
acute angle relative to the surface of the elongated main body/core
5300. Alternatively (or in addition), the channel 5310 may have a
"V" cross-sectional shape in which the two sidewalls 5314, 5316
extend from the base region of the resiliently deformable flap 5304
and/or row of bristles 5305.
[0228] One or more channels 5310 may extend from one of the ends or
end regions 5320, 5322 of the agitator 5210 generally towards a
central region 5324 of the agitator 5210. As generally illustrated
in FIG. 52, the channels 5310 may extend from the ends or end
regions 5320, 5322 and terminate in the central region 5324. As
such, a length of each of the channels 5310 measures less than a
length of the main body/core 5300. Portion 2326 of the channels
5310 may longitudinally overlap with each other in the central
region 5324 as the agitator 5210 rotates about the pivot axis
(i.e., the portions 2326 of the channels 5310 may contact the same
area of the floor as the agitator 5210 rotates). The channels 5310
may extend linearly and/or non-linearly across the agitator 5210.
It should be appreciated, however, that one or more of the channels
5310 may extend entirely or substantially entirely across the
length of the main body/core 5300.
[0229] The left and right channel 5310 may be
rotationally/circumferentially offset relative to each as the
agitator 5210 rotates. In other words, a channel 5310 on the left
side initially comes into contact with the surface to be cleaned
prior to a channel 5310 on the right side as the agitator rotates.
It should be appreciated that two or more channels 5310 on the left
side may initially come into contact with the surface to be cleaned
prior to one or more channels 5310 on the right side as the
agitator rotates. This arrangement of the left and right channels
5310 may repeat around the agitator 5210.
[0230] In at least one example, the agitator 5210 may include three
evenly spaced apart channels 5310 on the left side, and three
evenly spaced apart channels 5310 on the right side, though it
should be appreciated that this is not a limitation of the present
disclosure unless specifically claimed as such. The agitator 5210
may include less than or more than three left channels 5310 and/or
less than or more than three right channels 5310.
[0231] In at least one example, the soft cleaning feature 5302
(e.g., the nap) may extend over a substantial portion of the
surface of the cylindrical portion of the elongated main body/core
5300 (i.e., the portion of the elongated main body/core 5300 other
than the circular ends). As used herein, a substantial portion of
the surface of the cylindrical portion of the elongated main
body/core 5300 is intended to mean at least 75% of the surface of
the cylindrical portion of the elongated main body 5300, for
example, at least 80% of the surface of the cylindrical portion of
the elongated main body 5300, at least 85% of the surface of the
cylindrical portion of the elongated main body 5300, and/or at
least 90% of the surface of the cylindrical portion of the
elongated main body 5300, including all values and ranges therein.
The soft cleaning feature 5302 may extend over the entire surface
of the cylindrical portion of the elongated main body/core 5300
except where the channels 5310 are located.
[0232] The soft cleaning feature 5302 may be formed from a single,
unitary piece of material. Alternatively, the soft cleaning feature
5302 may be formed from a plurality of discrete pieces that are
coupled to the elongated main body/core 5300. Forming the soft
cleaning feature 5302 formed from a plurality of discrete pieces
may aid in manufacturing of the agitator 5210, particularly the
formation of the channels 5310.
[0233] As noted herein, the agitator 5210 may include a plurality
of deformable flaps 5304, wherein a length of each of the
deformable flaps 5304 measures less than a length of the main body
5300. As shown, the agitator 5210 includes a plurality of
deformable flaps 5304 that extend from end regions 5320, 5322 of
the agitator 5210 and/or main body 5300 to a central region 5324 of
the agitator 5210 and/or main body 5300. In at least one example,
the length of the deformable flaps 5304 may be substantially the
same as the length of the channel 5310 that is it disposed within.
As such, one example, of the flap 5304 may extend entirely or
substantially entirely across the length of the main body/core
5300.
