Note: Descriptions are shown in the official language in which they were submitted.
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CLEANING APPARATUS WITH RECIPROCATING OR ROTATING
BRUSH HEAD
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to hand held cleaning apparatus having a
reciprocating or rotating brush head.
2. The Relevant Technology
Household cleaning is a never ending business. Although there are numerous
types of sponges and brushes that are specially designed to clean large, open
surface
areas such as countertops, sinks, and bathtubs, there are fewer resources
available for
cleaning the difficult cracks, corners, and other hard to reach areas that are
ubiquitous in
a home. Although conventional sponges and brushes can certainly be used for
cleaning
corners and other hard to reach areas, the configuration and large size of
such
conventional cleaners makes them difficult to access such areas. The user is
often
required to apply extensive force by the ends or tips of the fingers so as to
force the
cleaner into the crack or comer to be cleaned. Such cleaning is tiring and
often results in
cramping of the hand and/or fingers.
This problem is compounded by the fact that corners and cracks are typically
where dirt, mold, soap scum, and other undesirables tend to grow or build-up.
As such,
extra energy or force is often necessary to clean such locations.
Conventional toothbrushes are often used to clean such hard to reach areas.
The problem with toothbrushes, however, is that because they are specifically
designed
for cleaning teeth around sensitive gums, toothbrushes are typically too soft
and do not
have a good angle for any extended, aggressive scrubbing of hard surfaces.
Furthermore,
because of the small handles on toothbrushes, any significant scrubbing using
a
toothbrush again produces fatigue and cramping of the hand.
Accordingly, what is needed are improved cleaning apparatus which can be
used for cleaning small, hard to reach areas, which can be used for durable,
extended
scrubbing, and which can be used with minimal fatigue.
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BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
Provided herein is cleaning apparatus comprising:
(i) a body assembly comprising:
an elongated body housing having a chamber;
a motor at least partially disposed within the chamber of the body
housing; and
a body drive shaft at least partially disposed within the chamber of
the body housing, the body drive shaft being coupled with the motor such
that during selective operation of the motor, the body drive shaft is rotated
continuously about a rotational axis thereof; and
(ii) a head assembly comprising:
an elongated head housing;
a head drive shaft disposed within the head housing and having a
rotational axis about which the head drive shaft rotates;
a brush head comprising a carrier plate having a plurality of bristles
secured thereon and having a rotational axis about which the brush head
rotates, the brush head being mounted on the head housing and being coupled
with the head drive shaft such that continuous rotation of the head drive
shaft
facilitates reciprocating rotation of the brush head, the rotational axis of
the
brush head intersecting the rotational axis of the head drive shaft so as to
form an inside angle therebetween in a range between about 110 to about
1400, the inside angle remaining constant during reciprocating rotation of the
brush head, the head assembly being adapted to be selectively coupled with
the body assembly so that the body drive shaft is coupled with the head drive
shaft.
Also provided herein is a cleaning system kit comprising:
(i) a body assembly comprising:
an elongated body housing having a chamber;
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a motor at least partially disposed within the chamber of the body
housing; and
a body drive shaft at least partially disposed within the chamber of
the body housing, the body drive shaft being coupled with the motor such
that during selective operation of the motor, the body drive shaft is rotated
continuously about a rotational axis thereof;
(ii) a first head assembly comprising:
a first head housing;
a first head drive shaft disposed within the first head housing and
having a rotational axis about which the first head drive shaft rotates;
a first brush head comprising a carrier plate having a plurality of
bristles secured thereon and having a rotational axis about which the first
brush head rotates, the first brush head being mounted on the first head
housing and being coupled with the first head drive shaft such that
continuous rotation of the first head drive shaft facilitates reciprocating
rotation of the first brush head, the rotational axis of the first brush head
intersecting the rotational axis of the first head drive shaft so as to form
an
inside angle therebetween in a range between about 110 to about 140 , the
inside angle remaining constant during reciprocating rotation of the first
brush head, the first head assembly being adapted to be selectively coupled
with the body assembly so that the body drive shaft is coupled with the first
head drive shaft; and
(iii) a second head assembly comprising:
a second head housing;
a second head drive shaft disposed within the second head housing
and having a rotational axis about which the second head drive shaft rotates;
a second brush head comprising a carrier plate having a plurality of
bristles secured thereon, the second brush head having a rotational axis about
which the second brush head rotates and having a configuration that is
different than the first brush head, the second brush head being mounted on
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the second head housing and being coupled with the second head drive shaft
such that continuous rotation of the second head drive shaft facilitates
rotation of the second brush head, the rotational axis of the second brush
head intersecting the rotational axis of the second head drive shaft so as to
form an inside angle therebetween in a range between about 110 to about
140 , the inside angle remaining constant during reciprocating rotation of the
second brush head, the second head assembly being adapted to be selectively
coupled with the body assembly so that the body drive shaft is coupled with
the second head drive shaft.
Further provided herein is a cleaning apparatus comprising:
(i) a body assembly comprising:
an elongated body housing having a chamber;
a motor at least partially disposed within the chamber of the body
housing;
a body drive shaft at least partially disposed within the chamber of
the body housing, the body drive shaft being coupled with the motor such that
during
selective operation of the motor, the body drive shaft is rotated about a
rotational axis
thereof; and
a gear assembly disposed between the motor and the body drive
shaft, the gear assembly increasing the torque produced on the drive shaft by
the
motor by a ratio in a range between about 1.5:1 to about 3.5:1; and
(ii) a head assembly comprising:
an elongated head housing;
a head drive shaft disposed within the head housing and having a
rotational axis about which the head drive shaft rotates; and
a carrier plate having a rotational axis about which the carrier plate
rotates, the carrier plate being coupled with the head drive shaft such that
rotation of
the head drive shaft facilitates rotation of the carrier plate, the rotational
axis of the
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carrier plate intersecting the rotational axis of the head drive shaft so as
to form an
inside angle greater than 95 , the inside angle remaining constant during
rotation of
the carrier plate, the head assembly being adapted to be selectively coupled
with the
body assembly so that the body drive shaft is coupled with the head drive
shaft; and
a cleaning element secured to the carrier plate.
