CN111936021A

CN111936021A - Brush roller for vacuum cleaner

Info

Publication number: CN111936021A
Application number: CN201980007912.2A
Authority: CN
Inventors: 加里·A·卡斯佩尔; 托得·理查德·范通厄伦; 杰克·安德鲁·莫汉; 杰弗里·A·斯科尔滕
Original assignee: Pizza Hut Inc
Current assignee: Pizza Hut LLC
Priority date: 2018-01-10
Filing date: 2019-01-07
Publication date: 2020-11-13
Also published as: AU2019207468A1; EP3716833A1; CA3087466C; KR20200116929A; JP2021510329A; WO2019139846A1; EP3716833A4; AU2019207468A2; JP7273832B2; AU2019207468B2; CA3087466A1

Abstract

A brush roll (60, 90, 120, 150) for a surface cleaning apparatus (10), comprising: a brush pin (62, 92, 122, 152) defining an axis (X) and having opposing bristle supports (70, 102, 130, 160) and a shroud surface (74, 134, 138, 164, 168) between the opposing bristle supports (70, 102, 130, 160); and a plurality of bristles (72, 104, 132, 162) protruding from the bristle support (70, 102, 130, 160). The guard surfaces (74, 134, 138, 164, 168) include opposing convexly curved surfaces (86, 138, 168) extending between bristle supports (70, 102, 130, 160) that intersect the guard surfaces (74, 134, 138, 164, 168) at outer corners (88, 148, 178).

Description

Brush roller for vacuum cleaner

Citations to related applications

This application claims the benefit of U.S. patent application No. 15/866,978 filed on day 10/1 in 2018, which is a continuation-in-part application of U.S. patent application No. 14/966,139 filed on day 11/12 in 2015, which claims the benefit of U.S. provisional patent application No. 62/090,959 filed on day 12/12 in 2014, which are incorporated herein by reference in their entirety.

Background

The vacuum cleaner may include an agitator for agitating debris on the surface to be cleaned so that the debris is more easily ingested into the vacuum cleaner. In some cases, the agitator includes a brush roller that rotates within a base or bottom nozzle. Such brushrolls may be rotatably driven, for example, by a motor, turbo fan or mechanical gear train. The brushroll typically has a generally cylindrical pin with a plurality of bristle tufts extending radially from the pin. In operation, debris on the surface to be cleaned is swept away by the brush roll; in some cases, elongated debris (such as hair) may become entangled around the brush roll and must be removed by the user by manually pulling or cutting the hair from the brush roll.

Disclosure of Invention

According to one aspect of the present disclosure, a brushroll for a vacuum cleaner includes a brush pin configured to be mounted for rotation about a central rotational axis extending longitudinally therethrough, and the brush pin has opposed bristle supports defining mounting surfaces and has a shield surface including opposed convexly curved surfaces extending between the opposed bristle supports, the brushroll further including a plurality of bristle tufts secured to each of the opposed bristle supports and protruding from one of the mounting surfaces, wherein the mounting surfaces intersect the convexly curved surfaces at outer corners.

Drawings

In the drawings:

FIG. 1 is a schematic cross-sectional view of a conventional brushroll for a vacuum cleaner;

FIG. 2 is a view similar to FIG. 1, showing the brushroll during operation;

figure 3 is a perspective view of a vacuum cleaner according to a first aspect of the present disclosure, with a portion cut away for clarity;

FIG. 4 is a perspective view of a brushroll for the vacuum cleaner of FIG. 3;

FIG. 5 is a cross-sectional view of the brushroll taken along line V-V of FIG. 4;

6-7 are views similar to FIG. 5 showing the brushroll during operation;

FIG. 8 is a perspective view of a brush roll according to a second aspect of the present disclosure;

FIG. 9 is a cross-sectional view of the brush roll taken along line IX-IX of FIG. 8;

FIG. 10 is a perspective view of a brush roll according to a third aspect of the present disclosure;

FIG. 11 is a cross-sectional view of the brush roll taken along line XI-XI of FIG. 10;

FIG. 12 is a perspective view of a brush roll according to a fourth aspect of the present disclosure; and

fig. 13 is a cross-sectional view of the brush roller taken along line XIII-XIII of fig. 12.

Detailed Description

The present disclosure relates to vacuum cleaners, and in particular to vacuum cleaners having a rotatable brushroll or an accessory tool for a vacuum cleaner. In particular, the present disclosure relates to an improved brush roll design that reduces hair tangling. According to one aspect of the present disclosure, a brushroll includes a pin, a plurality of bristles protruding from the pin, and a shield surface positioned relative to the bristles to minimize hair snagging.

According to another aspect of the present disclosure, a brushroll includes a pin, a plurality of bristles projecting from the pin, and a cutting channel positioned relative to the bristles to allow hairs to be cut from the pin.

According to another aspect of the present disclosure, the brush roll includes a concavely curved tuft surface to which bristle tufts are mounted or secured to minimize hair entanglement.

According to yet another aspect of the disclosure, the brush roll includes offset sets of swept bristles clustered at acute angles to reduce the drive torque required to rotate the brush roll.

The brushroll may be used with a variety of vacuum cleaners, including upright, cylinder, stick, autonomous or robotic vacuum cleaners, or hand-held vacuum cleaners, or accessory tools thereof. Furthermore, the vacuum cleaner or accessory tool may additionally be configured to dispense and/or extract fluid, where the fluid may be, for example, a liquid or a vapor. As used herein, unless otherwise specifically indicated, the term "surface cleaning apparatus" includes both vacuum cleaners and accessory tools for vacuum cleaners.