[0234] Turning back to FIG. 52, the flap 5304 may extend generally
helically around at least a portion of the elongated main body 5300
and may be formed of a resiliently deformable material. The flap
5304 may have a height that is less than, equal to, or greater than
the height of the soft cleaning feature 5302. According to one
example, the height of the flap 5304 may be measured from a base
5208 of the flap 5304 to the cleaning edge 5207 of the flap 5304,
where the base 5208 is configured to be secured to the agitator
5210 (e.g., the elongated main body 5300). Alternatively, the
height of the flap 5304 may be measured from the axis of rotation
of the agitator 5210 to the cleaning edge 5207 of the flap 5304. In
at least one example, the flap 5304 may have a height such that the
flap 5304 extends beyond the outer radius of the soft cleaning
feature 5302. For example, the flap 5304 may extend 0-15 mm beyond
the outer radius of the soft cleaning feature 5302, e.g., 1-15 mm,
1-10 mm, and/or 2-8 mm, including all ranges and values
therein.
[0235] One or more of the end regions 5201, 5203 of the flap 5304
may include a chamfer or taper (e.g., the flap 5304 may include a
taper in only one or each end region 5201, 5203). As such, the
height of the flap 5304 in at least a portion of the end regions
5201, 5203 may be less than the height of the flap 5304 in a
central region 5205. In other words, the taper may cause a cleaning
edge 5207 of the flap 5304 to approach the elongated main body
5300. The taper of the end regions 5201, 5203 may be constant
(e.g., linear) and/or nonlinear. In at least one example, the
middle of the flap 5304 may have the largest height. The taper of a
first end region 5201 may be the same as or different than the
taper of the second end region 5203.
[0236] The first end region 5201 may be arranged within one of the
end regions of the elongated main body 5300 and the second end
region 5203 may be arranged within the central region 5324 of the
elongated main body 5300. The taper of the first end region 5201
may be configured to be at least partially received in an end cap,
for example, a migrating hair end cap such as the end caps
described herein (e.g., but not limited to, end caps 5001), and/or
the end caps described in U.S. Ser. No. 16/656,930, filed Oct. 18,
2019, which is fully incorporated herein by reference. The taper of
the first end region 5201 may reduce wear and/or friction between
the flap 5304 and the end caps, thereby enhancing the lifespan of
the flap 5304 and the end caps. In at least some examples, the
taper of the first end region 5201 may reduce fold-over of flap
5304 (both within the end cap and the portion of the flap 5304
disposed proximate to and outside of the end cap) as the flap 5304
rotates within the end cap. Reducing fold-over of the flap 5304 may
increase contact between the flap 5304 and the surface to be
cleaned, thereby enhancing the cleaning performance. The flap 5304
(e.g., optionally including, but not limited to, the first end
region 5201) may also contact the end cap 5001, e.g., the ribs 5002
as described herein.
[0237] The taper of the first end region 5201 may have a length and
a height. The length may be selected based on the dimensions of the
end cap to which it is received. For example, the length may be
same as the insertion distance of the flap 5304 in the end cap,
shorter than the insertion distance of the flap 5304 in the end
cap, or longer than the insertion distance of the flap 5304 in the
end cap. The taper of the first end region 5201 helps relieve the
bend of the flap 5304 as it is tucked into the end cap. By way of
example, the taper of the first end region 5201 may have a length
of between 5-9 mm, and a height of between 1-3 mm and/or a length
of 7 mm and a height of 2 mm.
[0238] The taper of the second end region 5203 may be configured to
enhance hair migration along the agitator 5210. In particular, the
taper may enhance hair migration since hair will tend to migrate to
smallest diameter. Thus, the taper of the second end region 5203
may allow hair to be more effectively migrated towards a specific
location. In addition, the taper of the second end region 5203 may
function as a hair storage area. To this end, the central region
5324 of the agitator 5210 may have a smaller overall diameter
compared to the overall diameter of the proximate end regions 5330,
5332. As such, hair may build up and wrap around the central region
5324 of the agitator 5210. The taper of the second end region 5203
of a first flap 5304 may partially overlap with the taper of the
second end region 5203 of an adjacent flap 5304 within the central
region 5324. When the flap 5304 is optionally used in combination
with a debrider unit and/or ribs as described in U.S. Ser. No.
16/656,930, filed Oct. 18, 2019 (which is fully incorporated herein
by reference) and described herein, the teeth of the debrider unit
and/or ribs may optionally be longer in a region proximate the
second end region 5203 of the flap 5304.
