Agitator Element for a Vacuum Cleaner

The present invention relates to an agitator element for a cleaner head of a vacuum cleaner, as well as to a cleaner head comprising such an agitator element, and to a vacuum cleaner comprising such a cleaner head.

A vacuum cleaner usually comprises a cleaner head having a housing defining a suction chamber. The housing is configured to be moved over a floor or other surface that needs to be cleaned while air is drawn into the suction chamber together with dust, hair, and other dirt that is thereby removed from the surface. An outlet of the housing is coupled to a motor via a wand or hose. The motor provides for the suction needed to generate the airflow through the suction chamber. In many modern vacuum cleaners, the cleaner head comprises one or more brush bars or other types of agitator elements that rotate while the housing moves over the surface to be cleaned. The agitator elements serve to detach dirt from the surface and to increase the chance that it is picked up, thereby improving the cleaning performance of the vacuum cleaner.

Typically, vacuum cleaner heads experience some degree of hair ingress during use, which means that hair can ingress into or between parts of the cleaner head. Hair can also become wound around the agitator elements which can damage the agitator elements and which can also reduce their ability to detach dirt and hair from the floor, especially if a thick layer of hair becomes wrapped around the agitator elements.

It is desirable for a vacuum cleaner to pick up as much dirt from the floor surface as possible. It is therefore desirable for the vacuum cleaner head to be able to collect dirt from the edges of a room or furniture so that no part of the floor is left uncleaned.

It is against this background that the present invention has been developed.

In a first aspect, the present invention provides an agitator element for a vacuum cleaner, the agitator element comprising: a support member having opposed first and second end surfaces, and an elongate surface which extends between the first and second end surfaces, wherein the first end surface is located proximate a first end of the agitator element, and wherein the second end surface is located proximate a second end of the agitator element; and agitation material which extends away from the first end surface of the support member such that the outermost extremity of the agitation material defines the outermost extremity of the first end of the agitator element.

The agitator element of the present invention is advantageous because the agitator material extends beyond the end of the support element meaning that the width of floor that can be cleaned is larger than the elongate width of the support element.

Optionally the agitation material comprises fabric which covers at least a portion of the first end surface. Many different fabrics with many different aesthetic and functional characteristics may be selected as the agitation material. Fabric may be readily applied to the support element as a full covering, or as a partial covering. Fabric agitation material(s) may be used alone on in combination with other agitation materials such as bristles.

The first end surface optionally surrounds a recessed portion of the support member. The recessed portion may be a closed ended hole in the support member, or it may a through hole which extends along the full length of the support member.

At least part of the fabric agitation material may extend from the first end surface into the recessed portion to help secure the fabric to the support member and to avoid peeling or shedding of the fabric from the first end surface.

In one example, the agitator element comprises a stud located within the recessed portion, wherein an outer portion of the stud engages the fabric agitation material located within the recessed portion to help secure the fabric on the support member. Optionally the stud is integral with the support member for ease of manufacture and to reduce the part count.

The agitation material optionally comprises a plurality of upstanding bristles either alone, or together with other agitation material(s) such as fabric agitation material.

The support member may comprise a main body and an end cap having an external surface, wherein the external surface of the end cap defines at least a portion of the first end surface of the support member. The provision of an end cap may help to facilitate rapid assembly of the agitation element. In one example the agitation material may cover the external surface of the end cap.

Optionally the agitation material extends away from the elongate surface of the support member. At least a portion of the agitation material which extends away from the elongate surface may optionally be continuous with at least a portion of the agitation material which extends away from the first end surface so that the same fabric may be used on the first end surface and on the elongate surface thereby providing continuity of material between the two surfaces.

The composition of the agitation material which extends away from the elongate surface may be different to the composition of the agitation material which extends away from the first end surface so that agitation material(s) most suited to positioning on the first end surface may be selected independently of the agitation material(s) selected for the elongate surface.

In one example agitation material extends away from the second end surface of the support member thereby further increasing the effective width of the agitator member. This can be especially useful when two or more agitation members are used end to end as any gap between the agitator members is at least partially spanned by agitation material.

Optionally the agitation material which extends away from the second end surface comprises fabric which covers at least a portion of the second end surface, wherein the second end surface surrounds a second recessed portion in the support member, and wherein at least part of the fabric agitation material extends from the second end surface into the second recessed portion to help secure the fabric to the support member and to avoid peeling or shedding of the fabric from the second end surface.

The agitator element optionally tapers from its first end towards its second end, or from its second end towards its first end. Tapered agitator elements are beneficial as any hair or other long fibres which are picked up by the agitator element tend to migrate along the length of the agitator element towards the tapered end where they can be removed. This helps to prevent hair and other long fibres from becoming tightly wrapped around the agitator element.

In a second aspect, the present invention provides a cleaner head for a vacuum cleaner comprising an agitator element as described above.

In a third aspect, the present invention provides a cleaner head for a vacuum cleaner, the cleaner head comprising: a housing defining a suction chamber comprising an outlet; and an agitator element as described above mounted for rotation within the housing.