Fig. 1 is a schematic cross-section of a conventional brushroll 200 for a vacuum cleaner. The brushroll 200 includes a brushpin 202 configured to be mounted for rotation about a central rotational axis X extending longitudinally through the pin 202. The pin 202 includes a cylindrical core 204 and one or more bristle supports 206 protruding from the core 204. A plurality of bristles 208 project from the bristle support 206; the plurality of bristles 208 may be arranged in a series of discrete tufts or a continuous strip. The bristles 208 may be arranged on the pin in various patterns, including straight, angled, spiral, or combinations thereof.

Fig. 1-2 illustrate an exemplary operation of the brushroll 200. During operation, the brushroll 200 is configured to be rotationally driven in the direction indicated by arrow R. The bristles 208 deflect as the bristles 208 contact the surface to be cleaned. Debris on the surface to be cleaned, which may include but is not limited to dirt, dust and hair, is swept away by the brushroll 200. In this example, for simplicity of illustration, a single hair H on a surface is shown to be picked up by the brushroll 200 of FIG. 1 by the bristles 208 in contact with the surface. As the brushroll 200 rotates, the bristles 208 lift the hair H off the surface and around the pin 202.

In some cases, the hair H may be pulled from the bristles 208 by the suction of the vacuum cleaner. In other cases, the hair H may wrap around the pin 202 as the bristles 208 holding the hair H continue along the rotational path defined by the pin 202, as shown in fig. 2.

When the bristles 208 holding the hair H are again in contact with the surface to be cleaned, the hair H extends from the attachment point P, at which at least one strand of the hair H is attached to at least one of the bristles 208. The surface to be cleaned defines a surface line S, as viewed from the side, and the deflected bristles 208 define a bristle deflection line Y, which is a tangent to the curve defined by the deflected bristles 208 at the attachment point P. The deflection angle a1 is defined by the angle formed by surface line S and line Z (which is a line orthogonal to bristle deflection line Y at the intersection of bristle deflection line Y and surface line S). The hair H defines a hair-winding line W, which is a line defined by the hair H from an attachment point P where it extends from or exits the bristles 208. In some cases, a portion of the hair H just extending from the bristles 208 may extend substantially linearly before bending around the pin 202, such that the hair-winding wire W may follow the linear portion of the hair H. The hair winding angle a2 is defined by the angle formed by the surface line S and the hair winding line W. Note that the hair H may be captured by the bristles 208 in various locations, however, regardless of the location at which the hair is attached to the bristles, the entangled hair H will have at least a portion that extends from the bristles 208 in a direction opposite the brush roll rotation R.

It has been found that for a brush roll design where the hair wrap angle a2 is greater than the deflection angle a1 (in other words, where a2 > a1), the hair is drawn toward the roots of the bristles 208 and wraps tightly around the pin 202. In this case, the hairs cannot be pulled down from the brush roller 200 by the suction force of the vacuum cleaner, and the user must manually remove the hairs.

Aspects of the present disclosure include brush roll designs in which the hair wrap angle A2 is less than or equal to the deflection angle A1 (in other words, where A2 ≦ A1). Such a brush roller prevents or greatly reduces the amount of hair entanglement during operation.

Figure 3 is a perspective view of a vacuum cleaner 10 in the form of an upright vacuum cleaner according to a first aspect of the present disclosure. Although shown and referred to herein as an upright vacuum cleaner, the vacuum cleaner 10 may alternatively be configured as a stick vacuum cleaner, autonomous or robotic vacuum cleaner, handheld vacuum cleaner, or as an appliance having a bottom nozzle or handheld accessory tool connected to a canister or other portable device by a suction hose. The vacuum cleaner 10 may be configured to have a fluid dispensing capability and/or an extraction capability.

For purposes of description in relation to the drawings, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal", and derivatives thereof shall for the purposes of this disclosure be referred to as being oriented in fig. 3 from the perspective of the user behind the vacuum cleaner, which defines the rear of the vacuum cleaner. However, it is to be understood that aspects of the disclosure may assume various alternative orientations, except where expressly specified to the contrary.

As shown, the vacuum cleaner 10 includes an upright body 12 pivotally mounted to a lower base 14. The upstanding body 12 generally includes a main support portion 16 that supports a collection system 18 for separating and collecting contaminants from the working gas stream for later disposal. In one conventional arrangement shown herein, the collection system 18 may include a cyclonic separator 20, which may be considered a cyclonic collection system for separating contaminants from the working airflow, and a removable dirt cup 22 for receiving and collecting the separated contaminants from the cyclonic separator 20. The cyclone separator 20 may have a single cyclone stage or multiple stages. In another conventional arrangement, the collection system 18 may include an integrally formed cyclone separator and dirt cup, wherein the dirt cup is provided with an open-bottomed dirt door for contaminant disposal. It should be understood that other types of collection systems 18 may be used, such as centrifugal separators or bulk separators. In yet another conventional arrangement, the collection system 18 may include a filter bag. The vacuum cleaner 10 may also be provided with one or more additional filters, either upstream or downstream of the collection system 18.

The upright body 12 is pivotally mounted to the base 14 for movement between an upright storage position, shown in fig. 3, and an inclined use position (not shown). The vacuum cleaner 10 may be provided with a detent mechanism, such as a pedal 24, pivotally mounted to the base 14 for selectively releasing the upright body 12 from the storage position to the use position. The details of such a brake pedal 24 are known in the art and will not be discussed in detail herein.

The upright body 12 also has an elongate handle 26 extending upwardly from the main support section 16, which at one end is provided with a handle 28 which can be used to manoeuvre the vacuum cleaner 10 over a surface to be cleaned. A motor cavity 30 is formed at the lower end of support portion 16 and houses a conventional suction source, such as a motor/fan assembly 36, positioned therein in fluid communication with collection system 18. The vacuum cleaner 10 may also be provided with one or more additional filters, either upstream or downstream of the motor/fan assembly.