[0239] The dimensions of the taper of the flap 5304 can impact the
performance and/or lifespan of the flaps 5304. Increasing the taper
(e.g., length and/or height) can improve hair migration; however,
too large of a taper can negatively impact cleaning performance.
For example, a taper of the second end region 5203 that is too
large can result in a gap wherein the flap 5304 does not
sufficiently contact the surface to be cleaned. On the other hand,
too small of a taper in the second end region 5203 (e.g., length
and/or height) may not result in sufficient hair migration.
[0240] Experimentation has shown that eliminating the inside
chamfer (e.g., eliminating the taper of the second end region 5203)
may eliminate the middle gap, which may result in an improved
cleaning performance and aesthetic appearance (no chamfer with a
kink); however, elimination of the middle gap, may cause hair build
up on the agitator 5210 due to insufficient hair migration. A taper
in the second end region 5203 having a length that is too short may
mitigate and/or eliminate the detrimental effects caused by the
middle gap and may encourage migration of hair; however, such a
configuration, may result in too steep of a chamfer and may cause a
bad kink. For example, experimentation has shown that a taper in
the second end region 5203 having a length of 5 mm and a height of
7 mm results in a taper that causes a kink that has an
aesthetically displeasing appearance to users and can cause the
flap 5304 to fold backwards, which may hurt cleaning/hair
removal.
[0241] A taper in the second end region 5203 having a length that
is too long may improve migration of hair and may not kink the flap
5304; however, it may result in a large middle gap. For example,
experimentation has shown that a taper in the second end region
5203 having a length of 30 mm and a height of 7 mm results in a
taper having a large cleaning gap that is potentially detrimental
to the overall cleaning performance.
[0242] The inventors of the instant application have unexpectedly
found that a taper in the second end region 5203 having a length of
15-25 mm and a height of 5-12 mm allows hair to migrate, while
minimizing the middle cleaning gap and a size of any resulting a
kink (e.g., the resulting kink is generally not visible and does
not substantially impact performance). By way of non-limiting
examples, the taper in the second end region 5203 may have a length
of 17-23 mm and a height of 6-10 mm, for example, a length of 20 mm
and a height of 7 mm. Put another way, the taper in the second end
region 5203 may have a length and a height having a slope of 1 to
0.3, for example, a slope of 0.28 to 0.42, a slope of 0.315 to
0.0385, and/or a slope of 0.35. In at least one example, the second
end region 5203 may have a taper of 25.times.7 mm. The overlap at
the central region 5324 of the channels 5310 and/or flaps 5304 may
be 10-20 mm.
[0243] One or more of the tapers in the first and/or second end
regions 5201, 5203 may be formed by removing a portion of the
outer, cleaning edge 5207 of the flap 5304 (e.g., the edge that
contacts the surface to be cleaned). This is particularly useful
when the flap 5304 is formed from a non-woven material (such as,
but not limited to rubber, plastic, silicon, or the like).
[0244] In embodiments where the flap 5304 is formed, at least in
part, from a woven material, it may be desirable to maintain a
selvedge in one or more of the first and/or second end regions
5201, 5203. The selvedge extends along the cleaning edge 5207 of
the flap 5304 and the selvedge may improve wear resistance of the
flap 5304 when to a portion of the cleaning edge 5207 of the flap
5304 that the does not include a selvedge (e.g., if a portion of
the flap 5304 were removed to create the taper). In at least one
example, a manufacturer's selvedge is maintained, and one or more
of the tapers in the first and/or second end regions 5201, 5203 may
be formed modifying the mounting edge of the flap 5304. In
particular, the cleaning edge 5207 of the flap 5304 may be
substantially linear prior to mounting to the agitator, and the
mounting edge (which may also be the base) of the flap 5304, in the
regions of the first and/or second end regions 5201, 5203, may have
a reduced length compared to the length of the flap 5304 in the
central region 5324 (e.g., the middle). In at least one example,
the mounting edge may include a plurality of segments (e.g., a
plurality of contoured "T" segments produced in a mold) that
straighten out when the flap 5304 is installed in the agitator body
5300, thereby resulting in a contoured (e.g., tapered) selvedge in
the first and/or second end regions 5201, 5203. In other words, the
flap 5304 may generally be described as including the plurality of
segment along the mounting edge that, when mounted to the body
5300, cause a taper to be formed within the flap 5304.