Additionally provided herein is a cleaning system kit comprising:
(i) a body assembly comprising:
an elongated body housing having a chamber;
a motor at least partially disposed within the chamber of the body
housing;
a body drive shaft at least partially disposed within the chamber of
the body housing, the body drive shaft being coupled with the motor such
that during
selective operation of the motor, the body drive shaft is rotated about a
rotational axis
thereof; and
a gear assembly disposed between the motor and the body drive
shaft, the gear assembly increasing the torque produced on the drive shaft by
the motor by a
ratio in a range between about 1.5:1 to about 3.5:1;
(ii) a first head assembly comprising:
a first head housing;
a first head drive shaft disposed within the first head housing and
having a rotational axis about which the first head drive shaft rotates; and
a first carrier plate having a rotational axis about which the first
carrier plate rotates, the first carrier plate being mounted on the first head
housing and being
coupled with the first head drive shaft such that rotation of the first head
drive shaft facilitates
rotation of the first carrier plate, the rotational axis of the first carrier
plate intersecting the
rotational axis of the first head drive shaft so as to form an inside angle
greater than 95 , the
inside angle remaining constant during rotation of the first carrier plate,
the first head
assembly being adapted to be selectively coupled with the body assembly so
that the body
drive shaft is coupled with the first head drive shaft; and
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a first cleaning element secured to the first carrier plate; and
(iii) a second head assembly comprising:
a second head housing;
a second head drive shaft disposed within the second head housing
and having a rotational axis about which the second head drive shaft rotates;
and
a second carrier plate having a rotational axis about which the second
carrier plate rotates and having a configuration that is different than the
first carrier plate, the
second carrier plate being mounted on the second head housing and being
coupled with the
second head drive shaft such that rotation of the second head drive shaft
facilitates rotation of
the second carrier plate, the rotational axis of the second carrier plate
intersecting the
rotational axis of the second head drive shaft so as to form an inside angle
greater than 95 ,
the inside angle remaining constant during rotation of the second carrier
plate, the second
head assembly being adapted to be selectively coupled with the body assembly
so that the
body drive shaft is coupled with the second head drive shaft; and
a second cleaning element secured to the second carrier plate.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present invention will now be discussed with
reference
to the appended drawings. It is appreciated that these drawings depict only
typical
embodiments of the invention and are therefore not to be considered limiting
of its scope.
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Figure 1 is a an elevated side view of one embodiment of the inventive
cleaning apparatus;
Figure 2 is a top plan view of the cleaning apparatus shown in Figure 1;
Figure 3 is an elevated front end view of the cleaning apparatus shown in
Figure 1;
Figure 4 is an elevated front view of the front face of the brush head shown
in
Figure 3;
Figure 5 is an exploded view of the cleaning apparatus shown in Figure 1;
Figure 6 is a cross sectional side view of the cleaning apparatus shown in
Figure 1;
Figure 7 is a perspective view of a subassembly of the cleaning apparatus
shown in Figure 1 showing a drive shaft coupled with a hub and brush head;
Figure 8 is an enlarged perspective view of the drive shaft shown in Figure 7;
Figure 9A is an enlarged perspective view of the hub shown in Figure 7;
Figure 9B is an enlarged perspective view of an alternative embodiment of the
hub shown in Figure 9A;
Figure 10 is an enlarge perspective view of the coupled parts shown in
Figure 7;
Figure 11 is a perspective view of an alternative embodiment of a cleaning
apparatus;
Figures 12A and 12B are exploded views of the cleaning apparatus shown in
Figure 11;
Figure 13 is a cross sectional side view of the cleaning apparatus shown in
Figure 11;
Figure 14A is an enlarged cross sectional side view of the button switch
assembly shown in Figure 13 in an off position;
Figure 14B is an enlarged cross sectional side view of the button switch
assembly shown in Figure 14A in a momentary position;
Figure 14C is an enlarged cross sectional side view of the button switch
assembly shown in Figure 14A in a on position;
Figure 15 is an enlarged perspective view of the hub shown in Figure 12A;
Figure 16 is an elevated side view of an alternative embodiment of a cleaning
apparatus having a brush head the pivots;
Figure 17 is an exploded view of the hinge of the cleaning apparatus shown in
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Figure 16;
Figures 18A and 18B are cross sectional side views of the head assembly
shown in Figure 16 in two different pivoted positions;
Figure 19 is a perspective view of an alternative embodiment of a brush
having a conical tip;
Figures 20A and 20B are cross sectional side views of an alternative
embodiment of a head assembly wherein the brush head is configured to
continuously
rotate;
Figure 21A is an exploded perspective view of the universal joint shown in
Figure 20A;
Figure 21B is a perspective view of the universal joint shown in Figure 21A;
Figure 22 is a cross sectional side view of an alternative embodiment of a
cleaning apparatus having a light source mounted to the body assembly; and
Figure 23 is a cross sectional side view of an alternative embodiment of a
cleaning apparatus having a light source mounted to the head assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates cleaning apparatus having a reciprocating or
rotating brush head. The cleaning apparatus is generally designed for domestic
use in
cleaning small, hard to reach areas such as cracks, corners, grooves and
crevices. For
example, the cleaning apparatus can be used for cleaning corners and around
faucets
on counter tops and in showers. It can also be used for spot scrubbing
materials such
as fabric and carpets. It is appreciated, however, that the apparatus can be
used for
cleaning any type of surface in commercial, residential, or any other
application. The
cleaning apparatus, however, is not designed for use as a toothbrush.
Depicted in Figures 1-3 is one embodiment of a cleaning apparatus 4
incorporating features of the present invention. Cleaning apparatus 4
generally
comprises a body assembly 5 having a removable head assembly 6. Head assembly
6
includes a head housing 7 having an upper head housing 22 which mates with a
lower
head housing 24. Each of head housings 22 and 24 extend between a proximal end
32
and an opposing distal end 34.
Head assembly 6 further includes a rotatable brush head 14 having a brush 16
mounted thereon. As will be discussed below in greater detail, brush head 14
comprises an annular carrier plate 122 having a top surface 124 and an
opposing
bottom surface 125. Depicted in Figure 4, a plurality of tufting holes 170 are
formed
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on bottom surface 125. In one embodiment tufting holes 170 are circular and
each
have a diameter in a range between about 1 mm to about 4 mm with about 2 mm to
about 3 mm being more common. Tufting holes 170 are shown disposed in
concentric rings. Alternatively, tufting holes 170 can also be randomly
disposed or be
in other patterns.
