Note: Descriptions are shown in the official language in which they were submitted.
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BRUSHROLL FOR VACUUM CLEANER
CROSS REFERENCE TO RELATED APPLICATIONS
100011 This paragraph is intentionally left blank.
BACKGROUND
[0002] Vacuum cleaners can include an agitator for agitating debris on a
surface to be
cleaned so that the debris is more easily ingested into the vacuum cleaner. In
some cases,
the agitator comprises a brushroll that rotates within a base or floor nozzle.
Such
brushrolls can be rotatably driven by a motor, a turbine fan or a mechanical
gear train, for
example. Brushrolls typically have a generally cylindrical dowel with multiple
bristle
tufts extending radially from the dowel. In operation, debris on a surface to
be cleaned is
swept up by the brushroll; in some cases, elongated debris such as hair may
become
wrapped around the brushroll and must be removed by a user by manually pulling
or
cutting the hair off the brushroll.
BRIEF SUMMARY
[0003] According to one aspect of the present disclosure, a brushroll for
a vacuum
cleaner includes a brush dowel configured to be mounted for rotation about a
central
rotational axis, which extends longitudinally through the brush dowel, and
having
opposing bristle supports defining mounting surfaces and a shroud surface
comprising
opposing convex curved surfaces extending between the opposing bristle
supports, and a
plurality of bristle tufts fastened to each of the opposing bristle supports
and projecting
from one of the mounting surfaces, wherein the mounting surfaces intersect the
convex
curved surfaces at outside corners.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] In the drawings:
[0005] FIG. 1 is a schematic cross section of a conventional brushroll for
a vacuum
cleaner;
[0006] FIG. 2 is a view similar to FIG. 1 showing the brushroll during
operation;
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[0007] FIG. 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;
[0008] FIG. 4 is a perspective view of a brushroll for the vacuum cleaner
of FIG. 3;
[0009] FIG. 5 is a cross-sectional view of the brushroll taken through line
V-V of
FIG. 4;
[0010] FIGS. 6-7 are views similar to FIG. 5 showing the brushroll during
operation;
[0011] FIG. 8 is a perspective view of a brushroll according to a second
aspect of the
present disclosure;
[0012] FIG. 9 is a cross-sectional view of the brushroll taken through line
IX-IX of
FIG. 8;
[0013] FIG. 10 is a perspective view of a brushroll according to a third
aspect of the
present disclosure;
[0014] FIG. 11 is a cross-sectional view of the brushroll taken through
line XI-XI of
FIG. 10;
[0015] FIG. 12 is a perspective view of a brushroll according to a fourth
aspect of the
present disclosure; and
[0016] FIG. 13 is a cross-sectional view of the brushroll taken through
line XIII-XIII
of FIG. 12.
DETAILED DESCRIPTION
[0017] The present disclosure relates to vacuum cleaners and in particular
to vacuum
cleaners or accessory tools for vacuum cleaners having a rotatable brushroll.
In particular,
the present disclosure relates to an improved brushroll design which reduces
hair wrap.
According to one aspect of the present disclosure, a brushroll includes a
dowel, a
plurality of bristles protruding from the dowel, and a shroud surface which is
positioned
relative to the bristles to minimize hair wrap.
[0018] According to another aspect of the present disclosure, a brushroll
includes a
dowel, a plurality of bristles protruding from the dowel, and a cutting
channel which is
positioned relative to the bristles to permit hair to be cut from the dowel.
[0019] According to another aspect of the present disclosure, a brushroll
includes
concave curved tufting surfaces to which bristle tufts are mounted or secured
to minimize
hair wrap.
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[0020] According to yet another aspect of the present disclosure, a
brushroll includes
offset, swept bristle tufts that are tufted at an acute angle to reduce the
drive torque
required to rotate the brushroll.
[0021] The brushrolls can be used with various vacuum cleaners, including
an
upright-type vacuum cleaner, a canister-type vacuum cleaner, a stick vacuum
cleaner, an
autonomous or robotic vacuum cleaner, or a hand-held vacuum cleaner, or
accessory
tools therefore. Furtheimore, the vacuum cleaner or accessory tool can
additionally be
configured to distribute a fluid and/or to extract a fluid, where the fluid
may for example
be liquid or steam. The term "surface cleaning apparatus" as used herein
includes both
vacuum cleaners and accessory tools for vacuum cleaners, unless expressly
noted.
[0022] FIG. 1 is a schematic cross section of a conventional brushroll 200
for a
vacuum cleaner. The brushroll 200 includes a brush dowel 202 configured to be
mounted
for rotation about a central rotational axis X extending longitudinally
through the dowel
202. The dowel 202 includes a cylindrical core 204 and one or more bristle
supports 206
projecting from the core 204. A plurality of bristles 208 protrude from the
bristle supports
206; the bristles 208 can be provided in a series of discrete tufts or in a
continuous strip.
