Cleaning Head for Vacuum Cleaner

This application claims the benefit of U.S. Provisional Application No. 63/568,675, filed Mar. 22, 2024, which is incorporated herein by reference in its entirety.

Vacuum cleaners have one or more cleaning heads with an inlet to the air path for cleaning a surface to be clean. One type of cleaning head is a floor base adapted to be moved over floor surfaces. Another type of cleaning head is an accessory tool. Vacuum cleaners are often provided with various types of accessory tools used for cleaning in places that the regular vacuum cleaner floor base cannot fit or are adapted for specialized cleaning operations. An accessory tool typically attaches to the vacuum cleaner via an auxiliary flexible vacuum hose and/or a rigid wand.

Removing hair from a surface to be cleaned is one cleaning operation for which specialized accessory tools have been developed. Pet hair tends to become imbedded on upholstery, making the removal of hair from upholstery particularly difficult. Many accessory tools do not perform well with imbedded hair on upholstery as hair tends to ball up when a tool is passed over the surface. This is mitigated by using a tool with a rotating agitator; however, a drawback of this solution is that hair commonly gets caught in the rotating agitator and/or in the bearings mounting the rotating agitator. Providing effective removal of pet hair from upholstery remains a challenge in the floor cleaning industry.

An cleaning head for a vacuum cleaner is provided with an improved hair cleaning features.

In one aspect of the disclosure, a cleaning head includes a housing having a brushroll chamber and defining an air path, an inlet into the brushroll chamber, the inlet in fluid communication with the air path, an attachment tube extending from the housing, the attachment tube being in fluid communication with the air path, a first brushroll mounted in the brushroll chamber and configured to rotate about a first axis in first direction, the first brushroll including a first set of tines, and a second brushroll mounted in the brushroll chamber and configured to rotate about a second axis in a second direction that is counter to the first direction, the second brushroll including a second set of tines, wherein the second set of tines are timed to interfere with the first set of tines as the first and second brushrolls counterrotate to pull hair into the air path above the first and second brushrolls.

In another aspect of the disclosure, an accessory tool for a vacuum cleaner includes a housing having a brushroll chamber and defining an air path, an inlet into the brushroll chamber, the inlet in fluid communication with the air path, an attachment tube extending from the housing, the attachment tube being in fluid communication with the air path, a first brushroll mounted in the brushroll chamber and configured to rotate about a first axis in first direction, the first brushroll including a first set of tines, a second brushroll mounted in the brushroll chamber and configured to rotate about a second axis in a second direction that is counter to the first direction, the second brushroll including a second set of tines, wherein the second set of tines are timed to interfere with the first set of tines as the first and second brushrolls counterrotate to pull hair into the air path above the first and second brushrolls.

In yet another aspect of the disclosure, an accessory tool for a vacuum cleaner includes a housing having a brushroll chamber and an air turbine chamber, and defining an air path, an inlet into the brushroll chamber, the inlet in fluid communication with the air path, an attachment tube extending from the housing, the attachment tube being in fluid communication with the air path, a first brushroll mounted in the brushroll chamber and configured to rotate about a first axis in first direction and comprising a first set of tines, a second brushroll mounted in the brushroll chamber and configured to rotate about a second axis in a second direction that is counter to the first direction and comprising a second set of tines, and an air turbine mounted in the air turbine chamber and configured to rotate about a turbine axis, the air turbine coupled with the first and second brushrolls to drive the rotation of the first and second brushrolls, wherein the second set of tines are timed to interfere with the first set of tines as the first and second brushrolls counterrotate to pull hair into the air path above the first and second brushrolls.

In still another aspect of the disclosure a vacuum cleaner includes a suction source configured to generate a working airstream through a working air path, a separating and collection assembly configured to separate hair and other debris from the working airstream, and an accessory tool including a housing having a brushroll chamber and defining a tool air path, an inlet into the brushroll chamber, the inlet in fluid communication with the tool air path, an attachment tube extending from the housing, the attachment tube fluidly connecting the tool air path with the working air path, a first brushroll mounted in the brushroll chamber and configured to rotate about a first axis in first direction, the first brushroll including a first set of tines, and a second brushroll mounted in the brushroll chamber and configured to rotate about a second axis in a second direction that is counter to the first direction, the second brushroll including a second set of tines, wherein the second set of tines are timed to interfere with the first set of tines as the first and second brushrolls counterrotate to pull hair into the air path above the first and second brushrolls

These and other features and advantages of the present disclosure will become apparent from the following description of particular embodiments, when viewed in accordance with the accompanying drawings and appended claims.