In the embodiment depicted, tufting holes 170 from an outer ring 172, a
middle ring 174, an inner ring 176 and a center tufting hole 178. As seen in
Figure 3,
disposed within each tufting hole 170 is a tuft 180 which is comprised of a
plurality of
bristles 182. The combined tufts 180 form brush 16. Bristles 182 can be made
of a
variety of different materials having different lengths and diameters. By
adjusting the
properties of the bristles 182, brush 16 can be formed having different
stiffnesses to
better suite different uses. In general, bristles having shorter length and
increased
diameter have increased stiffness.
Bristles 182 can be made from a variety of different natural or synthetic
materials. In one embodiment, bristles 182 are comprised of a polymer material
such
as nylon. In other embodiments, such as for use in cleaning a barbeque grill,
bristles
182 can be comprised of a metal such as brass, stainless steel, or copper. As
depicted
in Figure 1, each bristle has an exposed length L which is typically in a
range between
about 0.3 cm to about 2.5 cm with about 1 cm to about 2 cm being more common.
The depicted brush 16 has a substantially cylindrical configuration with a
maximum
diameter D that is typically in a range between about 1 cm to about 5 cm, with
about 1
cm to about 3 cm being common, and about 1.5 cm to about 2.5 cm being more
common. Larger brushes may have a diameter in a range from about 3 cm to about
5
cm. In alternative embodiments, brush 16 can have any desired configuration
and can
have any desired dimensions, including longer lengths and diameters, so as to
function for a particular purpose.
Because head assembly 6 is removable from body assembly 5, it is appreciated
that a variety of different head assemblies 6 can be made, each having a brush
16 of
different configuration and/or properties. For example head assembly 6 can be
formed each having a brush 16 with soft bristles, medium bristles, stiff
bristles or
combinations thereof. In one embodiment the soft bristles are comprised of a
polymeric material having a diameter in a range between about 0.15 mm to about
0.25
mm with about 0.18 mm to about 0.23 mm being more common. Medium polymeric
bristles typically have a diameter in a range between about 0.30 mm to about
0.48 mm
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with about 0.37 min to about 0.42 mm being more common. Finally, polymeric
stiff
bristles typically have a diameter in a range between about 0.48 mm to about
0.75 mm
with about 0.52 mm to about 0.58 mm being more common. By way of comparison,
bristles on tooth brushes typically have a diameter less than 0.15 mm so that
the
5 bristles are not so stiff as to damage the gums or enamel of the teeth.
In one embodiment having a combination of bristles 182, tufting holes 170 in
outer ring 172, middle ring 174, and inner ring 176 (Figure 4) are filled with
medium
bristles while center tufting hole 178 is filled with stiff bristles forming a
stopping
tuft. The bristles in the stopping tuft are shorter than the other bristles.
During use,
the stiffness of the stopping tuft helps limit the collapse of the other tufts
as the brush
is pressed against the surface to be cleaned. This helps to ensure that the
tips of the
bristles, as opposed to the sides, are primarily used for scrubbing. Bristles
having
different properties can also be defined by relative percentages. For example,
in a
brush having a stopping tuft and cleaning tufts, the bristles of the cleaning
tufts can
have a length that is at least 20% longer or at least 30% longer than the
bristles of the
stopping tuft and a diameter that is at least 30% smaller or at least 40%
smaller than
the bristles of the stopping tuft.
Similarly, in one embodiment depicted in Figure 3, brush 16 can comprise a
group of central tufts 8 which are surrounded by outer perimeter tufts 9. The
outer
perimeter tufts 9 are slightly longer and softer than central tufts 8. As
such, light
contact by brush 16 produces soft scrubbing by outer perimeter tufts 9 while
harder
biasing of brush 16 causes central tufts 8 to engage the surface, thereby
producing
harder scrubbing. In alternative embodiments, all the tufts/bristles can be
the same
length, diameter, or stiffness or any combination of lengths, diameters and
stiffness
can be used.
Body assembly 5 includes a body housing 12 having a substantially cylindrical
configuration. Body housing 12 can have a circular, elliptical or any other
desired
transverse cross section and is sized to comfortably fit within the hand of a
user. In
one embodiment, body housing 12 has a maximum diameter in a range between
about
2.5 cm to about 4.5 cm. Other dimensions can also be used. Body housing 12
comprises an upper body housing 18 which mates with a lower body housing 20.
Each of body housings 18 and 20 also extend from a proximal end 26 to an
opposing
distal end 28. Upper body housing 18 has an aperture 21 in which a flexible
button 23
is mounted (see Figure 5). Removably mounted to proximal end 26 of body
housing
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12 is an end cap 30. It is noted that button 23 is positioned on one side of
cleaning
apparatus 4 while brush 16 projects from the other side of cleaning apparatus
4. This
configuration enables the user to easily activate button 23 during using of
cleaning
apparatus 4. Furthermore, by having this configuration, the force used to
press down
on button 23, such as with the thumb of the user, can also be used for
pressing the
brush against the surface to be cleaned.
Head housing 7, body housing 12, and end cap 30 combine to form a housing
36. Housing 36 has a substantially cylindrical configuration with a length
extending
between proximal end 32 and end cap 30 that is typically in a range between
about 15
cm to about 35 cm with about 20 cm to about 30 cm being more common. Other
dimensions can also be used. In alternative embodiments housing 36 can have a
variety of other configurations. Although housing 36 may not be completely
symmetrical along its entire length, housing 36 has a substantially central
longitudinal
axis 38 extending therethrough.
As depicted in Figure 5, body housing 12 bounds a battery compartment 40, a
motor compartment 42, and a shaft compartment 43. A partition 44 is formed
between compartment 40 and 42 while a partition 46 is formed between
compartment
42 and 43. Battery compartment 40 is accessed through an opening 48 formed at
proximal end 26 of body housing 12. Opening 48 is selectively closed by end
cap 30.
An annular seal ring 50 forms a liquid tight seal between body housing 12 and
end
cap 30.