In fig. 3, the lower portion of the vacuum cleaner 10 is cut away to show features of the base 14. The base 14 may include an upper housing 32 coupled with a lower housing 34 to create a partially enclosed space therebetween. An agitator chamber 38 may be provided at the front of the lower housing 34 for receiving the brush roll 60. A suction nozzle opening 42 is formed in the lower housing 34 and is in fluid communication with the agitator chamber 38 and the collection system 18. Wheels 44 may be provided on the base 14 for maneuvering the vacuum cleaner 10 over a surface to be cleaned.

The brush roller 60 is positioned within the agitator chamber 38 for rotational movement about a central rotational axis X. A single brush roller 60 is shown; however, it is within the scope of the present disclosure to use a dual rotating brush roll. Further, it is within the scope of the present disclosure to mount the brush roll 60 within the agitator chamber 38 in a fixed or floating vertical position relative to the chamber 38 and the lower housing 34.

The brushroll 60 may be operatively coupled to and driven by the motor/fan assembly 36 in the motor chamber 30. The motor/fan assembly 36 may include a motor shaft 46 oriented substantially parallel to the surface to be cleaned and projecting from the motor cavity 30 into the rear of the base 14. A drive belt 48 operatively connects the motor shaft 46 to the brushroll 60 for transmitting rotational motion of the motor shaft 46 to the brushroll 60. Alternatively, a separate dedicated agitator drive motor (not shown) may be provided within the base 14 to drive the brush roll 60.

The base 14 may also include an optional nozzle height adjustment mechanism for adjusting the height of the nozzle opening 42 relative to the surface to be cleaned. A rotatable knob 54 for actuating the adjustment mechanism may be provided on the exterior of the base 14. In another variation, the nozzle height adjustment mechanism may be eliminated.

In operation, the vacuum cleaner 10 draws in debris laden air through the base 14 and into the collection system 18 where debris, which may include, but is not limited to, dirt, dust, hair and other debris, is substantially separated from the working airflow generated by the motor/fan assembly 36. The rotating motor shaft 46 of the motor/fan assembly 36 rotates the brushroll 60 via a drive belt 48 operatively connected therebetween. Alternatively, a separate dedicated agitator drive motor may rotate the brush roll 60. As the brushroll 60 rotates, the bristles sweep across the surface to be cleaned to release and propel debris into the working airflow generated by the motor/fan assembly 36, which carries the debris into the collection system 18. The working airflow then passes through the motor chamber 30 and through the motor/fan assembly 36 before being exhausted from the vacuum cleaner 10. Collection system 18 may be periodically emptied of debris.

Fig. 4 is a perspective view of the brush roller 60. The brush roll 60 comprises a brush pin 62 configured to be mounted for rotation about a central rotation axis X extending longitudinally through the pin 62. The brush pin 62 is mounted on an elongate shaft 64 extending centrally through the pin 62 and defining a central axis of rotation X about which the brush roll 60 rotates. The illustrated brush roller 60 is configured to be rotationally driven in a direction indicated by an arrow R. Bearings 66 are mounted on each end of the shaft 64. In operation, pin 62 rotates on bearing 66 about axis 64. The belt engaging surface 68 extends about the periphery of the pin 62 near one end and communicates with the belt 48 (fig. 3). The belt engaging surface 68 may comprise a pulley.

The brush pin 62 also includes one or more bristle supports 70 that project into the pin 62. Bristles 72 project from the bristle support 70 and may be provided as a series of discrete tufts or a continuous strip. The bristles 72 may be arranged on the pin 62 in various patterns, including straight, angled, spiral, or combinations thereof.

The brush roll 60 is designed to prevent or greatly reduce the amount of hair entanglement during operation by providing a guard surface 74 for the entanglement of hair. The guard surface 74 is disposed adjacent the bristles 72 so as to establish a shallower (shallow) hair wrap angle, as described in further detail below.

In the aspect shown, two bristle supports 70 and two corresponding rows of bristle tufts 76 are disposed on the pin 62, each tuft 76 containing a plurality of bristles 72 and extending in a generally helical pattern around the circumference of the pin 62. The outer surface of the brush pin 62 includes opposing curved portions, shown here as convexly curved surfaces 86, which define the guard surfaces 74, and opposing flat portions that define the mounting surfaces 78 of the bristle support 70 from which the tufts 76 project.

Fig. 5 is a cross-section of the brush roll 60 taken along line V-V of fig. 4. The brush pin 62 may define a hollow interior 80 extending along the length of the pin 62. The shaft 64 is received within the hollow interior 80. The bristle support 70 also includes a bristle support platform 82 that protrudes from the mounting surface 78 into the hollow interior 80 of the pin 62. Bristle holes 84 for the bristle tufts 76 may be formed in the mounting surface 78 and may extend at least partially into the platform 82.

In one non-limiting example, to produce the brushroll 60 shown in FIG. 5, a two-part mold may be used to form the outer profile of the pins 62, while a twist-off core may be used to de-core (core out) the interior of the pins 62, including the platform 82. Note that to form the brush roll 60 in a two-part mold, the bristle support 70 and guard surface 74 may extend 180 degrees or less along the length of the pin 62 so as to be in a stretched line. Brush holes 84 may be formed in pin 62 after molding by drilling holes in pin 62, or may be molded integrally with pin 62. The bristle tufts 76 may be assembled with the pins 62 by pressing the bristles 72 into the brush holes 84 and securing the bristles 72 using fasteners (not shown), such as, but not limited to, staples, wedges, or anchors. The pin 62 may comprise a polymeric material such as polypropylene, Acrylonitrile Butadiene Styrene (ABS), or styrene. The bristles 72 may comprise a polymeric material, such as nylon or polyester, for example, which allows the bristles 72 to flex and deflect when in contact with a surface to be cleaned during normal operation. Other manufacturing methods may be used to produce the brush roll 60 shown in fig. 5.