An accessory tool having improved pet hair cleaning features is described below. The accessory tool has multiple rotating brushrolls which counter-rotate to comb pet hair and other debris toward the middle of the brushrolls. As but one example, the brushrolls have agitating elements that interfere with each other to pull pet hair in between the brushrolls and into the air path of the tool. The pet hair is then released from the brushrolls into the air path internally within the tool.

As will be appreciated from the description herein, the accessory tool has myriad use applications, but is generally used to remove pet hair and other debris not limited to pet hair, from upholstered surfaces. The accessory tool also works well for non-upholstered surfaces and can be used for general vacuum cleaning as well. At least some aspects of the accessory tool provided herein function through the various elements thereof, as described below, to improve pet hair removal by combing the surface to be cleaned to initiate release of pet hair from the surface and pinching pet hair between rotating tines to complete the release of pet hair. By the dual combing and pinching action, pet hair is quickly and effectively removed from upholstered surfaces. Furthermore, pet hair is not retained on the brushroll and/or in the bearings of the brushroll. As such, certain features of the surface cleaning apparatus may be considered functional but may also be implemented in different aesthetic configurations.

In an exemplary embodiment shown in, wherein like numerals indicate corresponding parts throughout the several views, a cleaning head in the form of an accessory tool is illustrated and generally designated at. As discussed in further detail below, the accessory toolis provided with various features and improvements, including improved pet hair cleaning features to remove pet hair and other debris not limited to pet hair, from upholstered surfaces. Generally, the term “debris” as used herein includes pet hair, pet fur, non-pet hair, dirt, dust, stains, soil, and other debris.

For purposes of description related to the figures, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inner,” “outer,” and derivatives thereof shall relate to the accessory toolas oriented infrom the perspective of a user holding the toolin one hand. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary.

The accessory toolincludes a housingthat can be coupled to a vacuum cleaner, an inlet, a first brushroll, and a second brushroll. The housingcan include a brushroll chamberand defines an air path, indicated by arrows in. The brushroll chamberincludes the inletand mounts the first and second brushrolls,therein. The brushrolls,are rotatable about respective axesA,A, and can be driven by an air turbine or a motor to counterrotate, as described in further detail below.

An attachment tubeextends from the housingand is configured to selectively connect to a portion of a vacuum cleaner, such as a hose and/or wand of a vacuum cleaner. The attachment tubeis in fluid communication with the air path. The attachment tubecan form a handhold or grip for the tool. It is contemplated that the attachment tubeand/or the housingcan be adapted to fit in one hand of a user. Thus, the accessory toolcan a handheld accessory tool.

The housingin one embodiment, is generally formed by an upper housingand a lower housingthat are attached to one another by screws, snap fittings, welding, or other suitable attachments. In one embodiment, the upper and lower housings,may be secured together by a retaining ring, which may be removable to separate the housings,to clean the interior components.

The upper and lower housings,preferably form an ergonomic shape that can be held in, and controlled by, one hand of a user, providing the toolwith a “handheld” housing. One or both of the upper and lower housings,may be made of a transparent material, or have one or more windows therethrough, to provide visual feedback on the operation of the tool. As shown in, in one example the upper housingmay be transparent to view the brushrolls,and/or turbine.

At least a portion of the attachment tubeis hollow to defines a portion of a suction pathway of the tool, the suction pathway extending through the housingand including the air pathand inlet. The tubecan be somewhat tapered and sized to slide into (or around) the hose and/or wand of the vacuum cleaner and be retained thereon or therein by a friction fit. Alternatively, conventional bayonet fittings, threads, snap connectors, or other fittings may be used for this purpose.

Various configurations for the attachment tubeare possible. In one embodiment, the attachment tubeis integrally formed with one or both of the housings,. In another embodiment, the tubeis a separate part that is captured between the upper and lower housings,.

The attachment tubemay be rotationally fixed on the housingor may pivot relative to the housing. For example, the attachment tubemay be mounted to rotate about the longitudinal axis of the tube. The attachment tubeis shown as a generally cylindrical part having a circular profile, although other shapes for the tubeare possible.