As depicted in Figures 5 and 6, cleaning apparatus 10 further includes a motor
assembly 58. Motor assembly 58 comprises a motor 60 having a proximal end 62
and
an opposing distal end 64 that is mounted within motor compartment 42.
Projecting
from distal end 64 of motor 60 into shaft compartment 43 is a drive shaft 66
terminating at a first coupling 68. First coupling 68 terminates at an end
face 70. End
face 70 comprises a pair of sloping surfaces 72 that are connected by stepped
shoulders 74. An annular shaft seal 76 encircles first coupling 68 and forms a
liquid
tight seal between first coupling 68 and body housing 12.
Battery compartment 40 is configured to receive a plurality of batteries. For
example, in the embodiment battery compartment 40 is configured to receive
four
batteries 78 of a size AA. Other sizes and numbers of batteries can also be
used in
alternative embodiments. The positive end of batteries 78 bias against a first
contact
plate 80 which is in electrical communication with motor 60. The negative end
of
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batteries 78 bias against a second contact plate 82 which is mounted within
end
cap 30.
An elongated switch 88 has a first end 90 which is in electrical communication
with second contact plate 82 when end cap 30 is mounted to body housing 12.
Switch
88 comprises an elongated base 92 which extends along battery compartment 40,
a
riser 94 which extends along partition 44, and a flexible lever arm 96 which
projects
so as to be disposed between button 23 and motor 60. When button 23 is
manually
depressed, lever 96 is biased against motor 60, thereby closing the circuit
which is
energized by batteries 78. In turn, as the circuit is closed, the energy from
batteries 78
causes motor 60 to rotatably drive drive shaft 66. As button 23 is released,
the circuit
is broken and motor 60 is turned off. In alternative embodiments, it is
appreciated
that a variety of different switching mechanisms can be used so that motor 60
can be
continually activated without having to continually manually depress button
23.
Furthermore, it is appreciated that batteries 78 can be replaced with an
electrical cord.
With further reference to Figures 5 and 6, head assembly 6 further comprises a
drive shaft 100. As depicted in Figure 8, drive shaft 100 comprises an
elongated shaft
102 having a proximal end 104 and an opposing distal end 106. Distal end 106
terminates at a distal end face 108. Radially encircling and outwardly
projecting from
shaft 102 at distal end 106 is an annular flange 109. A bearing or bushing 162
(Figure
7) is mounted on shaft 102 so as to bias against flange 109. Mounted at
proximal end
104 of shaft 102 is a second coupling 110 having an end face 112 that is
complementary to end face 70 of first coupling 68. That is, second coupling
110 is
configured to mesh with first coupling 68 so that stepped shoulders 74 bias
against
one another. As a result, rotation of drive shaft 66 by motor 60 is
transferred through
couplings 68 and 110 to cause rotation of shaft 102.
Extending from end face 108 at distal end 107 of shaft 102 is a stem 114.
Mounted on the end of stem 114 is a rounded head 116. In the embodiment
depicted,
head 116 is spherical or substantially spherical. Here it is noted, as will be
discussed
below in greater detail, shaft 102 has a rotational axis and central
longitudinal axis
118, which in the depicted embodiment are the same, and stem 114 has a central
longitudinal axis 120. Stem 114 is eccentrically mounted on end face 108 of
shaft
102 so that central longitudinal axis 120 of stem 114 is offset from central
longitudinal axis 118 of shaft 102. Rotational axis 118 can also be the same
axis as
the rotational axis and central longitudinal axis of drive shaft 66 and can
also be the
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same as central longitudinal axis 38 of housing 36 (Figure 1).
Returning to Figure 5, brush head 14 comprises annular carrier plate 122, as
previously discussed, having top surface 124. Projecting from top surface 124
is a
spindle 126. Spindle 126 comprises a central axle 128 having an arm 130
projecting
from each side thereof. A rotational axis 127, about which brush 16 and brush
head
14 rotate, extends through spindle 126. Rotational axis 127 can also be the
central
axis for brush 16 and brush head 14. Mounted on spindle 126 is a hub 132. As
depicted in Figure 9A, hub 132 has opposing side surfaces 136 and 138 which
extend
between a top surface 140 and an opposing bottom surface 142. Hub 132 also
includes a front face 144 and an opposing back face 146. A passage 148 extends
from
top surface 140 to bottom surface 142. A side channel 150 extends through side
surfaces 136 and 138 adjacent to bottom surface 142 so as to intersect with
passage
148.
During assembly, hub 132 is received over spindle 126 so that axle 128
extends through passage 148 and arms 130 are received within side channel 150.
A
bearing or bushing 151 (Figure 5) is mounted on axle 128 at top surface 140 of
hub
132. In this configuration, hub 132 is engaged with spindle 126 such that
rotation of
hub 132 facilitates rotation of spindle 126 and thus the remainder= of brush
head 14.
In alternative embodiment, it is appreciated that hub 132 can be integrally
formed
with brush head 14.
Hub 132 further comprises a channel 152 formed on front face 144 and
extending to top surface 140. Channel 152 is vertically aligned with passage
148 and
is bounded by a first engagement surface 156, a spaced apart second engagement
surface 158, and an inside face 159 extending therebetween. Engagement
surfaces
= 25 156 and 158 are opposingly facing and are in substantially parallel
alignment.
Recessed along each engagement surface 156 and 158 is a locking channel 160.
Each
locking channel 160 is elongated and is slightly arched along the length
thereof. The
distance between engagement surfaces 156 and 158 of hub 132 is smaller than
the
diameter of rounded head 116.
As depicted in Figures 7 and 10, however, hub 132 is configured so that head
116 can be snap-fit between engagement surfaces 156 and 158 so that head 116
is
resiliently captured within locking channels 160 formed on engagement surfaces
156
and 158. In this configuration, head 116 is resiliently biased between faces
156
and 158.
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In an alternative embodiment depicted in Figure 9B, locking channels 160 can
be eliminated so that engagement surfaces 156 and 158 are substantially flat.
In this
embodiment, head 116 can be sized to snugly or loosely fit between engagement
surfaces 156and158.