As described above, the brush roll 60 is designed to prevent or greatly reduce the amount of hair entanglement during operation by providing a guard surface 74 for entangling hair. In the aspect shown, the brush pin 62 defines a major diameter D1, which is the diameter defined by the smallest circle that can encompass the shroud surface 74 of the pin 62. The bristle tufts 76 define a trim diameter D2 that is slightly larger than the major diameter D1. The flat mounting surface 78 is recessed below the major diameter D1, and thus below the guard surface 74, which allows the bristles 72 on the flat mounting surface 78 to deflect when contacting a surface to be cleaned, while keeping any hairs at or near the tips of the bristles 72. For example, the bristle support 70 defines a minor diameter D3 of the brush pin 62. The minor diameter D3 may be defined at the tuft location of the bristle tufts 76 in the bristle support 70. Minor diameter D3 may be smaller than major diameter D1 and trim diameter D2. In the example shown, the minor diameter D3 is a diameter defined by a minimum circle that may contact both mounting surfaces 78 of the bristle support 70 at the tuft location of the bristle tufts 76. Other configurations for a brushroll having a bristle support 70 and a guard surface 74 can have a major diameter D1 and a minor diameter D3 defined in other ways, so long as the guard surface 74 defines D1 and the bristle support 70 defines D3.

The outer surface of the brush pin 62 shown in fig. 5 also includes an outer corner 88 where the convexly curved surface 86 defining the shield surface 74 meets an opposing flat portion defining the mounting surface 78. The outer corner 88 is where the two converging

surfaces

78, 86 meet. Further, brush pin 62 shown in FIG. 5 is symmetrical about multiple axes, including a first axis of symmetry extending generally along the location where minor diameter D3 is defined and a second axis of symmetry orthogonal to the first axis of symmetry and located generally at the location where trim diameter D2 is shown in FIG. 5.

Fig. 6-7 illustrate exemplary operation of the brushroll 60. The brush roller 60 is designed to have a hair wind angle A2 that is less than or equal to the deflection angle A1 (in other words, where A2. ltoreq. A1). During operation, the brush roll 60 rotates in direction R, and debris, including but not limited to dirt, dust, and hair on the surface to be cleaned, is swept away by the brush roll 60. In this example, for purposes of simplicity of illustration, in fig. 6, a single hair H on the surface is shown to be picked up by the brush roller 60 through bristle tufts 76 that contact the surface. The bristle tufts 76 lift the hair H off the surface and around the pins 62 as the brush roller 60 rotates. In some cases, the hair H may be pulled away from the brush roller 60 by the suction force of the vacuum cleaner. In other cases, as the bristle tufts 76 holding the hairs H continue to advance along the rotational path determined by the pins 62, the hairs H may wrap around the shield surface 74, as shown in fig. 7, extending from the attachment points P to the bristle tufts 76 and around the pins 62. Because the hair wind angle a2 is shallower, the hair H remains at or near the tips of the bristle tufts 76, and the hair H is not pulled toward the roots of the bristles 72, nor does the hair H wind tightly around the pin 62. When the bristle tufts 76 holding the hairs H are again in contact with the surface to be cleaned, the hairs H can be pulled away from the bristle tufts 76 by the frictional contact with the surface to be cleaned and the resulting deflection of the bristle tufts 76. Although the hairs H may return to the surface, as the vacuum cleaning operation continues, the same hairs H may be picked up again by the brush roller 60 and pulled off the brush roller 60 by the suction force of the vacuum cleaner. It should also be noted that the brush roll 60 may rotate one or more turns before the hairs H are pulled from the brush roll 60 or released back to the surface to be cleaned by suction.

In one example, the hair wrap angle A2 of the brush roller 60 may be about half of the bristle deflection angle A1. Maintaining the minor diameter D3 smaller than the major diameter D1 substantially pulls the bristle tips closer to the guard surface 74 so that the trim diameter D2 remains slightly larger than the major diameter D1 and hair entanglement can be prevented. If the hair wrap angle A2 is made too shallow, essentially by making the major diameter D1 of the guard surface 74 larger relative to the trim diameter D2, the guard surface 74 will prevent the bristle tufts 76 from engaging the surface to be cleaned.

Fig. 8 is a perspective view of a brush roll 90 according to a second aspect of the present disclosure. The brushroll 90 may be used with the vacuum cleaner 10 of figure 3, described above, or with other vacuum cleaners and accessory tools, and is designed to accommodate an auxiliary device for cutting entangled hair. In one aspect, the accessory device comprises scissors or another handheld cutting implement. The brush roller 90 includes a brush pin 92 configured to be mounted for rotation about a central axis of rotation X extending longitudinally through the pin 92. The brush pin 92 is mounted on an elongate shaft 94 which extends through the centre of the pin 92 and defines a central axis of rotation X about which the brush roll 90 rotates. The illustrated brush roller 90 is configured to be rotationally driven in the direction indicated by the arrow R. Bearings 96 are mounted on each end of the shaft 94. In operation, pin 92 rotates on bearing 96 about axis 94. A belt engaging surface 98 extends about the periphery of the pin 92 near one end and may be in communication with a belt, such as the belt 48 (fig. 3). The belt engaging surface 98 may comprise a pulley.

The brush pin 92 further includes a cylindrical core 100 and one or more bristle supports 102 protruding from the core 100. Bristles 104 project from the bristle support 102 and may be arranged in a series of discrete tufts or a continuous strip. The bristles 104 may be arranged on the pin 92 in various patterns, including straight, angled, spiral, or combinations thereof.

The brushroll 90 is designed to accommodate the auxiliary means for cutting the entangled hair by providing at least one upstanding rib 106 adjacent the bristles 104 which defines a channel 108 into which scissors or another cutting implement can be inserted to cut the hair entangled about the pin 92.