According to one aspect of the disclosure, the housingcan include an air turbine chamber, and an air turbineis mounted in the air turbine chamberand is configured to rotate about a turbine axisA. The air turbineis coupled with the first and second brushrolls,, to drive the rotation of the first and second brushrolls,about their respective axesA,A.

In one configuration, the brushroll axesA,A line in a plane, and the turbine axisA is disposed outside the plane. The benefit is that both brushrolls,can be engagement with a surface to be cleaned with the toolheld in an ergonomic position via the attachment tubewith the wrist elevated and comfortable.

The air turbinecomprises a vaned turbine wheelrotatably mounted within the housing on a pair of bearings. The turbine wheelcan, for example, be captured between the upper and lower housings,, with the bearingsfit into corresponding slotsin the upper and lower housings,(only visible on the lower housingin) and suspend the vaned turbine wheelso that it freely rotates within the air turbine chamber.

The air turbinecan be coupled with the brushrolls,by a belt, a gear set, and/or another drive mechanism. In the embodiment shown, a beltdirectly couples the air turbine with the first brushroll. The air turbinecan include a drive gearthat drives the belt, which, in turn, drives a driven gearon the first brushroll. The second brushrollis indirectly coupled with the air turbineby a set of enmeshed gears,on the brushrolls,.

The air turbine chamberis in fluid communication with the brushroll chamberby way of a turbine inlet. The turbine chamberis also in fluid communication with the attachment tubeby way of a turbine outlet. In this manner, the turbine chamberis fluidly interposed between the brushroll chamberand the attachment tubeand is driven by air passing therebetween.

Air can exit the brushroll chamberabove and/or between the brushrolls,. The turbine inlet, which can also define an air exit from the brushroll chamberin some embodiments, can be disposed above and rearward of the brushroll chamber.

The air turbinemay alternatively be configured to be driven by air that is separate from the air entering the brushroll chamber. In such an embodiment, the brushroll chambercommunicates directly with the attachment tube, and a separate turbine inlet (not shown) is provided through the housingat a location remote from the brushroll chamberto allow ambient air to enter the turbine chamber. The turbine inletbetween the brushroll chamberand turbine chamberis eliminated, but the turbine outletis still in fluid communication with the attachment tubeso that the vacuum draws air through the air turbineto drive its rotation.

While the turbineis shown in this embodiment as rotating about an axisA that is parallel to the brushroll axesA,A, it will be appreciated that it may be oriented at any other suitable angle to the brushroll axesA,A.

It will be appreciated that the air turbinemay be replaced by other brushroll drive devices. For example, the air turbinecan be replaced by an electric motor (not shown) powered by batteries or by electrical leads connected to the power source of the vacuum cleaner to which the toolis attached. The motor is coupled with the first and second brushrolls,, to drive the rotation of the first and second brushrolls,about their respective axesA,A.

According to one aspect of the disclosure, the first and second brushrolls,counterrotate. The first brushrollrotates about a first brushroll axisA in a first directionR and the second brushrollrotates about a second brushroll axisA in a second directionR opposite to or opposing the first directionR.

Each brushroll,respectively comprises an elongated agitator body, referred to herein as a dowel,to which a plurality of tines,, also referred to herein as a set of tines, are affixed, and which extend outwardly therefrom. The elongated agitator body or dowel,is configured to extend along and rotate about axisA,A, respectively. In the illustrated embodiment, the dowel,have 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.

Referring to, according to one aspect of the disclosure, the tines,are configured to interrupt each other as the brushrolls,counterrotate, pulling pet hair (and other debris) into the air path. As but one example, the tines,comb the surface to be cleaned, and pull pet hair toward the middle of the inlet. The tines,are timed to interfere with each other to pull pet hair in between the brushrolls,and into the air pathabove the brushrolls,. The pet hair is then released from the brushrolls,into the air pathinternally within the tool.

The brushrolls,are rotatably mounted within the housingon a pair of bearings,, respectively, that pivotally mounted at each end of the dowel,(only one of the pair of bearings,is visible in). The brushrolls,can, for example, be captured between the upper and lower housings,, with the bearings,fit into corresponding slots,in the upper and lower housings,(only visible on the lower housingin) and suspend the dowel,so that the brushrolls,freely rotate within the brushroll chamber.