Optionally the cleaner head comprises a second agitation element, wherein the housing comprises a first side and a second side, and wherein the agitator element is mounted for rotation on the first side of the housing, and the second agitator element is mounted for rotation on the second side of the housing, wherein the respective first or second ends of the agitator elements are located adjacent to one another.

In a fourth aspect, the present invention provides a vacuum cleaner comprising a cleaner head as described above.

Features described above in connection with the first aspect of the invention are equally applicable to the second, third and fourth aspects of the invention, and vice versa.

shows a hand-held vacuum cleanercomprising a main body, a wandand a cleaner head. The main bodycomprises a separating system, in the form of a cyclonic separator, a motor and impeller (not visible) arranged to draw air through the separating system, and a power supply, in the form of a battery, for powering the motor. The main bodyhas a handlewhich is gripped by a user, and a clean air outletthrough which air that has passed through the separating systemis discharged. The wandis attached at one end to the main bodyand at the other end to the cleaner head. The wandprovides fluid communication between the cleaner headand the separating systemand supports the cleaner headduring use.

shows the cleaner headof the vacuum cleaner. The cleaner headhas a housing, which at least partially defines a suction chamber comprising an outletfor expulsion of air and debris towards the vacuum cleaner. The cleaner headcomprises a first agitator elementand a second agitator element. In this embodiment, the agitator elements,are implemented as frustoconical agitator elements,as will be described in greater detail below.

The first and second agitator elements,are each mounted for rotation about respective axes R, R. Each agitator element,comprises a first, free endand a second endat which they are mounted to the cleaner head. In this embodiment, the agitator elements,have a frustoconical shape which tapers towards the first endin a direction along the axis of rotation R, R. Both agitator elements,are cantilevered from opposing sides of a hub portionof the cleaner headat their respective second endsIt should be appreciated that a portion of one or both agitator elements,may not be tapered. For example, the shape of one or both agitator elements,may consist of a cylindrical portion combined with a frustoconical portion. In other embodiments, the agitator elements,may be fully cylindrical.

In the illustrated embodiment, the hub portionis at a laterally central position with respect to the overall cleaner head, although this may not always be the case. For example, if the first and second agitator elements,have different lengths, then the hub portioncould be offset laterally relative to the laterally central part of the cleaner head. The hub portionserves to rotatably support the second endsof the agitator elements,and may comprise a drive housing holding a drive mechanism for rotating the agitator elements,. In an alternative embodiment, the agitator elements may be cantilevered from separate hubs located at the first endsof the agitator elements,, or the agitator elements,may be supported by hubs located at both the firstand secondends of the agitator elements,.

show perspective and cross-sectional views respectively of the first agitator element. It will be understood that all of the features described hereinbelow with respect to the first agitator elementapply equally to the second agitator element, and that only the first agitator elementis described in detail below for the sake of brevity.

As best shown in, the agitator elementcomprises a fabric agitation materialwhich is supported by a support member. The support membercomprises an elongate surfacewhich extends between a first end surfaceof the support memberlocated proximate the first endof the agitator elementand a second end surfaceof the support memberlocated proximate the second endof the agitator element. The support memberhas a recessed portionlocated proximate the first endof the agitator elementand a second recessed portionlocated proximate the second endof the agitator elementsuch that the first and second end surfaces,of the support memberare annular.

The fabric agitation materialcomprises a woven material having a fluffy outer layerand a backing layer. The backing layeris attached to the support memberwith an adhesive such that the whole of the elongate surfaceand the first and second end surfaces,are covered by the agitation material. The agitation material is wrapped around the ends of the support membersuch that the agitation materialextends from the first and second end surfaces,into the recessed portionand the second recessed portion. In an alternative example (not shown), the agitation materialmay end at the radially innermost edge of the first and/or second end surfaces,such that it does not extend into one or both of the recessed portionor second recessed portion.

The agitation materialextends away from the elongate surface, and away from the first and second end surfaces,such that the outermost extremity of the agitation materialdefines the outermost extremities of the agitator element. Consequently, the outermost extremity of the agitation materialat the first endof the agitator elementdefines the outermost extremityof the first endof the agitator element, and the outermost extremity of the agitation materialat the second endof the agitator elementdefines the outermost extremityof the second endof the agitator element.

show perspective and cross-sectional views respectively of an alternative arrangement for the agitator element. The agitator elementofis the same in all respects to the agitator element shown inexcept in that the agitation materialcomprises a common backing layerwith two differing outer layers,.

The outer layers comprise a first outer layerwhich is the same as the fluffy outer layerof, and a second outer layer. The material properties of the second outer layerare different to those of the first outer layerso that the agitator elementmay fulfil two functions at the same time. For example the first outer layermay be selected for its ability to detach dirt, while the second outer layeris selected for its ability to polish.

The first and second outer layers,of the agitator elementmay comprise any suitable material. For example, both outer layers,may be fluffy but with fibres orientated in different directions, and/or with fibres of differing stiffnesses. Alternatively, one of the outer layers may be fluffy while the other is not. It will be understood that the embodiment shown inis an example only and that it is not essential that the fluffy layer be located in the region of the agitator head indicated by reference numeral.