In the aspect shown, two rows of bristle supports 102 and two corresponding rows of bristle tufts 110 are provided on the pin 92, each tuft 110 containing a plurality of bristles 104. The rows extend in a generally helical pattern around the circumference of the pin 92. In addition, two sets of opposing standing ribs 106 project radially from the pin 92, although only one set is visible in FIG. 8. The ribs 106 may extend axially in one or more rows along the core 100 of the pin 92 to define channels 108. Alternatively, the channel 108 may be formed between one of the upstanding ribs 106 and the bristle support 102.

A circumferential gap 112 may extend around the pin 92 to separate adjacent bristle supports 102 and ribs 106 and also allow the rotating brushroll 90 to clean the ribs on the lower housing 34, thereby preventing carpet from being drawn into the nozzle opening 42 (fig. 4).

Fig. 9 is a cross section of the brush roller 90 taken along line IX-IX of fig. 8. The brush pin 92 may define a hollow interior 114 extending along the length of the pin 92. The shaft 94 is received within the hollow interior 114. Brush apertures 116 for the bristle tufts 110 can be formed in the bristle support 102.

In one non-limiting example, to produce the brushroll 90 shown in fig. 9, a two-part mold may be used to form the outer profile of the pins 92, including the bristle supports 102 and ribs 106, while a twist-off core may be used to cored out the interior of the pins 152. The ribs 106 are oriented in the tensile line. Brush holes 116 may be formed in pin 92 after molding by drilling holes in pin 92, or may be molded integrally with pin 92. The bristle tufts 110 can be assembled with the pins 92 by pressing the bristles 104 into the brush holes 116 and securing the bristles 104 using fasteners (not shown), such as, but not limited to, staples, wedges, or anchors. The peg 92 may comprise a polymeric material such as polypropylene, ABS, or styrene. The bristles 104 may comprise a polymeric material, such as nylon or polyester, for example, which allows the bristles 104 to flex and deflect when in contact with a surface to be cleaned during normal operation. Other manufacturing methods may be used to produce the brush roll 90 shown in fig. 9.

During operation, brush roll 90 rotates in direction R, and debris, including but not limited to dirt, dust, and hair on the surface to be cleaned, is swept by brush roll 90. In some cases, hair may wrap around the pin 92 rather than being pulled away from the brush roll 90 by the suction of the vacuum cleaner. In this case, scissors or another cutting implement may be inserted into the channel 108 defined by the ribs 106 to cut the hair wrapped around the pin 92.

In another aspect, the height of the stand ribs 106 may be increased such that the outer perimeter defined by the tops of the stand ribs 106 forms a shroud surface to minimize the hair wrap angle a2, as described with respect to the first aspect.

It should be appreciated that the brush roll 60 of fig. 4-7 may also be designed to receive an auxiliary device, such as scissors or another handheld cutting implement, for cutting entangled hair in a manner similar to the brush roll 90 of fig. 8-9. In one aspect, ribs 106 and/or channels 108 may be provided in the pin 62.

Fig. 10-11 illustrate a brush roll 120 according to a third aspect of the present disclosure. The brushroll 120 may be used with the vacuum cleaner 10 of fig. 3, described above, or with other vacuum cleaners and accessory tools, and differs from the first aspect of the brushroll 60 by having a dimpled rather than flat tufted surface, as described in further detail below.

The brushroll 120 includes a brushpin 122 configured to be mounted for rotation about a central rotational axis X extending longitudinally through the pin 122. The brush pin 122 is mounted on an elongate shaft 124 extending through the centre of the pin 122 and defining a central axis of rotation X about which the brush roll 120 rotates. The illustrated brush roller 120 is configured to be rotationally driven in the direction indicated by the arrow R. Bearings 126 are mounted on each end of the shaft 124. In operation, the pin 122 rotates on the bearing 126 about the shaft 124. The belt engaging surface 128 extends about the circumference of the pin 122 near one end and may be in communication with a belt, such as the belt 48 (fig. 3). The belt engaging surface 128 may comprise a pulley.

The brush pin 122 also includes one or more bristle supports 130 that project into the pin 122. Bristles 132 project from the bristle support 130 and may be provided as a series of discrete tufts or a continuous strip. The bristles 132 may be arranged on the pin 122 in various patterns, including straight, angled, spiral, or combinations thereof.

The brushroll 120 is designed to prevent or greatly reduce the amount of hair entanglement during operation by providing a guard surface 134 for the entanglement of hair. The shield surface 134 is disposed adjacent the bristles 132 to establish a shallower hair wrap angle, the benefits of which are discussed above with respect to the first aspect of the brushroll 60.

In the illustrated aspect, two bristle supports 130 and two corresponding rows of bristle tufts 136 are provided on the pin 122, each tuft 136 containing a plurality of bristles 132 and extending in a generally helical pattern around the circumference of the pin 122. The entire outer surface of the brush pin 122 includes opposing convex curved surfaces 138 (which together define the shield surface 134) and opposing concave curved surfaces 140 (which define the mounting surface of the bristle support 130 from which the tufts 136 project).

Fig. 11 is a cross section of the brush roller 120 taken along line XI-XI of fig. 10. The brush pin 122 may define a hollow interior 142 extending along the length of the pin 122. The shaft 124 is received within the hollow interior 142. The bristle support 130 also includes a bristle support platform 144 that projects from the concave curved surface 140 into the hollow interior 142 of the pin 122. Bristle apertures 146 for bristle tufts 136 may be formed in the concave curved surface 140 and may extend at least partially into the platform 144.

