EP4531644A1

EP4531644A1 - Cleaner head for a vacuum cleaner

Info

Publication number: EP4531644A1
Application number: EP23730578.4A
Authority: EP
Inventors: Joel KNOX; Alexander HORNE; Maxine ARPINO-JAMES
Original assignee: Dyson Technology Ltd
Current assignee: Dyson Technology Ltd
Priority date: 2022-05-30
Filing date: 2023-05-15
Publication date: 2025-04-09
Also published as: GB202207980D0; WO2023233228A1; KR20250011149A; CN119255738A; GB2619299A

Abstract

A cleaner head (20) for a vacuum cleaner comprises a housing, at least two rotatable brush bars (22, 24), and a hair diverter (50, 52). The housing defines a suction chamber comprising an outlet (34). The brush bars have an outer surface and are at least partly arranged inside the housing. The brush bars comprise a proximal end and a distal end. The proximal ends of the two brush bars face each other such that an outlet-facing clearance is formed therebetween. The hair diverter is situated in between the clearance and the outlet and is in direct contact with the outer surface of both brush bars. A width of the hair diverter spans more than a full width of the clearance. (Figure 4)

Description

CLEANER HEAD FOR A VACUUM CLEANER

TECHNICAL FIELD

The present invention relates a cleaner head for a vacuum cleaner as well as to a vacuum cleaner comprising such a cleaner head.

BACKGROUND

A cleaner head of a vacuum cleaner usually comprises 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 brush bars 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, cleaner heads experience some degree of hair ingress during use, which means that hair can ingress into or between parts of the cleaner head. This is, for example, commonly seen inside rotating brush bars. For the brush bar to spin freely with minimal part wear there is often a small gap between the two surfaces moving relatively to each other. This in-turn can lead to hair working its way into the brush bar assembly. If the build-up is unchecked the hair can cause mechanical failures such as reduced bearing life or increased motor load. The hair build up can also cause burning or unpleasant smells is enough friction if created. SUMMARY

The present invention provides a cleaner head for a vacuum cleaner. The cleaner head comprises a housing, at least two rotatable brush bars, and a hair diverter. The housing defines a suction chamber comprising an outlet. The brush bars have an outer surface and are at least partly arranged inside the housing. The brush bars comprise a proximal end and a distal end. The proximal ends of the two brush bars face each other such that an outlet-facing clearance is formed therebetween. The hair diverter is situated in between the clearance and the outlet and is in direct contact with the outer surface of both brush bars. A width of the hair diverter spans more than a full width of the clearance.

The hair diverter, due to its positioning in between the clearance and the outlet, helps to prevent hairs entering the gap or clearance between the two brush bars and finding a way into the interior of the rotating brush bars or the brush bar drive units. When, in use, the cleaner head encounters a hair that bridges both brush bars, the hair diverter picks it up from the outer surface of the two brush bars and ensures that it does not migrate into the small gap between them. Instead, the hair migrates under the hair diverter. From there, the hair may either migrate away from the clearance onto the outer surface of only one of the two brush bars or be left behind on the floor for later pick-up in another pass of the cleaner head. In both cases, the hair does not get tangled up inside the rotating brush bars.

In preferred embodiments, the hair diverter may comprise a rounded nose, positioned to be in direct contact with the outer surface of both brush bars and shaped to peel a hair off the outer surfaces and guide the hair underneath the hair diverter. The rounded shape of the nose reduces the risk of the hair adhering to the hair diverter itself and ensures a smooth migration of the hair away from the clearance and under the hair diverter.

The outer surface of the rotatable brush bars may be at least partly deformable, for example because it comprises bristles and/or a fabric covering. The hair diverter may interact with this partly deformable surface by slightly pushing into it to effectively peel of any hairs lying on top of it. Preferably, the hair diverter widens in a direction away from the clearance and towards the outlet. The narrower portion of the hair diverter, which may be partly inside the clearance and is in direct contact with the brush bars’ outer surfaces, is wide enough to avoid hairs migrating into the brush bar interiors. As the hair is led away from the clearance towards the outlet, the widening shape of the hair diverter ensures that if the hair is picked up by one of the brush bars this will happen at a safe lateral distance from the clearance. As a result, that the hair will not be caught up in the clearance later.