[0245] In at least one example, the flap 5304 (see, e.g., FIG. 53)
may include a protrusion/wall 5311 extending generally outward from
the base 5208. The protrusion/wall 5311 may be formed, at least in
part, from a polyester fabric. Optionally, the back of the
protrusion/wall 5311 (viewed based on the rotation of the agitator
5210) may include a silicon layer, and the front of the protrusion
5311 may include the polyester fabric. The protrusion/wall 5311 may
have a height of 8-12 mm from the base 5208, for example, 10.1 or
10.6 mm. The protrusion/wall 5311 extend below the outer surface of
the soft cleaning feature 5302, substantially even with the soft
cleaning feature 5302, or beyond the outer surface of the soft
cleaning feature 5302. In at least one example, the protrusion/wall
5311 may extend up to 3 mm beyond the outer surface of the soft
cleaning feature 5302, for example, approximately 0.5-2 mm beyond
the outer surface of the soft cleaning feature 5302 and/or
approximately 1-1.5 mm beyond the outer surface of the soft
cleaning feature 5302.
[0246] The base 5208 may be configured to secure the flap 5304 to
the agitator 5210 (e.g., the elongated main body 5300) such that
the protrusion/wall 5311 extends generally radially outward from
the agitator 5210. In at least one example, the base 5208 may be
configured to be at least partially received within a slot or
groove 5354 formed in the agitator 5210 (e.g., the elongated main
body 5300) and disposed within channel 5310. The base 5208 and the
slot 5354 may form a T-slot type connection; however, it should be
appreciated that the base 5208 and the slot 5354 may form any other
type of connection.
[0247] As noted herein, the agitator 5210 may include a row of
bristles and/or a plurality of tufts arranged in a row 5305,
wherein a length of each of the row of bristles 5305 measures less
than a length of the main body 5300. As shown, the agitator 5210
includes a plurality of row of bristles 5305 that extend from end
regions 5320, 5322 of the agitator 5210 and/or main body 5300 to
the central region 5324 of the agitator 5210 and/or main body 5300.
The row of bristles 5305 may be the same length, shorter, or longer
than the corresponding, adjacent deformable flap 5304. In at least
one example, the length of the row of bristles 5305 may be
substantially the same as the length of the channel 5310 that is it
disposed within. As such, one example, of the row of bristles 5305
may extend entirely or substantially entirely across the length of
the main body/core 5300.
[0248] The row of bristles 5305 may extend generally helically
around at least a portion of the elongated main body 5300, e.g.,
proximate to and/or adjacent to a corresponding flap 5304. It
should be appreciated that the row of bristles 5305 may be used in
combination with the flap 5304, without the flap 5304, or may be
eliminated. The row of bristles 5305 may have a height that is less
than, equal to, or greater than the height of the soft cleaning
feature 5302 and/or the flap 5304. According to one example, the
height of the row of bristles 5305 may be measured from a base 5368
of the row of bristles 5305 to the distal most edge 5370 of the row
of bristles 5305, where the base 5368 is configured to be secured
to the agitator 5210 (e.g., the elongated main body 5300).
Alternatively, the height of the row of bristles 5305 may be
measured from the axis of rotation of the agitator 5210 to the
distal most edge 5360 of the row of bristles 5305. In at least one
example, the row of bristles 5305 may have a height such that the
row of bristles 5305 extends beyond the outer radius of the soft
cleaning feature 5302. For example, the row of bristles 5305 may
extend 0-15 mm beyond the outer radius of the soft cleaning feature
5302, e.g., 1-15 mm, 1-10 mm, and/or 2-8 mm, including all ranges
and values therein.
[0249] The base 5368 may be configured to secure the row of
bristles 5305 to the agitator 5210 (e.g., the elongated main body
5300) such that the row of bristles 5305 extends generally radially
outward from the agitator 5210. In at least one example, the base
5368 may be configured to be at least partially received within a
slot or groove 5372 formed in the agitator 5210 (e.g., the
elongated main body 5300) and disposed within channel 5310. The
base 5368 and the slot 5372 may form a T-slot type connection;
however, it should be appreciated that the base 5368 and the slot
5372 may form any other type of connection.