In one non-limiting example, to produce the brushroll 120 shown in fig. 10-11, a two-part mold may be used to form the outer profile of the pins 122, while a unscrewing core may be used to cored out the interior of the pins 122, including the lands 144. It should be noted that to form the brushroll 120 in a two-part mold, the bristle support 130 and the guard surface 134 may extend 180 degrees or less along the length of the pin 122 so as to be in a stretched line. Brush holes 146 may be formed in pin 122 after molding by drilling holes in pin 122, or may be molded integrally with pin 122. The bristle tufts 136 may be assembled with the pins 122 by pressing the bristles 132 into the brush holes 146 and securing the bristles 132 using fasteners (not shown), such as, but not limited to, staples, wedges, or anchors. The pin 122 may comprise a polymeric material such as polypropylene, Acrylonitrile Butadiene Styrene (ABS), or styrene. The bristles 132 may comprise a polymeric material, such as nylon or polyester, for example, which allows the bristles 132 to flex and deflect when in contact with a surface to be cleaned during normal operation. Other manufacturing methods may be used to produce the brush roll 120 shown in fig. 10-11.

The concave curved surface 140 intersects the convex shroud surface 138 at an outer corner 148 where the two converging

surfaces

138, 140 meet. Further, the brush pin 122 shown in FIG. 11 is symmetrical about a plurality of axes, including a first axis of symmetry extending generally along a location defining the minor diameter D3, and a second axis of symmetry orthogonal to the first axis of symmetry and substantially at the location where the trim diameter D2 is shown in FIG. 11.

As described above, the brushroll 120 is designed to prevent or greatly reduce the amount of entangled hair during operation by providing a shield surface 134 for the entangled hair. For example, the concave curved surface 140 is recessed below the major diameter D1, and thus below the guard surface 134, which allows the bristles 132 on the concave curved surface 140 to deflect when contacting a surface to be cleaned, while retaining any hair at or near the tips of the bristles 132.

In the aspect shown, the brushroll 120 also includes a bristle support 130 defined by a concavely curved surface 140 rather than the flat surface 78 of the first aspect (fig. 5) with respect to the brushroll 60. Having a concavely curved surface 140 defining the tufted surface of the brush roll 120, i.e., the surface on which the bristle tufts 136 are mounted or secured, may provide improved hair entanglement reduction. The concave curved surface 140 intersects the convex shroud surface 138 at an outer corner 148 (shown herein as a convex edge 148), which may prevent hair from wedging into the base of the bristle tufts 136. In the case of a flat mounting surface, the hair may be pulled across the mounting surface and pulled toward or to the base of the bristle tuft. However, in the case of the concavely curved surface 140, the defining groove-shaped tufting surface prevents hairs from wedging into the base of the tuft 136, as hairs bridging the raised edge 148 create a gap separating the hairs from the base of the tuft 136. For purposes of description, the term "concavely curved surface" refers to a surface that curves inwardly toward the central axis of rotation X, forming a clustered surface that is recessed from the outer corner 148. Although the concave curved surface 140 is shown in the figures as a symmetrical inward curved shape, non-uniform and asymmetrical inward curved depressions are also contemplated. Furthermore, non-arcuate depressions, such as planar or V-shaped tuft surfaces, for example, which are inwardly depressed towards the central axis of rotation X, are also conceivable.

The illustrated aspect of the brushroll 120 also has bristle tufts 136 that are positioned equidistant from the raised edges 148 and protrude radially from the pins 122 at the midpoint of the concave curved surface 140.

It should be appreciated that the brush roll 120 of fig. 10-11 may also be designed to receive an auxiliary device, such as scissors or another handheld cutting implement, for cutting entangled hair in a manner similar to the brush roll 90 of fig. 8-9. In one aspect, the ribs 106 and/or channels 108 may be disposed in the pin 122.

Fig. 12-13 illustrate a brushroll 150 according to a fourth aspect of the present disclosure. The brushroll 150 may be used with the vacuum cleaner 10 of fig. 3, described above, or with other vacuum cleaners and accessory tools, and differs from the third aspect of the brushroll 120 by having offset tufts of sweeping bristles clustered at acute angles, as described in further detail below.

Brushroll 150 includes a brushroll pin 152 configured to be mounted for rotation about a central axis of rotation X extending longitudinally through pin 152. The brush pin 152 is mounted on an elongate shaft 154 extending through the centre of the pin 152 and defining a central axis of rotation X about which the brush roll 150 rotates. The illustrated brush roller 150 is configured to be rotationally driven in the direction indicated by the arrow R. A bearing 156 is mounted on each end of the shaft 154. In operation, pin 152 rotates on bearing 156 about shaft 154. A strap engaging surface (not shown) may extend around the periphery of pin 152 and may be in communication with a strap, such as strap 48 (fig. 3).

The brush pin 152 also includes one or more bristle supports 160 that project into the pin 152. Bristles 162 project from the bristle support 160 and may be provided as a series of discrete tufts or a continuous strip. The bristles 162 may be arranged on the pin 152 in various patterns, including straight, angled, spiral, or combinations thereof.

The brushroll 150 is designed to prevent or greatly reduce the amount of hair entanglement during operation by providing a guard surface 164 for the entanglement of hair. The guard surface 164 is disposed adjacent the bristles 162 to establish a shallower hair wrap angle, the benefits of which are discussed above with respect to the first aspect of the brushroll 60.

In the illustrated aspect, two bristle supports 160 and two corresponding rows of bristle tufts 166 are provided on the dowel 152, each tuft 166 containing a plurality of bristles 162 and extending in a generally helical pattern around the circumference of the dowel 152. The entire outer surface of the brush pin 152 includes an opposing convex curved surface 168 (which together define the shield surface 164) and an opposing concave curved surface 170 (which defines the mounting surface of the bristle support 160 from which the tuft 166 protrudes).