The hair diverter may be wedge-shaped to allow an efficient airflow around the hair diverter while simultaneously providing sufficient structural support to ensure that the hair diverter is not easily damaged during use of the vacuum cleaner.

In preferred embodiments, the brush bars taper from a wider base at the proximal end to a narrower tip at the distal end. Such frustoconical brush bars have been found to be able to drive any hair, dust, or other dirt that may adhere to the outer surface of one of the brush bars outward to the distal ends of the cleaner head. When combined with the hair diverter, the frustoconical brush bars provide a very effective way to ensure that hairs do not end up inside the brush bars or brush bar drive unit. First, the hair diverter ensures that the hair does not get trapped inside the clearance between the two brush bars. Instead, the hair migrates under the hair diverter. From there, the hair may be picked up by one of the brush bars that, due to its conical shape moves the hair further away from the clearance to a distal end of the cleaner head.

In some embodiments of the cleaner head according to the invention, the housing comprises a soleplate and the hair diverter extends from the soleplate. An advantage of arranging the hair diverter at the soleplate may be that it is positioned close to the floor surface where the hair is initially picked up. This makes it possible for the hair diverter to engage a hair as soon as it is encountered by the brush bars and to guide it away from the clearance at an early stage. A portion or all of the hair diverter may be situated below the outlet in order to not disturb the airflow through the suction chamber into the outlet. In alternative embodiments, the cleaner head may comprise a drive housing for comprising a drive mechanism for rotating the brush bars and the hair diverter may extend from the drive housing. Other structural components of the cleaner head may be similarly suitable for serving as a basis for the hair diverter. The hair diverter may either be mounted to such other structural components or be an integral part of their design. If at least a portion of the hair diverter is situated at the height of the outlet, it preferably has an aerodynamic shape that is designed such that the hair diverter has little or no effect on the airflow through the suction chamber into the outlet. In some embodiments, at least a portion or all of the hair diverter may be situated above the height of the outlet to avoid affecting this airflow.

It is noted that a cleaner head may comprise more than one hair diverter. For example, one hair diverter may extend from the soleplate, and another one from the drive housing. It may also be possible to have more than one hair diverter extending from the same cleaner head component. When one cleaner head comprises two or more hair diverters, each hair diverter will contact the brush bars at a different height. Whenever a first hair diverter fails to pick up and guide away a hair that bridges both brush bars, a later one may then still be able to do this and avoid the hair migrating deeper into the clearance and the brush bar interiors.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure l is a perspective view of a handheld vacuum cleaner;

Figure 2 is a perspective view of the cleaner head of the vacuum cleaner shown in Figure 1;

Figure 3 is a partial perspective view of a cleaner head according to a first embodiment of the invention; Figure 4 is a bottom view of the cleaner head of Figure 3;

Figure 5 is a perspective cross-section of the cleaner head of Figure 3;

Figure 6 is a partial side view of a cleaner head according to a second embodiment of the invention; and

Figure 7 is a close-up of another partial side view of the cleaner head of Figure 6.

DETAILED DESCRIPTION

Figure 1 shows a hand-held vacuum cleaner 2 according to an embodiment of the disclosure and comprising a main body 4, a wand 6 and a cleaner head 20. The main body 4 comprises a separating system 10, in the form of a cyclonic separator, a motor and impeller (not visible) arranged to draw air through the separating system 10, and a power supply 12, in the form of a battery, for powering the motor. The main body 4 has a handle 14 which is gripped by a user, and a clean air outlet 16 through which air that has passed through the separating system 10 is discharged. The wand 6 is attached at one end to the main body 4 and at the other end to the cleaner head 20. The wand 6 provides fluid communication between the cleaner head 20 and the separating system 10 and supports the cleaner head 20 during use.