The bearings,are preferably located in bearing compartments,that are generally isolated from the remainder of the brushroll chamberto prevent pet hair and other debris from clogging the bearings. As such, the compartments,can be disposed on the lateral sides of the brushroll chamber, with the bearings,at or near corresponding lateral ends of the brushrolls,.

The driven gear, over which the beltfits, and first enmeshed gearare located along the length of the first doweland the second enmeshed hearis located along the length of the second dowel. The gears,,can be in one bearing compartmentto prevent pet hair and other debris from clogging the gears,,. As such, the gears,,can be at or near a lateral end of the brushrolls,corresponding to the bearing compartment.

The housingcan have an air leak holein the bearing compartment. The air leak holeallows a small amount of sacrificial air to flow through the bearing compartmentand into the brushroll chamber, preventing pet hair and other debris from being pulled from the brushroll chamberinto the bearing compartment. A similar air leak hole() can be provided in the other bearing compartment. The air leak holes,can be at or near the lateral sides of the housing.

The brushroll chamberis formed on one side by the upper housing, and on the other side by the lower housing. The inletcan be formed in the lower housingand is generally below the axesA,A of the brushrolls,. The brushrolls,are positioned within the brushroll chambersuch that the tines,, including at least tipsT,T of the tines,, pass through the inletas the brushrolls,rotate.

Referring to, in an embodiment where an air turbinedrives the brushrolls,, the toolcan comprise one or more relief cutouts,on an undersideof the housingaround the inlet. The relief cutouts,ensure air turbineruns smoothly by maintaining proper airflow through the inleteven when the undersideof the housingaround the inletis sealed by an underlying surface to be cleaned. As but one example, one or more relief cutoutscan be disposed on a front edgeof the inletand/or one or more relief cutoutscan be disposed on a rear edgeof the inlet.

According to one aspect of the disclosure, the toolcan include one or more suction-focusing notches,on the undersideof the housingaround the inlet. The suction-focusing notches,focus suction between the brushrolls,by directed incoming air toward a center of the inlet. As but one example, one suction-focusing notchcan be disposed on a first lateral edgeof the inletand/or one suction-focusing notchcan be disposed on a second lateral edgeof the inlet. The suction-focusing notchon the side of the inletcorresponding to the driven side of the brushrolls,may be longer than the second suction-focusing notchto accommodate for the drive mechanism.

The dowels,are separated by a gap, which may lie generally at the center of the inlet, and preferably the suction-focusing notches,are aligned with the gapto focus suction at the gap, thereby working in concert with the counterrotating brushrolls,to direct pet hair and other debris toward the center of the inletand into the gap.

The tines,extend from a first end or rootR,R that abuts, is attached to, or is integral with the dowel,to a second end or tipT,T. One or more of the tines,can extend radially from the dowel,, respectively, e.g., in a straight line extending from the axisA,A. It is also contemplated that one or more of the tines,can extend at an angle from the dowel,in a straight line that does not pass through the axisA,A. For tines that extend in a straight line, the rootR,R and tipT,T line in a plane. It is further contemplated that one or more of the tines,can be curved, with the rootR,R extending radially or angularly from the dowel,and the tipT,T being out of plane with the rootR,R.

In the embodiment shown, the tines,generally extend radially from the dowel,when not subjected to external force. When subjected to an external force, the tines,may flex and bend, such as when in contact with the surface to be cleaned or each other. The tipsT,T are configured to bend out of plane with the rootR.R when in interference with each other or with the surface.

The tines,each have an engagement surfaceS,S that contacts the surface to be cleaned or another tine during rotation of the brushrolls,. The tipsT,T of the tines preferably extend below and/or through the inlet(see) so that at least of a portion of the engagement surfacesS,S rub across the surface to be cleaned to comb hair from the surface. The tines,also each have a non-engagement surfaceN,N opposite the engagement surfaceS,S that does not contact the surface to be cleaned or another tine during rotation of the brushrolls,.

One or more of the tines,can have a flat, paddle-like body including the rootR,R and tipT,T and defining the engagement surfaceS,S. The flat, paddle-like body has a width W greater than its thickness T. Each tine,has a length L, defined as the distance between its rootR,R at the dowel surface and its tipT,T, a width W defined as the distance between lateral sidesL,L of the tine, and a thickness T defined as the distance between the engagement surfaceS,S and non-engagement surfaceN,N. The lateral sidesL,L can join the engagement surfaceS,S and non-engagement surfaceN,N.