Fig. 13 is a cross section of the brush roller 150 taken along line XIII-XIII of fig. 12. The brush pin 152 may define a hollow interior 172 extending along the length of the pin 152. The shaft 154 is received within the hollow interior 172. Bristle holes 176 for bristle tufts 166 can be formed in concave curved surface 170.

In one non-limiting example, to produce the brushroll 150 shown in fig. 12-13, a two-part mold may be used to form the outer profile of the pins 152, while a unscrewing core may be used to core the interior of the pins 152. It should be noted that to form the brushroll 150 in a two-part mold, the bristle supports 160 and the guard surfaces 164 may extend 180 degrees or less along the length of the pins 152 so as to be in a stretched line. Brush holes 176 may be formed in pin 152 after molding by drilling holes in pin 152, or may be molded integrally with pin 152. The bristle tufts 166 may be assembled with the pins 152 by pressing the bristles 162 into the brush holes 176 and securing the bristles 162 using fasteners (not shown), such as, but not limited to, staples, wedges, or anchors. The pin 152 may comprise a polymeric material such as polypropylene, Acrylonitrile Butadiene Styrene (ABS), or styrene. The bristles 162 may comprise a polymeric material, such as nylon or polyester, for example, which allows the bristles 162 to flex and deflect when in contact with a surface to be cleaned during normal operation. Other manufacturing methods may be used to produce the brushroll 150 shown in fig. 12-13.

As described above, the brushroll 150 is designed to prevent or greatly reduce the amount of entangled hair during operation by providing a shield surface 164 for entangled hair. For example, the concave curved surface 170 is recessed below the major diameter D1, and thus below the guard surface 164, which allows the bristles 162 on the concave curved surface 170 to deflect when contacting a surface to be cleaned, while retaining any hair at or near the tips of the bristles 162.

In the aspect shown, the brushroll 150 also includes a bristle support 160 defined by a concave curved surface 170 that intersects the convex shroud surface 168 at an outer corner 178 where the two converging

surfaces

168, 170 meet. The outer corners 178 are shown herein as raised edges 178, the benefits of which are discussed above with respect to the third aspect of the brushroll 120. In the aspect shown, still further, the brushroll 150 includes bristle tufts 166 that are tufted at an acute angle relative to the concave tufting surface 170, i.e., the tufting surface to which the bristle tufts 166 are mounted or secured, rather than radially 78 with respect to the third aspect (fig. 11) of the brushroll 120. In particular, tuft 166 defines and lies on a centerline axis 180 extending orthogonally through the center of tuft 166, and concave tuft surface 170 defines a centerline axis 182 extending orthogonally through the center of concave tuft surface 170, and axes 180, 182 intersect at an acute angle 184 exterior to pin 152. This provides each tuft 166 with an angled back sweep (swept) or angled tip or terminal 186 in the direction of rotation R.

Additionally, bristle tufts 166 are offset on concave tufting surface 170, i.e., closer to one edge 178 than the other bristle tufts, or not equidistant, or offset from centerline axis 182, rather than being centered on the concave tufting surface (as with the third aspect of brush roll 120 (fig. 11)) or equidistant from convex edge 148. The offset angled tufts 166 reduce the drive torque required to rotate the brushroll 150, which may be useful for certain vacuum aspects, including autonomous or robotic vacuum cleaners. While the bristle tufts 166 in fig. 12-13 are shown both offset from the centerline axis 182 and angled with respect to the concave tuft surface, other configurations are also contemplated. For example, bristle tufts 166 may be offset, but not angled, i.e., oriented parallel to centerline axis 182. Alternatively, bristle tufts 166 can be tufted at centerline axis 182, i.e., not offset, but angled relative to the centerline axis, rather than radial relative to the centerline axis as shown in fig. 10-11.

It should be appreciated that the brushroll 150 of fig. 12-13 may also be designed to receive an auxiliary device, such as scissors or another handheld cutting implement, for cutting entangled hair in a manner similar to the brushroll 90 of fig. 8-9. In one aspect, the ribs 106 and/or channels 108 may be disposed in the pin 152.

Although the

brushrolls

60, 90, 120, 150 are described herein as being rotatably driven by a motor, it should be appreciated that the

brushrolls

60, 90, 120, 150 may be driven by other means, such as, but not limited to, a turbo fan or a mechanical gear train.

The vacuum cleaner 10 and

various brushrolls

60, 90, 120, 150 disclosed herein provide an improved brushroll design that addresses the problem of hair tangling. Aspects of the present disclosure include brush roll designs in which the hair wrap angle A2 is less than or equal to the deflection angle A1 (in other words, where A2 ≦ A1). Such a brush roll releases hairs that are not pulled away from the brush roll by the suction of the vacuum cleaner back onto the surface to be cleaned, rather than tightly wrapping the hairs around the brush roll. These brushrolls provide the opportunity to prevent or greatly reduce the amount of hair entanglement during operation. Other aspects of the present disclosure include a brushroll design, wherein hair can be easily cut from the brushroll.

While aspects of the present disclosure have been described in detail in connection with certain specific aspects thereof, it should be understood that this is by way of illustration and not of limitation. Reasonable variations and modifications are possible within the scope of the foregoing disclosure and drawings without departing from the spirit of the disclosure as defined in the following claims. Hence, specific dimensions and other physical characteristics relating to the aspects disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Claims

1. A vacuum cleaner (10) comprising:

a base (14) including an agitator chamber (38) and a suction nozzle opening (42) in fluid communication with the agitator chamber (38);

an upstanding body (12) pivotally mounted to the base (14) and including a main support portion (16) supporting a cyclonic collection system (18) including a cyclonic separator (20);

a suction source (36) in fluid communication with the cyclonic collection system (18); and

a brush roll (60, 90, 120, 150) positioned within the agitator chamber (38) for rotational movement about a central rotational axis (X), the brush roll (60, 90, 120, 150) comprising:

a brush pin (62, 92, 122, 152) configured to be mounted for rotation about the central axis of rotation (X) extending longitudinally through the brush pin (62, 92, 122, 152), and comprising:

opposed bristle supports (70, 102, 130, 160) defining a mounting surface (78); and

a shield surface (74, 134, 138, 164, 168) comprising opposing convexly curved surfaces (86, 138, 168) extending between the opposing bristle supports (70, 102, 130, 160); and

a plurality of bristle tufts (76, 110, 136, 166) secured to each of the opposing bristle supports (70, 102, 130, 160) and projecting from one of the mounting surfaces (78);

wherein the mounting surface (78) intersects the convexly curved surface (86, 138, 168) at an outer corner (88, 148, 178).