Figure 2 shows a cleaner head 20 according to embodiments of the disclosure. The cleaner head 20 has a housing 32, which at least partially defines a suction chamber comprising an outlet 34 for expulsion of air and debris towards the vacuum cleaner 2. The cleaner head 20 comprises a first agitator element 22 and a second agitator element 24. In this embodiment, the agitator elements 22, 24 are implemented as frustoconical brush bars 22, 24 with an at least partly deformable outer surface. The outer surface may, e.g., comprise a fabric covering such as a felt-like material. Optionally, the outer surface may comprise bristles. The bristles may be applied in the form of linear or helical strips. The first and second brush bars 22, 24 are each mounted for rotation about respective axes Rl, R2. Each brush bar 22, 24 comprises a distal, free end 26a, 26b and a proximal end 28a, 28b at which they are mounted to the cleaner head 20. In this embodiment, the brush bars 22, 24 have a frustoconical shape which tapers towards the distal end 26a, 26b in a direction along the axis of rotation Rl, R2. Both brush bars 22, 24 are cantilevered from opposing sides of a hub portion 30 of the cleaner head 20 at their respective second ends 28a, 28b. It should be appreciated that a portion of one or both brush bars 22, 24 may not be tapered. For example, the shape of one or both brush bars 22, 24 may consist of a cylindrical portion combined with a frustoconical portion. In other embodiments, the brush bars 22, 24 may be fully cylindrical.

In the illustrated embodiment, the hub portion 30 is at a laterally central position with respect to the overall cleaner head 20, although this may not always be the case. For example, if the first and second brush bars 22, 24 have different lengths, then the hub portion 30 could be offset laterally relative to the laterally central part of the cleaner head 20. The hub portion 30 serves to rotatably support the proximal ends 28a, 28b of the brush bars 22, 24 and may comprise a drive housing holding a drive mechanism for rotating the brush bars 22, 24. As a consequence of the conical geometry of the brush bars 22, 24 and partly to allow the brush bars 22, 24 to spin freely with minimal part wear, there may be a small gap or clearance 31 between the two proximal ends 28a, 28b moving relatively to each other. It has been observed that such a clearance 31 may lead to hair working its way into the brush bar assemblies. If the build-up is unchecked the hair can cause mechanical failures such as reduced bearing life or increased motor load. The hair build up can also cause burning or unpleasant smells is enough friction if created.

In Figures, 3 to 7, aspects of different embodiments of cleaner heads 20 with a hair diverter 50, 52 are illustrated. The hair diverters 50, 52 are used to avoid hair getting trapped and tangled up inside the clearance 31 between the two brush bars 22, 24. Figure 3, for example, shows a partial perspective view of a cleaner head 20 according to a first embodiment. Figures 4 and 5 respectively show a bottom view and a perspective crosssection of the cleaner head of Figure 3. The cleaner head 20 of Figures 3 to 5 comprises a housing, two rotatable brush bars 22, 24, and a hair diverter 50. The housing defines a suction chamber comprising an outlet 34. As can be seen in Figure 3, the outlet 34 is configured to be coupled to the wand 6 of the vacuum cleaner 2. The brush bars 22, 24 have an at least partly deformable outer surface 221 (see the cross section in Figure 5) and are at least partly arranged inside the housing. The brush bars 22, 24 comprise a proximal end 28a, 28b and a distal end 26a, 26b. The proximal ends 28a, 28b of the two brush bars 22, 24 face each other such that an outlet-facing clearance 31 is formed therebetween. Even though the clearance 31 may be narrow, hairs would be able to find their way inside had the hair diverter 50 not been there. As can be seen in Figures 3, 4, and 5, the hair diverter 50 is situated in between the clearance 31 and the outlet 34 and is in direct contact with the at least partly deformable outer surface 221 of both brush bars 22, 24. A width of the hair diverter 50 spans more than a full width of the clearance 31. As shown in the Figures, the hair diverter 50 may comprise a rounded nose 51, positioned to be in direct contact with the at least partly deformable outer surface 221 of both brush bars 22, 24 and shaped to peel a hair off the outer surfaces 221 and guide the hair underneath the hair diverter 50. Preferably, the edges of the nose 51 are rounded in all directions. The rounded shape of the nose 51 reduces the risk of the hair adhering to the hair diverter 50 itself and ensures a smooth migration of the hair away from the clearance 31 and under the hair diverter 50. It is noted that, although the hair diverter 50 may function optimally in combination with the at least partly deformable brush bar surfaces 221 of this embodiment, it may function in a similar way when in contact with a more rigid brush bar surface.