[0250] The row of bristles 5305 may be arranged behind the flap
5304 as the agitator 5210 rotates (i.e., counterclockwise as
illustrated in FIG. 53). Alternatively (or in addition), one or
more row of bristles 5305 may be arranged in front of the flap
5304. The row of bristles 5305 and the flap 5304 may be arranged at
passive and aggressive angles as the agitator 5210 rotates. As used
herein, a passive angle means that the base 5372 of the row of
bristles 5305 is arranged normal to the surface to be cleaned prior
to the tip 5370 of the row of bristles 5305 being arranged normal
to the surface to be cleaned as the agitator 5210 rotates, and
similarly that the base 5354 of the flap 5304 is arranged normal to
the surface to be cleaned prior to the tip 5207 of the 5304 being
arranged normal to the surface to be cleaned as the agitator 5210
rotates. As used herein, an aggressive angle means that 5370 of the
row of bristles 5305 is arranged normal to the surface to be
cleaned prior to base 5372 of the row of bristles 5305 being
arranged normal to the surface to be cleaned as the agitator 5210
rotates, and similarly that the flap 5304 is arranged normal to the
surface to be cleaned prior to base 5354 of the flap 5304 being
arranged normal to the surface to be cleaned as the agitator 5210
rotates. In at least one example, the flap 5304 may be arranged at
an aggressive angle and the corresponding, adjacent row of bristles
5305 may be arranged at a passive angle, though it should be
appreciated that this angle configuration may be reversed.
[0251] The tips 5370, 5207 of the row of bristles 5305 and the flap
5304 may be spaced 0-5 mm apart, for example, 0-3 mm, 1-5 mm,
and/or 1-3 mm, including all ranges and values therein. Because the
flap 5304 and corresponding, adjacent row of bristles 5305 may be
arranged at different angles, the length of the flap 5304 and
corresponding, adjacent row of bristles 5305 may be different
(though they may extend the same radial distance relative the soft
cleaning feature 5302). Alternatively (or in addition), one or more
of the row of bristles 5305 and/or corresponding, adjacent flap
5304 may be arranged substantially normal to the elongated main
body 5300 and/or one or more of the row of bristles 5305 and/or
corresponding, adjacent flap 5304 may be arranged substantially
parallel to each other.
[0252] As noted herein, one or more flaps 5304 and/or one or more
corresponding, adjacent rows of bristles 5305 may be disposed
within a channel 5310. The channel 5310 may be configured to
provide a space to allow the flap 5304 and/or corresponding,
adjacent row of bristles 5305 to move and generate a flicking
motion as the agitator 5210 rotates. The movement of the flap 5304
and/or corresponding, adjacent row of bristles 5305 within the
channel 5310 may generally prevent debris (such as hair or the
like) from becoming entangled on the agitator 5210 and/or assisting
in the migration of the debris (e.g., towards the debrider unit
50).
[0253] Turning now to FIGS. 55-56, one example of an agitator drive
mechanism 5500 is generally illustrated. Rather than having an
agitator motor configured to drive an agitator by way of one or
more gears and/or belts, the agitator drive mechanism 5500 includes
an agitator 5210 including a motor 5502, a motor cavity 5504
configured to receive at least a portion of the motor 5502, and one
or more cooling air passageways 5506 (and optionally one or more
fan blades 5508, best seen in FIG. 56) configured to allow air 5510
(best seen in FIG. 56) to be drawn through the motor cavity 5504,
across the motor 5502, and through the cooling air passageway 5506
to cool the motor 5502. The motor cavity 5502, cooling air
passageways 5504, and fans 5506 may be at least partially disposed
within the agitator 5210 (e.g., within the elongated main body/core
5300) such that a longitudinal axis of the motor cavity 5502 is
concentric with the rotation axis 20 of the agitator 5210. The
longitudinal axis of the cooling air passageway 5506 motor may also
be concentric with the rotation axis 20 of the agitator 5210. While
the agitator drive mechanism 5500 will be described in context with
the agitator 5210, it should be appreciated that the agitator drive
mechanism 5500 may be used with any agitator 18 known to those
skilled in the art and/or described herein.