Returning to Figure 5, head housing 7 is enclosed over drive shaft 100 and hub
132 so that head housing 7 rides against bearings 151 and 162. Bayonet slots
164 are
formed on distal end 28 of body housing 12 while bayonet prongs 166 project
from
proximal end 32 of head housing 7. As such, head assembly 6 can be removably
connected to body assembly 5 using the bayonet connection (Figure 1).
In the above assembled configuration, couplings 68 and 110 are mated.
Accordingly, as button 23 is depressed, motor 60 is energized causing drive
shaft 66
and drive shaft 100 to each rotate about their rotational or central
longitudinal axis. In
turn, because stem 114 and rounded head 116 are mounted eccentrically on shaft
102,
head 116 rotates in a circle. That is, as shaft 102 spins or rotates, head 116
begins to
rotate in an enlarged circle so as to bias against engagement surface 158 of
hub 132
causing hub 132 with connected brush head 14 and brush 16 to rotate in a first
direction about axle 128. The length and arch of locking channels 160 allows
for free
rotation of head 116 within locking channels 160.
Once head 116 has moved to its furthest extent in one direction, head 116 then
begins to bias against the opposing engagement surface 156 causing hub 132,
with
connected brush head 14 and brush 16, to rotate in the opposing direction
about axle
128. As such, rapid rotation of drive shaft 100 with head 116 causes hub 132
with
connected brush head 14 and brush 16 to rapidly reciprocate. By securing head
116
within locking channels 160, a snug engagement can be formed between hub 132
and
head 116. This snug fit optimizes the transfer of movement between drive rod
100 and
hub 132. That is, the snug fit eliminates slop between hub 132 and drive rod
100 even
after head 116 has begun to wear within locking channels 160.
Once cleaning apparatus 4 is energized, brush 16 can be biased against a
surface for cleaning. It is noted that brush 16 is positioned at an
orientation relative
housing 36 so as to optimize convenience and use. For example, with reference
to
Figure 6, in one embodiment brush 16 projects relative to the central
longitudinal axis
of body assembly 5 or head assembly 6 so as to form a set inside angle 0
therewith
typically in a range between about 90 to about 180 with about 110 to about
140
being more common. Other angles can also be used. Expressed in other terms,
rotational axis 127 of brush head 14 or brush 16 intersects with rotational
axis 38 of
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the drive shaft or of central longitudinal axis 118 of housing 36 so as to
form the set
inside angle 0 as discussed above. By having the angle 0 at about 110 to
about 140 ,
the user is able to more conveniently place and use brush 16 while holding
onto
5 housing 36.
The present invention may be embodied in other specific forms without
departing from its spirit or essential characteristics. The described
embodiments are to
be considered in all respects only as illustrative and not restrictive. For
example, it is
appreciated that locking channels 160 need not merely be recessed within inner
side
10 walls 156 and 158 but can completely extend through hub 132.
Furthermore, it is not
necessary that head 116 be spherical. In alternative embodiments, it is
appreciated that
head 116 can be elliptical or have a variety of other configurations that mate
with
complementary locking channels.
Depicted in Figure 11 is an alternative embodiment of a cleaning apparatus
200 incorporating features of the present invention. Like elements between
cleaning
apparatus 4 and 200 are identified by like reference characters. Cleaning
apparatus
comprises a head assembly 202 and a body assembly 204. Turning to Figure 12A,
body assembly 204 comprises a body housing 206 which is molded as a tubular
member. Body housing 206 comprises a handle portion 208 having a proximal end
210 and an opposing distal end 212. Distal end 212 terminates at and end face
214
from which a tapered, tubular stem 216 projects. A pair of opposing bayonet
slots 217
are formed along stem 216. Handle portion 208 and stem 216 are typically
comprised
of a substantially rigid plastic such as ABS. An overlay 218, comprised of a
softer,
flexible plastic such as TPE or rubber, is molded over a section of handle
portion 208.
Overlay 218 allows improved gripping of cleaning apparatus 200.
Body housing 206 has an interior surface 220 which bounds a chamber 222.
Turning to Figure 12B, secured within chamber 222 is a guide 224. Guide 224
comprises an elongated partition wall 226 having a proximal end 228 and an
opposing
distal end 230. The sides of partition wall 226 are curved so that batteries
78 can be
complementary received on each side thereof. A cantilevered latch 232 is
formed at
proximal end 238 at both the top and bottom of partition wall 226. Each latch
232
terminates at a barb 234. A spring 236 is positioned between partition wall
226 and
each latch 232 so that each latch 232 can be selectively compressed toward
partition
wall 226 and, when released, each latch 232 resiliently rebounds. As depicted
in
Figure 13, holes 235 are formed through each side of handle portion 208 at
proximal
end 210. An engaging portion 238 of overlay 218 is molded over holes 235.
Guide
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224 is positioned within chamber 222 to that each latch 232 is aligned with a
corresponding hole 235. A user is thus able to manually press inward on the
flexible
engaging portions 238 of overlay 218 so as to selectively inwardly press
latches 232.
Latches 232 are used for securing an end cap 240 to proximal end 210 of body
housing 206. Specifically, end cap 240 has an interior surface 242 with a pair
of
opposing catches 244 formed thereon. When end cap 240 is pushed onto proximal
end
210 of body housing 206, barbs 234 on latches 232 engage catches 244 so as to
securely lock end cap 240 on body housing 206. To remove end cap 240, engaging
portions 238 are manually depressed as discussed above so as to inwardly flex
latches
232 and thus release barbs 234 from catches 244.
Returning to Figure 12B, cupped support 246 is formed at distal end 230 of
partition wall 226 and is used to support motor 60. Motor 60 rotates an
initial shaft
250 which in turn rotates a drive shaft 254. Drive shaft 254 has a head 255
formed at
a distal end thereof. Head 255 typically has a non-circular transverse cross
section
such that it can engage with a coupler as discussed below in greater detail.
In the
embodiment depicted, head 255 comprises a flattened portion of drive shaft
254. In
alternative embodiments, head 255 can have any number of different polygonal
or
non-circular transverse cross sections.
A conventional gear assembly 252 extends between initial shaft 250 and drive
shaft 254 so that the torque produced by drive shaft 254 is adjusted relative
to the
torque produced by initial shaft 250 by a ratio in a range between about 1.5:1
to about
3.5:1. Increasing the torque capacity of drive shaft 254 enable brush 16 to
continue to
reciprocate or rotate even when substantial bearing force is applied to brush
16 while
scrubbing. This is contrary to many conventional electric toothbrushes where
it is
desired that the brush stop moving or significantly slow when too much force
is
applied so that the toothbrush does not damage the gums.