In this first embodiment, the hair diverter 50 extends from a soleplate 40 of the cleaner head housing. The underside of the soleplate 40 (see Figure 4) is mostly flat and slides or hovers over the floor surface during use. The top surface of the soleplate 40 (see Figure 3) is inclined relative to the underside and provides a ramp that guides the airflow in the direction of the outlet 34. In this embodiment, the hair diverter forms an integral part of the soleplate 40. In other embodiments it may be provided as a separate part that is later mounted to the soleplate 40. Because the hair diverter 50 is arranged at the soleplate 40, it is positioned close to the floor surface where the hair is initially picked up. This makes it possible for the hair diverter 50 to engage a hair as soon as it is encountered by the brush bars 22, 24 and to guide it away from the clearance 31 at an early stage. A portion or all of the hair diverter 50 may be situated below the outlet 34 in order to not disturb the airflow through the suction chamber into the outlet 34.

The hair diverter 50, due to its positioning in between the clearance 31 and the outlet 34, helps to prevent hairs entering the gap or clearance 31 between the two brush bars 22, 24. When, in use, the cleaner head 20 encounters a hair that bridges both brush bars 22, 24, the hair diverter 50 picks it up from the outer surface 221 of the two brush bars 22, 24 and ensures that it does not migrate into the small gap 31 between them. Instead, the hair migrates under the hair diverter 50. From there, the hair may either migrate outward, away from the clearance 31, onto the outer surface 221 of only one of the two brush bars 22, 24. If that doesn’t happen, the hair may just be left behind on the floor for later pick-up in another pass of the cleaner head 20. In both cases, the hair does not get tangled up inside the rotating brush bars 22, 24.

Preferably, the hair diverter widens in a direction away from the clearance 31 and towards the outlet. The narrower portion of the hair diverter, which may be partly inside the clearance 31 and is in direct contact with the brush bars, is wide enough to avoid hairs migrating into the brush bar interiors. As the hair is led away from the clearance 31 towards the outlet, the widening shape of the hair diverter ensures that if the hair is picked up by one of the brush bars this will happen at a safe lateral distance from the clearance 31. As a result, that the hair will not be caught up in the clearance 31 later.

As clearly shown in Figures 3 and 5, the hair diverter 50 of this embodiment is wedge- shaped with an aerodynamically shaped top surfaces to allow an efficient airflow around the hair diverter 50 while simultaneously providing sufficient structural support to ensure that the hair diverter 50 is not easily damaged during use of the vacuum cleaner 20. A properly designed wedge may bring the additional advantage that it may lead to higher flow velocities and improved pick up of dirt by the cleaner head 20.

Tests have shown that the combined use of the frustoconical brush bars 22, 24 and a hair diverter 50, provides a very effective way to ensure that hairs do not end up inside the brush bars 22, 24 or brush bar drive unit. First, the hair diverter 50 ensures that the hair does not get trapped inside the clearance 31 between the two brush bars 22, 24. Instead, the hair migrates under the hair diverter, from where it is picked up by one of the brush bars 22, 24 that, due to their conical shape move the hair further away from the clearance 31 to one of the distal ends of the cleaner head 20.