[0254] In at least one example, the end caps 5001 may be configured
to include a cooling air inlet 5512 and a cooling air outlet 5514
to allow the cooling air 5510 to flow to/from the lateral ends of
the cleaning head 12. The cooling air inlet 5512 and/or cooling air
outlet 5514 may be configured to be in fluid communication with the
motor cavity 5504 cooling air passageways 5506. Optionally, the
cooling air inlet 5512 and/or cooling air outlet 5514 may include a
grating, screen, mesh, or the like to generally prevent debris from
inadvertently/unintentionally being drawn into the cooling air 5510
flowing through the agitator 5210. While the cooling air inlet 5512
is illustrated proximate to the motor cavity 5502, it should be
appreciated that the motor cavity 5502 may be proximate to the
cooling air outlet 5514 or may be located anywhere between the
cooling air inlet 5512 and the cooling air outlet 5514.
[0255] The cooling air 5510 may be independent of the vacuum
airpath (i.e., the cooling air 5510 is not drawn into the vacuum
airpath). Put another way, the motor cavity 5502 and the cooling
air passageways 5504 are not fluidly coupled to the vacuum airpath
and may be generally considered to be sealed from the vacuum
airpath.
[0256] The motor 5502 may include any AC or DC motor known to those
skilled in art such as, but not limited to, a high torque low-cost
brushless DC (BLDC) motor. In any event, the motor 5502 may be
mounted, coupled, or otherwise secured to the cleaning head 12
(e.g., the cleaning head body/frame 13) and may be configured to be
removably received at least partially into the motor cavity 5504.
In at least one example, the motor 5502 may be permanently (i.e.,
non-removably) coupled to the cleaning head body/frame 13. The
motor 5502 may optionally include a cover 5516 at least partially
encasing the motor 5502.
[0257] The motor 5502 may include one or more fasteners 5520
configured to engage corresponding fasteners 5522 of the agitator
5210 to transmit torque generated by the motor 5502 to the agitator
5210 and rotate the agitator 5210. The fasteners 5520, 5522 may
include any fasteners configured to transmit torque from the motor
5502 to the agitator 5210. The fasteners 5520, 5522 may optionally
be configured to allow the agitator 5210 to be removed from the
motor 5502. Non-limiting examples of the fasteners 5520, 5522
include splines, grooves, protrusions, channels, tapered
connections (e.g., Morse tapers), and the like.
[0258] The motor cavity 5504 may be configured to provide a fluid
pathway around the motor 5502 such that the cooling air 5510 may
flow over/through/around the motor 5502 and into the cooling air
passageways 5506. While the motor cavity 5504 is shown proximate a
first lateral end region of the agitator 5210, it should be
appreciated that the motor cavity 5504 may be located anywhere
within the agitator 5210. For example, the motor cavity 5504 may be
generally centrally located within the agitator 5210, and a first
and second cooling air passageway 5506 may extend from the motor
cavity 5504 to the two opposite lateral end regions of the agitator
5210.
[0259] In at least one example, one or more of the cooling air
passageways 5506 may have the substantially the same
cross-sectional size (e.g., diameter) compared to the motor cavity
5504. Alternatively, one or more of the cooling air passageways
5506 may have a larger or smaller cross-sectional size (e.g.,
diameter) compared to the motor cavity 5504. One or more fan blades
5508 may be at least partially disposed within the agitator 5210,
e.g., within the motor cavity 5504 and/or cooling air passageways
5506. Alternatively (or in addition), one or more fan blades 5508
may be at least partially disposed outside of the agitator 5210,
for example, in one or more of the end caps 5001. Rotation of the
agitator 5210 may cause the fan blades 5508 to rotate and generate
the cooling airflow 5510. The fan blades 5508 may be configured to
push and/or pull the cooling airflow 5510 through the agitator 5210
(e.g., motor cavity 5504 and/or cooling air passageways 5506).
[0260] With reference to FIG. 56, a lateral end of the agitator
2510 may include a pin cavity 5630 configured to receive a first
end a rotation pin (not shown) that is concentrically aligned with
the pivot axis 22. The second end of the rotation pin may be
received in the end cap 5001, for example, a cavity 5632 of the
removable end cap 5001a. In at least one example, the pin cavity
5630 may be formed as part of the fan blades 5508. The pin cavity
5630, 5632 may optionally include one or more bearings to
facilitate rotation of the agitator 5210 about the pivot axis
22.