It is appreciated that there are a variety of different mechanism that can be
used to transfer electricity from batteries 78 to motor 60. In the illustrated
embodiment, the four batteries 78 are disposed in parallel. The negative end
of the
back two batteries 78 bias against a corresponding spring 256 which are each
in
electrical communication with a transfer spring 258. The springs are mounted
on a
plate 255 which is secured within end cap 240. Transfer spring 258 biases
against a
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contact 260. An electrical lead 262 extends from contact 260 to motor 60. The
positive end of the front two batteries 78 bias against a correspond contact
264 which
are each in electrical communication with a flexible switch 266. Switch 266 is
positioned above motor 60 such that when switch 266 is biased against motor
60, the
circuit is complete and motor 60 is energized.
In an alternative embodiment, batteries 78 can be positioned in series rather
then parallel. In this embodiment, springs 256 are in electrical communication
with
each other but transfer spring 256, contact 260, and lead 262 are eliminated.
Likewise, the two contacts 264 are separated from each other. One of contacts
264 is
in direct electrical communication with motor 60 while the other contact 264
remains
connected with switch 266. Placing batteries 78 in series increases the
voltage to
provide more power to the motor.
Turning to Figure 12A, an opening 270 is formed on a top surface body
housing 206 so as to communicate with chamber 222. Opening 270 is aligned with
motor 60 and switch 266. Secured within opening 270 is a flexible diaphragm
272.
Diaphragm 272 has a top surface 274 and an opposing bottom surface 276. A
projection 278 is formed on top surface 274. A cover plate 280 has an
elongated hole
282 extending therethrough and is secured over opening 270 so that hole 282 is
aligned with projection 278. A button 284 is slidably mounted to cover plate
280 by a
catch 286 and a retainer 288.
As depicted in Figure 14A, button 284 comprises a generally cup-shaped body
290 having an interior surface 292 with a stem 294 projecting therefrom.
Button 284
is comprised of a resiliently flexible material which is typically a natural
or synthetic
rubber. Retainer 288 comprises a substantially circular frame 296 having an
opening
298 extending therethrough. Opening 298 is at least partially bounded by a lip
300.
Retainer 288 is comprised of a substantially rigid material or at least a
material that is
more rigid than the material used for button 284. Button 284 is secured to
retainer
288 so that stem 294 passes through opening 298. In one embodiment, button 284
is
secured to retainer 288 by being molded directly onto retainer 288 during the
formation of button 284, i.e., overlay molding process.
Catch 286 (Figure 14B) comprises a base 302 having an opening 304
extending therethrough. A pair of barbed prongs 306 upwardly project from a
top
surface of base 302 on opposing sides of opening 304. Catch 286 is used to
secure
button 284 on cover plate 280. Specifically, button 284 and retainer 288 are
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13
positioned on the top surface of cover plate 280 so that stem 294 is aligned
with
opening 282 of cover plate 280. Prongs 306 of catch 286 are then pushed up
through
opening 282 of cover plate 280 from the bottom surface thereof so that prongs
engage
with lip 300 of retainer 288 by a snap fit connection.
In this assembled configuration, button 284 can selectively side on cover
plate
280 between an off position as shown in Figure 14A and an on position as shown
in
Figure 14C. In the off position, projection 278 of diaphragm 272 is disposed
between
stem 294 of button 284 and switch 266 and is at least partially disposed
within
opening 304 of catch 286. In this position, switch 266 is spaced apart from
motor 60
so that no electrical contact is made. From the off position, there are two
ways in
which a user can energize motor 60. In one approach, as depicted in Figure
14B, a
user can simply press down on the center of button 284. In so doing, stem 294
is
pressed down against projection 278 which in turn pushes down switch 266 so
that
switch 266 contacts motor 60, thereby energizing motor 60. When the user
releases
button 284, button 284 resiliently returns to the off position.
In the second approach as depicted in Figure 14C, the user manually slides
button 284 along cover plate 280. In so doing, base 302 of catch 286 rides
over
projection 278 which pushes projection 278 downward again causing switch 266
to
contact motor 60, thereby energizing motor 60. Motor 60 remains energized
until
button 284 is again moved back to the off position. The button
assembly thus
enables a single, integral button to activate the motor in two different modes
of
operation.
Returning to Figure 12A, head assembly 202 comprises a head housing 201
which includes upper head housing 22 and lower head housing 24 each having
proximal end 32 and opposing distal end 34. Head housing 201 bounds a channel
316
extending along the length thereof which is at least partially divided by
complementary partition walls 317 formed on housing 22 and 24. Secured between
housing 22 and 24 at proximal end 32 is an engagement ring 312. Engagement
ring
312 has opposing bayonet prong 318 formed on an interior surface thereof. Head
assembly 202 is removably secured to body assembly 204 by inserting stem 216
of
body housing 206 within proximal end 32 of head assembly 202 so that bayonet
prongs 318 are received within bayonet slots 217 and then rotating head
assembly 202
relative to body assembly 204.
Head assembly 202 comprises a drive shaft 320 having a proximal end 322
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and an opposing distal end 324. Proximal end 322 has a coupler 326 secured
thereto.
Coupler 326 has a socket 328 formed on the free end thereof that is designed
to
removably engage with head 255 on drive shaft 254 extending from motor 60.
Specifically, socket 328 has a configuration complementary to head 255 such
that
when head 255 is received within socket 328, rotation of drive shaft 254
causes
rotation of drive shaft 320. Head 255 is removably received within socket 328
when
head assembly 202 is removably coupled with body assembly 204 as discussed
above.
An enlarged disk 330 is secured to distal end 324 of drive shaft 320. In the
embodiment depicted, disk 330 has a substantially cylindrical configuration
that
includes a proximal end face 332 and an opposing distal end face 334. Distal
end 324
of drive shaft 320 is centrally secured to proximal end face 332. In contrast,
stem 114
and rounded head 116 are mounted on distal end face 334 at a location spaced
radially
outward from the rotational axis of drive shaft 320. That is, stem 114 is
eccentrically
mounted on end face 334 in the same manner as discussed above with regard to
cleaning apparatus 4.