Figures 6 and 7 respectively show a partial side view and a close-up of another partial side view of a cleaner head 20 according to a second embodiment. In this embodiment, the hair diverter 52 extends from a drive housing 60. The drive housing 60 is part of the central hub portion 30 and provided for holding a drive mechanism (not shown) for rotating the brush bars 22, 24. When extending from the drive housing 60, the hair diverter 52 is located at a higher position than when extending from the soleplate 40, which means that hairs will be caught by the hair diverter slightly later, but at a point where the nose of the hair diverter 52 makes a larger angle with the outer surface 221 of the brush bar 22, 24 which may help to peel the hair off the outer surface 221. Additionally, by being located deeper inside the cleaner head 20, the drive housing based hair diverter 52 may be better protected against damage because it will not come into contact with the floor surface and any obstacles located thereon.

Other structural components than the sole plate 40 or the drive housing 60 may be equally suitable for serving as a basis for a hair diverter 50, 52. The hair diverter 50, 52 may either be mounted to such other structural components or be an integral part of their design. If at least a portion of the hair diverter 50, 52 is situated at the height of the outlet 34, it preferably has an aerodynamic shape that is designed such that the hair diverter 50, 52 has little or no effect on the airflow through the suction chamber into the outlet 34. In some embodiments, at least a portion or all of the hair diverter 50, 52 may be situated above the height of the outlet 34 to avoid affecting this airflow.

It is noted that a cleaner head may comprise more than one hair diverter. For example, one hair diverter may extend from the soleplate, and another one from the drive housing.

It may also be possible to have more than one hair diverter extending from the same cleaner head component. When one cleaner head comprises two or more hair diverters, each hair diverter will contact the brush bars at a different height. Whenever a first hair diverter fails to pick up and guide away a hair that bridges both brush bars, a later one may then still be able to do this and avoid the hair migrating deeper into the clearance 31 and the brush bar interiors.

Claims

1. A cleaner head for a vacuum cleaner, the cleaner head comprising: a housing defining a suction chamber comprising an outlet, at least two rotatable brush bars with an outer surface, the brush bars being at least partly arranged inside the housing and comprising a proximal end and a distal end, the proximal ends of the two brush bars facing each other such that an outlet-facing clearance is formed therebetween, and a hair diverter, situated in between the clearance and the outlet and in direct contact with the outer surface of both brush bars, a width of the hair diverter spanning more than a full width of the clearance.

2. A cleaner head according to claim 1, wherein the hair diverter comprises a rounded nose, positioned to be in direct contact with the outer surface of both brush bars and shaped to peel hair off the outer surfaces and guide the hair underneath the hair diverter.

3. A cleaner head according to claim 1 or 2, wherein the hair diverter widens in a direction away from the clearance and towards the outlet.

4. A cleaner head according to any preceding claim, wherein the hair diverter is wedge-shaped.

5. A cleaner head according to any preceding claim, wherein the brush bars taper from a wider base at the proximal end to a narrower tip at the distal end.

6. A cleaner head according to any preceding claim, wherein the housing comprises a soleplate and the hair diverter extends from the soleplate.

7. A cleaner head according to claim 6, wherein, in use, at least a portion of the hair diverter is situated below the outlet.

8. A cleaner head according to claim 7, wherein, in use, the complete hair diverter is situated below the outlet.

9. A cleaner head according to any of claims 1 to 5, further comprising a drive housing for comprising a drive mechanism for rotating the brush bars, wherein the hair diverter extends from the drive housing.

10. A cleaner head according to claim 9, wherein, in use, at least a portion of the hair diverter is situated at the height of the outlet.

11. A cleaner head according to claim 9 or 10, wherein, in use, at least a portion of the hair diverter is situated above the height of the outlet.

12. A cleaner head according to any preceding claim, wherein the outer surface of the rotatable brush bars is at least partly deformable.

13. A cleaner head according to claim 12, wherein the at least partly deformable outer surface of the rotatably brush bars comprises a fabric covering.

14. A cleaner head according to claim 12 or 13, wherein the at least partly deformable outer surface of the rotatably brush bars comprises bristles.

15. A vacuum cleaner comprising a cleaner head as claimed in any preceding claim.