In the embodiment shown, the tines,may include one or a plurality of rectilinear or generally rectilinear bodies, e.g., where the lateral sidesL,L are parallel or generally parallel to each other and where the engagement surfaceS,S is parallel or generally parallel to the non-engagement surfaceN,N. It is contemplated that tines,may have alternate configurations, such as, for example, rounded, cylindrical, triangular, square, polygonal, irregular, uniform, non-uniform, and/or tapered. It is also contemplated that the tines,may have a different configuration at the tipT,T and at the rootR,R. The tines,can have a smooth outer surfacesS,S,N,N as shown in the figures; however, in other embodiments, the tines,can have a textured outer surface.

According to one aspect of the disclosure, the tine width W is greater than the tine thickness T, alternatively tine width W is at least 3× of the tine thickness T, alternatively tine width W is at least 4× of the tine thickness T, alternatively tine width W is at least 5× of the tine thickness T. Tines that are wider than they are thick have be found to be better for picking up hair by providing more tine surface area, e.g., a larger engagement surfaceS,S, for combing the surface to be cleaned while keeping the tines flexible. The tine length L is greater than either the tine width W or thickness T. While dimensions of the tines may vary, in one embodiment the tine length L is about 12 mm, the tine width W is about 4.5 mm, and the tine thickness T is about 1.5 mm. It is also contemplated that the width W and thickness T can be constant from root to tip or may vary. It is further contemplated that the dimensions of the tines can be the same for each tine and each brushroll or may differ.

The tines,in the illustrated example are arranged in multiple rows, with each row extending in a generally helical formation from a first lateral end to a second lateral end of the brushroll. It is contemplated that in alternative embodiments a single row of tines may be provided. It is also contemplated that rows may be arranged in a formation other than helical, such as a straight row extending linearly between the ends of the brushroll, a double helical pattern (e.g., ‘wrapping’ around the circumference of the brushroll two or more times), a chevron or V-shaped pattern, or in any other suitable formation.

In being timed to interfere with each other, the position of the tines,are synchronized with each other and with the rotation of the brushrolls,to produce interference of the tines,during at least a portion of the rotation, such as during a portion of brushroll rotation in which the tines,are moving through the gapin between the dowels,. It is envisioned that the brushrolls,may include any number of tines,and/or any timing configuration, including where the tines,are timed to interfere one at time or more than one at a time. Preferably, at least one tine,on each brushroll,are timed to engage each other during a portion of the brushroll rotation in which the tines,are moving through the gapbetween the dowels,. The tines,can be offset and/or staggered around each brushroll,such that the engagement moves laterally back and forth from one lateral end to the other lateral end of the brushroll. It is further contemplated either brushroll,may have one or more tines that do not interfere with a tine on the other brushroll. However, in a preferred embodiment, the first brushrollhas multiple tinesthat interfere with a corresponding set of multiple tineson the second brushroll.

According to one aspect of the disclosure, at least one of the tineson the first brushrolland at least one of the tineson the second brushrollare timed to interfere with each other through a number of degrees of rotation during a period in which said tines,are moving through the gapin between the dowels,, for example through at least 60 degrees of rotation of the brushrolls,, alternatively through at least 90 degrees of rotation of the brushrolls,, alternatively through at least 75 degrees of rotation of the brushrolls,alternatively through at least 120 degrees of rotation of the brushrolls,. During the interference period, the amount of interference between the tines,changes, with the tines,initially contacting at the tipsT,T, then more of the engagement surfacesS,S coming into contact, and then moving out of contact until the tines,contact at the tipsT,T again, until finally the tines,disengaging from each other.shows some examples of different stages of interface between tines,.

The brushrolls,may have tines,as the only agitation element thereon. However, in other embodiments of the tool, the brushrolls,may have bristles (not shown) and/or other agitation elements such as, but not limited to, fabric, felt, nap, and/or pile (or any combination thereof) in addition to the tines,. Disposing bristles or other agitation elements on the brushrolls,may increase the agitation of the surface to be cleaned, thereby more effectively loosening debris thereon.