It is noted that centrally positioning enlarged disk 330 at the end of drive
shaft
320 helps to stabilize drive shaft 320 during the rotation of eccentrically
mounted
rounded head 116. In alternative embodiments, however, drive shaft 320 can
have the
same diameter as disk 330 or disk 330 can be eliminated and an arm formed
between
drive shaft 330 and stem 114. Other conventional techniques can also be used
to
eccentrically position rounded head 116. A cylindrical bushing 336 encircles
drive
shaft 320 toward distal end 324 and is supported within supports 338 formed on
the
interior surface of head housing 201.
As with cleaning apparatus 4, cleaning apparatus 200 includes brush head 14.
Brush head 14 comprises carrier plate 122 having bottom surface 125 with brush
16
comprised of bristles formed thereon. Plate 122 also has top surface 124 with
spindle
126 and arms 130 projecting therefrom. Axle 128 centrally projects from
spindle 126
and has a rotational axis extending therethrough. A tubular bushing 340 is
secured to
upper head housing 22 and encircles axle 128 (Figure 13). Axle 128 and spindle
126
are received within a hub 342 with a wear plate 341 positioned between bushing
340
and spindle 126.
As depicted in Figure 15, hub 342 comprises a substantially cylindrical base
344 having a front face 346, a back face 348, and opposing side faces 350 and
351
which each extend between a top surface 352 and an opposing bottom surface
354. A
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passage 356 centrally extends through base 344 from top surface 352 to bottom
surface 354. A side channel 358 extends through side surfaces 350 and 351
adjacent
to bottom surface 354 so as to intersect with passage 356. Side channel 358 is
configured so that when spindle 126 is received within passage 356, arms 130
are
5 received
within side channel 358 so that hub 342 is interlocked with brush head 14.
Wear plate 341 also has tabs projecting from the side thereof which are
received
within side channel 358 of hub 342 so that wear plate 341 is secured to hub
342. In
one embodiment where bushing 340 is metal and spindle 126 is plastic, wear
plate
341 prevents bushing 340 from producing undue wear on spindle 126.
10 Projecting
from back face 348 of base 344 is a guide 360. Guide 360
comprises a first side wall 362, a complementary spaced apart second side wall
364,
and a back wall 366 extending therebetween. Guide 360 partially bounds a
channel
368 that is vertically aligned with passage 356. Channel 368 is bounded by a
first
engagement surface 370, a spaced apart second engagement surface 372, and an
15 inside
face 374 extending therebetween. Engagement surfaces 370 and 372 are
opposingly facing, are substantially flat, and are in substantially parallel
alignment.
The distance between engagement surfaces 370 and 372 of hub 342 is
substantially
equal to the diameter of rounded head 116.
Comparable to the embodiment depicied in Figure 10 and as illustrated in
Figure 13, rounded head 116 is received within channel 368. As rounded head
116 is
continuously rotated about thé rotational axis of drive shaft 320 due to the
rotation of
drive shaft 254, rounded head 116 alternatingly pushes against opposing
engagement
surfaces 370 and 372 so as to cause hub 342, brush head 14, and brush 16 to
reciprocate in a rotational pattern about the rotation axis extending through
spindle
126.
As with cleaning apparatus 4, in cleaning apparatus 200 the rotational axis of
drive shaft 320 intersects with the rotational axis of brush head 14 so as to
form an
inside angle 0 that is typically greater than 95 and is more commonly in a
range
between about 110 to about 140 . As rounded head 116 travels in its circular
pattern,
rounded head 116 travels longitudinally along the length of side walls 362 and
364.
Because of the above discussed angular orientation of brush head 14, rounded
head
116 is disposed farther away from the rotational axis of brush head 14 when
rounded
head 166 is disposed at the bottom of side walls 362 and 364 and is closer to
the
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rotational axis of brush head 14 when rounded head 166 is disposed at the top
of side
walls 362 and 364. Accordingly, to ensure that rounded head 166 is retained
within
channel 368 during its circular movement, side walls 362 and 364 are wider at
the
bottom than at the top.
In one embodiment rounded head 116 has a substantially spherical
configuration. This design has a number of benefits. For example, in part
because of
the above discussed angular orientation of brush head 14, rounded head 116
contacts
engagement surfaces 370 and 372 along a number of different points on rounded
head
116 that are longitudinally spaced proximal to distal and top to bottom. By
making
rounded head 116 spherical, this helps to ensure continued minimal contact
between
rounded head 116 and engagement surfaces 370 and 372 so as to minimize wear.
Furthermore, due to tolerances in mounting brush head 14, on occasion as
brush 16 is biased against a surface for cleaning, brush head 14 will tilt
slightly
causing the distal end of rounded head 116 to bias against inside face 374 of
hub 342
(Figure 15). This contact between rounded head 116 and inside face 374 helps
to
stabilize and reinforce brush head 14. By making rounded head 116 spherical,
the
contact surface between rounded head 116 and inside face 374 is minimized. It
is also
noted that both of side walls 362 and 364 terminate at an outside edge 376.
These
outside edges 376 are designed so that they can bias against= distal end face
334 of
disk 330 as brush head 14 is tilted =during use so as to also help stabilize
and reinforce
brush head 14.
In the forgoing embodiment, bush 16 has a fixed orientation relative to body
assembly 204. In one alternative embodiment depicted in Figure 16, a cleaning
apparatus 386 is provided having a head assembly 388 wherein brush 16 can be
pivoted along arrow 390 so as to selectively adjust the orientation of brush
16 relative
body assembly 204. Like elements between head assembly 202 and head assembly
388 are identified by like reference characters.
Head assembly 388 comprises a proximal head housing 392, a distal head
housing 394, and a hinge 396 pivotally connecting housing 392 and 394
together. As
depicted in Figure 17, proximal housing 392 has a distal end 398. An opening
399 is
formed at distal end 398 through which drive shaft 320 extends (Figure 18A).