2. The vacuum cleaner (10) of claim 1, wherein the opposing bristle supports (70, 102, 130, 160) extend helically about the brush pin (62, 92, 122, 152) relative to the central axis of rotation (X), and a plurality of bristle tufts (76, 110, 136, 166) are secured to each bristle support (70, 102, 130, 160) and arranged in helically extending rows on the mounting surface (78).

3. The vacuum cleaner (10) of claim 1, wherein an outer surface of the brush pin (62, 92, 122, 152) is comprised of the opposing bristle supports (70, 102, 130, 160) and the opposing convexly curved surfaces (86, 138, 168).

4. The vacuum cleaner (10) of claim 1, wherein the brush pin (62, 92, 122, 152) includes a first axis of symmetry and a second axis of symmetry orthogonal to the first axis of symmetry.

5. The vacuum cleaner (10) of claim 1, wherein the mounting surface (78) is recessed inwardly toward the central axis of rotation (X) below the shroud surface (74, 134, 138, 164, 168).

6. The vacuum cleaner (10) of claim 5, wherein the mounting surface (78) includes a concavely curved surface (140, 170) extending between the outer corners (148, 178), and the bristle tufts (136, 166) protrude from the concavely curved surface (140, 170) between the outer corners (148, 178).

7. The vacuum cleaner (10) of claim 6, wherein the bristle tufts (166) are offset on the concave curved surface (170) such that each bristle tuft (166) is not equidistant from the outer corner (178).

8. The vacuum cleaner (10) of claim 6, wherein each of the plurality of bristle tufts (166) is located on a centerline axis (180) that extends orthogonally through a center of the bristle tuft (166), and each of the concave curved surfaces (170) defines a centerline axis (182) that extends orthogonally through a center of the concave curved surface (170), and the centerline axis (180) of one bristle tuft (166) and the centerline axis (182) of the associated concave curved surface (170) intersect at an acute angle (184) outside of the brush pin (152).

9. The vacuum cleaner (10) of claim 8, wherein the bristle tufts (166) are offset on the concave curved surface (170) such that each bristle tuft (166) is not equidistant from the outer corner (178).

10. The vacuum cleaner (10) of claim 1, wherein the vacuum cleaner (10) is one of an upright vacuum cleaner, a cylinder vacuum cleaner, a stick vacuum cleaner, an autonomous vacuum cleaner, and a handheld vacuum cleaner.

11. A brushroll (60, 90, 120, 150) for a vacuum cleaner (10), comprising:

a brush pin (62, 92, 122, 152) configured to be mounted for rotation about a central axis of rotation (X) extending longitudinally through the brush pin (62, 92, 122, 152), and comprising:

12. The brush roll (60, 90, 120, 150) of claim 11, wherein the opposing bristle supports (70, 102, 130, 160) extend helically about the brush pin (62, 92, 122, 152) relative to the central axis of rotation (X), and a plurality of bristle tufts (76, 110, 136, 166) are secured to each bristle support (70, 102, 130, 160) and arranged in helically extending rows on the mounting surface (78).

13. The brush roll (60, 90, 120, 150) of claim 11, wherein the plurality of bristle tufts (76, 110, 136, 166) are arranged in one of a straight, angled, and spiral pattern on the brush pin (62, 92, 122, 152).

14. The brush roll (60, 90, 120, 150) of claim 11, wherein an outer surface of the brush pin (62, 92, 122, 152) is comprised of the opposing bristle supports (70, 102, 130, 160) and the opposing convexly curved surfaces (86, 138, 168).

15. The brush roll (60, 90, 120, 150) of claim 11, wherein the brush pin (62, 92, 122, 152) includes a first axis of symmetry and a second axis of symmetry orthogonal to the first axis of symmetry.

16. The brush roll (60, 90, 120, 150) of claim 11, wherein the mounting surface (78) is recessed inwardly toward the central axis of rotation (X) below the guard surface (74, 134, 138, 164, 168).

17. The brush roll (120, 150) of claim 16, wherein the mounting surface (78) includes a concave curved surface (140, 170) extending between the outer corners (148, 178), and the bristle tufts (136, 166) protrude from the concave curved surface (140, 170) between the outer corners (148, 178).

18. The brushroll (150) of claim 17, wherein the bristle tufts (166) are offset on the concave curved surface (170) such that each bristle tuft (166) is not equidistant from the outer corners (178).

19. The brush roll (150) of claim 17, wherein each of the plurality of bristle tufts (166) is located on a centerline axis (180) that extends orthogonally through a center of the bristle tuft (166), and each of the concave curved surfaces (170) defines a centerline axis (182) that extends orthogonally through a center of the concave curved surface (170), and the centerline axis (180) of one bristle tuft (166) and the centerline axis (182) of the associated concave curved surface (170) intersect at an acute angle (184) outside of the brush pin (152).

20. The brushroll (150) of claim 19, wherein the bristle tufts (166) are offset on the concave curved surface (170) such that each bristle tuft (166) is not equidistant from the outer corners (178).