In the embodiment ofthe two outer layers,of the agitation materialare woven together with a common backing layer. In an alternative example, one or both of the outer layers,may be applied to the backing layerwith an adhesive. The outer layers,may therefore be flocked, or may comprise non-woven materials such as felt or combed natural or synthetic fibres. The backing materialmay be a woven or non-woven material. For some materials, such as felted materials, there may be no backing layer such that the material is attached directly to the support member.

In an alternative embodiment (not shown), the agitator elementmay comprise separate pieces of agitation materialwhich do not have a backing layer, or which do not share a common backing layer. Such separate pieces may be attached to the support membernext to one another so that the whole of the elongate surface, and the first and second end surfaces,are covered by agitation materials. Alternatively only parts of the elongate surface, and the first and second end surfaces,may be covered by agitation materials. In either case, the agitation materialsmay optionally extend into one or both of the recessed portionor second recessed portion

In a further alternative example, the agitation material or materialsmay comprise a plurality of upstanding bristles which are supported directly by the support member, or which are applied to, or formed with, a backing materialof one or more pieces of fabric agitation material. Bristles may be used together with, or instead of, fabric agitation material. The bristles may project in any suitable direction from the support member.

The agitator elementmay comprise any number and/or configuration of agitation materials. The composition of the agitation materialon the first and/or second end surfaces,may be different to the composition of the agitation materialon the elongate surface.

is a cross-sectional view of a further alternative agitator element. The agitator elementofis the same in all respects to the agitator element shown inexcept in that the support membercomprises an integral studlocated at the first endof the agitator element, and in that the fabric agitation materialhas been processed at the second endafter attachment to the support member.

As shown, the studis connected to the main body of the support memberby an annular wallthereby defining an annular recessed portionat the first endof the agitator elementbetween the studand the main body of the support element. The agitator materialextends from the first end surfaceinto the annular recessed portionsuch that an outer portionof the stud engages the fabric agitation material located within the recessed portion. Because the radial depth of the annular recessed portionis less than the thickness of the agitation material, the fluffy outer layerof the agitation materialis compressed within the annular recessed portion. This compression may be sufficient to hold the agitation materialin the annular recessed portion. Alternatively or additionally, an adhesive and/or retaining formations may be formed in the surfaces of the recessed annular portionto help hold the agitation materialin place.

The agitation materialat the second endof the agitator elementhas been processed after it has been attached to the support memberby removal of the outer layerof the agitation materialfrom within the second recessed portion. The backing layerremains in place within the second recessed portion. In an alternative example, the backing layer may also be removed during the process.

It will be understood that an annular recessed portion can be provided at the second endof the agitator elementas well as at the first endby provision of an integral stud at the second endSimilarly, some or all of the agitation materialmay be removed from within the recessed portion at the first endof the agitator elementwhether or not the recessed portion at the first endis annular as shown inor non-annular as shown in.

show partial cross-sectional and perspective views respectively of an alternative arrangement for the firstand/or secondend of the agitator element. Although the first endof the agitator element is illustrated in, it will be understood that the same arrangement could also, or alternatively, be used at the second end

The first endof the agitator elementshown inis the same in all respects to the agitator element shown inexcept in that a separate studis used in place of the integral stud. The studis positioned in the recessed portionafter the agitation materialhas been applied to the support elementand clipped into place by engagement of a clip formationat the innermost end of the studand annular wall. The outermost end of the studcomprises a radially extending lipwhich compresses the agitation naturalbetween the edge of the lipand the main body of the support member. The agitation materiallocated in the recessed portionmay be held in place by the studalone or an adhesive may be used together with the stud.

show partial cross-sectional and isometric views respectively of another alternative arrangement for the firstand/or secondend of the agitator element. Although the first endof the agitator element is illustrated in, it will be understood that the same arrangement could also, or alternatively, be used at the second end

In this example, the support membercomprises a main bodyand an end cap. The main bodyof the support memberis covered with agitation material and the outer endof the end capis covered with agitation material. The end capis held in place by a clip formationlocated at the innermost end of the end cap. The clip formationengages with an annular walllocated at the outermost end of the main body.

In an alternative arrangement to the arrangement shown in, the end capmay comprise a recessed portion such that the first endof the agitator element resembles the first endillustrated inand

show partial cross-sectional and isometric views respectively of a still further alternative arrangement for the firstand/or secondend of the agitator element. Although the first endof the agitator element is illustrated in, it will be understood that the same arrangement could also, or alternatively, be used at the second end

In this example, the support membercomprises a walllocated at its outermost end proximate the first endof the agitator element wherein the outermost surface of the wallcomprises the first end surfaceof the support member. The elongate surfaceof the support member is covered by a first agitation materialand the first end surfaceis covered by a second agitation material. Alternatively, the agitation material on the first end surfacemay be the same as the agitation material on the elongate surface.

An annular rimsurrounds the covered portion of the first end surfacesuch that a portion of the support elementis not covered by agitation material,. This is not essential and in another example the agitation material,may cover all of the first end surface.