Hinge
396 comprises a pair of rounded prongs 400A and 400B projecting on each side
of
opening 399. Hinge 396 comprises two identical halves with the components for
the
two halves identified by the suffixes A and B. Only one of the halves will be
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17
Described in detail herein with the understanding that the other half (prong
400B,
circular ring 402B, and opposing notches 404B) is identical thereto.
Projecting from
an outside face of prong 400A is a circular ring 402A. A pair of opposing
notches
404A are formed on ring 402A.
Hinge 396 also comprises a pair of rounded arms 406A and 406B projecting
from a proximal end of distal head housing 394. Arm 406A has an inside face
410A
to an outside face 412A. A substantially circular recessed pocket 414A is
formed on
inside face 410A. Pocket 414A has a plurality of rounded notches 416A formed
on
the perimeter edge of pocket 414A on opposing sides thereof. Each notch 416A
is
separated by a ridge 417A. A circular recess 408A is formed on the floor of
pocket
414A and is sized to receive ring 402 A.
A spring 418 A is provided and is comprised of a resilient flexible material
such as metal commonly used in springs. Spring 418A comprises a ring body 420A
having an exterior surface 422A and an interior surface 424A. A pair of
rounded tabs
426 A project from exterior surface 422 A on opposing sides of ring body 420
A.
Likewise, a pair of rectangular tabs 428A project from interior surface 424A
on
opposing sides of ring body 420A.
During assembly, tabs 428A of spring 418A are received within corresponding
notches 404A on prong 400A so that spring 418A is secured to prong 400A. Next,
arm 406A is positioned so that spring 418A is received within pocket 414A and
ring
402A is received within recess 408A. Tabs 426A are received within
corresponding
notches 416A so that arm 406A is fixed relative to prong 400A. When it is
desired to
change the orientation of brush 16, a force is applied to distal head assembly
394
along arrow 390 (Figure 16). The force causes spring 418A to rotate within
pocket
414A. Specifically, spring 418A deflects as tabs 426A pass over ridges 417A
and then
resiliently rebounds as tabs 426A pass into the adjacent notches 416A. In
part, the
resistance of the movement of distal head assembly 394 is based on the
stiffness of
springs 418A and 418B.
As depicted in Figures 18A and 18B, as a result of hinge 396, brush head 14
can now rotate over an angle of 90 . For example, the angle 0 previously
discussed
can be selectively adjusted from about 90 to about 180 . As also depicted in
Figures
18A and 18B, the internal components of head assembly 388 are substantially
the
same as the internal components of head assembly 202. The shape of hub 342,
however, has been modified slightly so that rounded head 116 is retained
between
sidewalls 362 and 364 as head 116 moves in the circular pattern, independent
of the
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18
orientation of brush head 14. It is also noted from Figure 16, that brush 16
has a
larger diameter than prior depicted brushes 16 and that some bristles 182 are
longer
than others. It is appreciated that the present invention can comprise a kit
having a
single body assembly and a plurality of different head assemblies which can be
selectively secured to the body assembly. Each head assembly can have a brush
having a different size, configuration, and/or physical properties, such as
stiffness of
bristles. For example, depicted in Figure 19 is a brush 16 having a conical
tip 434 for
better reaching and scrubbing the inside of corners.
In the above discussed embodiments, the head assemblies are designed so that
the brushes rotate in a reciprocating manner. In alternative embodiments, the
head
assembly can be designed so that the brush rotates in a continuous circular
manner.
For example, depicted in Figure 20A is a head assembly 436. Like elements
between
head assembly 436 and head assembly 388 are identified by like reference
characters.
Head assembly 436 comprises proximal head housing 392, distal head housing 394
and hinge 396. A brush head 438 has a first side with brush 16 projecting
therefrom
and an opposing second side with a spindle 440 projecting therefrom. Spindle
440 is
coupled with a universal joint 441. A drive shaft 442 is disposed within
proximal
housing 392. Drive shaft 442 has coupler 326 mounted on a proximal end thereof
and
universal joint 441 mounted on a distal end thereof.
= Depicted in Figures 21A and 21B, universal joint 441 comprises a cup 444 and
a ball 446. Spindle 440 projects from one side of cup 444 while a rounded
socket 448
is formed on the opposing side of cup 444. Socket 448 is bounded by an
interior
surface 450 from which a pair of opposingly, spaced apart, rounded projections
452
extend adjacent to the mouth of socket 448. Ball 446 is rounded and is adapted
to fit
within socket 448. An elongated, rounded slot 454 is recessed on each opposing
side
of ball 446. Slots 454 are configured so that when ball 446 is received within
socket
448, projections 452 are received within corresponding slots 454. In one
embodiment, slots 454 can be combined to form one long slot. In this assembled
configuration, continuous rotation of drive shaft 442 causes rotation of ball
446,
which, due to the engagement between projections 452 and slots 454, causes
continuous rotation of cup 444, spindle 440, brush head 438 and brush 16.
Furthermore, because slots 454 are elongated, ball 446 can rotate within
socket 448 by projections 452 sliding longitudinally within elongated slots
454. As a
result, as depicted in Figures 20A and 20B, spindle 440 is free to pivot
relative to
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19
drive shaft 442, thereby enabling distal head assembly 394 to pivot relative
to
proximal head assembly 392 as a results of hinge 396 as discussed above.
Depicted in Figure 22 is an alternative embodiment of cleaning apparatus 200.
In this embodiment a light source 460, such as a light emitting diode (LED) is
mounted on the bottom side of body assembly 204 toward the distal end thereof.
Light
source 460 is oriented so as to direct light toward brush 16 so as to increase
visibility
of the cleaning surface during use. Leads 462 extend from light source 460 to
motor
60 such that when motor 60 is energized, light source 460 is also energized.
In an
alternative embodiment, a second button switch can also be provided for light
source
460.
Depicted in Figure 21 is another alternative embodiment of cleaning apparatus
200. In this embodiment light source 460, is mounted on the bottom surface of
head
assembly 202 so as to direct light toward brush 16. Again, leads 462 extend
between
light source 460 and motor 60. In this embodiment, however, contacts 464 are
formed
at the connection between head assembly 202 and body assembly 204.
The described embodiments are to be considered in all respects only as
illustrative and not restrictive. All changes which come within the meaning
and range
of equivalency of the claims are to be embraced within their scope, provided
that such
are supported by the description.