[0261] To remove the agitator 5210 from cleaning head 12, the
removable end cap 5001a is removed from the cleaning head 12 as
described herein. The agitator 5210 may then be urged towards the
lateral end of the cleaning head 12 that the removable end cap
5001a was previously coupled to, as generally illustrated by arrow
5660. Arrow 5660 may be generally parallel to the pivot axis 22. As
the agitator 5210 is moved laterally, the fasteners 5520 of the
motor 5502 come out of engagement with the fasteners 5522 of the
motor cavity 5504 and the motor is removed from the agitator 5210.
The motor 5502 ultimately remains coupled to the cleaning head 12.
One benefit of arranging the motor 5502 within the agitator 5210 is
that the overall size of the cleaning head 12 is reduced. This
allows the cleaning head 12 to fit into smaller areas compared to
cleaning heads having a motor coupled to the agitator using gears
or a drive belt. In addition, larger wheels (e.g., wheels 16) may
be used, thus increasing the maneuverability of the cleaning head
12.
[0262] An example of an agitator for a vacuum cleaner, consistent
with the present disclosure, may include a body and at least one
deformable flap extending from the body. The deformable flap may
include at least one taper. The at least one taper causes a
cleaning edge of the deformable flap to approach the body.
[0263] In some instances, the at least one taper may extend in an
end region of the at least one deformable flap. In some instances,
the at least one taper may include a first taper and a second
taper, each taper extending in a corresponding end region of the
deformable flap. In some instances, the first taper may have a
first slope and the second taper may have a second slope, the first
slope measuring differently from the second slope. In some
instances, the deformable flap may comprise a woven material. In
some instances, the deformable flap may include a selvedge along
the cleaning edge. In some instances, the deformable flap may
include a mounting edge, the mounting edge having a plurality of
segments that, when mounted to the body, cause the taper to be
formed within the deformable flap. In some instances, the at least
one deformable flap may include a plurality of deformable flaps,
each deformable flap extending helically around the body, and,
wherein, a length of each deformable flap measures less than a
length of the body. In some instances, each deformable flap may
extend from an end region of the body to a central region of the
body. In some instances, the agitator may further include at least
one bristle strip, the at least one bristle strip extending
substantially parallel to a corresponding deformable flap. In some
instances, a length of the at least one bristle strip may measure
less than a length of the corresponding deformable flap.
[0264] An example of a vacuum cleaner, consistent with the present
disclosure, may include an agitator chamber including one or more
ribs and an agitator disposed within the agitator chamber such that
at least a portion of the agitator engages the one or more ribs.
The agitator may include a body and at least one deformable flap
extending from the body. The deformable flap may include at least
one taper. The at least one taper causes a cleaning edge of the
deformable flap to approach the body.
[0265] In some instances, the one or more ribs may be disposed at
opposing distal ends of the agitator chamber. In some instances,
the at least one taper may include a first taper and a second
taper, the first and second tapers extending within opposing end
regions of a corresponding deformable flap. In some instances, the
ribs may extend from an agitator cover. In some instances, the
agitator cover may be an end cap. In some instances, the agitator
may further include at least one bristle strip, the at least one
bristle strip extending substantially parallel to a corresponding
deformable flap. In some instances, a length of the at least one
bristle strip may measure less than a length of the corresponding
deformable flap. In some instances, the at least one taper may
include a first taper and a second taper, each taper extending in a
corresponding end region of the deformable flap. In some instances,
the first taper may have a first slope and the second taper may
have a second slope, the first slope measuring differently from the
second slope. In some instances, the body may include a taper that
extends towards a central region of the body.
[0266] While the principles of the invention have been described
herein, it is to be understood by those skilled in the art that
this description is made only by way of example and not as a
limitation as to the scope of the invention. Other embodiments are
contemplated within the scope of the present invention in addition
to the exemplary embodiments shown and described herein. It will be
appreciated by a person skilled in the art that a surface cleaning
apparatus and/or agitator may embody any one or more of the
features contained herein and that the features may be used in any
particular combination or sub-combination. Modifications and
substitutions by one of ordinary skill in the art are considered to
be within the scope of the present invention, which is not to be
limited except by the claims.
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