The bristles 208 can be arranged in various patterns on the dowel, including
straight,
angled, helical, or combinations thereof.
[0023] FIGS. 1-2 show 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. As the bristles 208 come into contact with the surface
to be
cleaned, the bristles 208 are deflected. Debris, which can include, but is not
limited to,
dirt, dust, and hair, on the surface to be cleaned is swept up by the
brushroll 200. In the
present example, for purposes of simple illustration, a single hair H on the
surface is
shown as being picked up by the brushroll 200 in FIG. 1 by the bristles 208 in
contact
with the surface. The bristles 208 lift the hair H off the surface and around
the dowel 202
as the brushroll 200 rotates.
[0024] In some cases, the hair H may be pulled off the bristles 208 by the
suction
force of the vacuum cleaner. In other cases, as the bristles 208 holding the
hair H
continue along the rotational path determined by the dowel 202, the hair H can
become
wrapped around the dowel 202, as shown in FIG. 2.
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[0025] As the bristles 208 holding the hair H again come into contact with
the surface
to be cleaned, the hair H extends from an attachment point P. which is where
at least one
strand of hair H is attached to at least one bristle 208. When viewed from the
side, the
surface to be cleaned defines a surface line S, and the deflected bristles 208
define a
bristle deflection line Y, which is the tangent line to the curve defined by
the deflected
bristles 208 at the attachment point P. A deflection angle M is defined by the
included
angle formed by the surface line S and a line Z, which is the line orthogonal
to the bristle
deflection line Y at the intersection of the bristle deflection line Y with
the surface line S.
The hair H defines a hair wrap line W, which is the line defined by the hair H
from the
attachment point P where it extends from or leaves the bristles 208. In some
cases, the
portion of the hair H extending immediately from the bristles 208 may extend
substantially linearly before curving around the dowel 202, and so that hair
wrap line W
can follow that linear portion of the hair H. A hair wrap angle A2 is defined
by the
included angle formed by the surface line S and the hair wrap line W. It is
noted that the
hair H can be caught in various locations by the bristles 208, but that,
regardless of where
the hair is attached to the bristles, the wrapped hair H will have at least
some portion that
extends from the bristles 208 in the direction opposite to brushroll rotation
R.
[0026] It has been found that for brushroll designs where the hair wrap
angle A2 is
greater than the deflection angle Al (in other words, where A2 > Al), the hair
is pulled
toward the root of the bristles 208 and becomes tightly wrapped around the
dowel 202. In
this case, the hair cannot be pulled off the brushroll 200 by the suction
force of the
vacuum cleaner, and the user must manually remove the hair.
[0027] Aspects of the present disclosure include brushroll designs in which
the hair
wrap angle A2 is less than or equal to the deflection angle Al (in other
words, where A2
< Al). Such brushrolls prevent or greatly reduce the amount of hair wrap
during
operation.
[0028] FIG. 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. While
shown and
referred to herein as an upright vacuum cleaner, the vacuum cleaner 10 can
alternatively
be configured as a stick vacuum cleaner, an autonomous or robotic vacuum
cleaner, a
hand-held vacuum cleaning device, or as an apparatus having a floor nozzle or
a hand-
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held accessory tool connected to a canister or other portable device by a
vacuum hose.
Additionally, the vacuum cleaner 10 can be configured to have fluid
distribution
capability and/or extraction capability.
[0029] For purposes of description related to the figures, the terms
"upper," "lower,"
"right," "left," "rear," "front," "vertical," "horizontal," and derivatives
thereof shall relate
to the present disclosure as oriented in FIG. 3 from the perspective of a user
behind the
vacuum cleaner, which defines the rear of the vacuum cleaner. However, it is
to be
understood that the aspects of the present disclosure may assume various
alternative
orientations, except where expressly specified to the contrary.
[0030] As illustrated, the vacuum cleaner 10 comprises an upright body 12
pivotally
mounted to a lower base 14. The upright body 12 generally comprises a main
support
section 16 supporting a collection system 18 for separating and collecting
contaminants
from a working airstream for later disposal. In one conventional arrangement
illustrated
herein, the collection system 18 can include a cyclone separator 20, which can
be thought
of as a cyclonic collection system, for separating contaminants from a working
airstream
and a removable dirt cup 22 for receiving and collecting the separated
contaminants from
the cyclone separator 20. The cyclone separator 20 can have a single cyclonic
separation
stage, or multiple stages. In another conventional arrangement, the collection
system 18
can include an integrally formed cyclone separator and dirt cup, with the dirt
cup being
provided with a bottom-opening dirt door for contaminant disposal. It is
understood that
other types of collection systems 18 can be used, such as centrifugal
separators or bulk
separators. In yet another conventional arrangement, the collection system 18
can include
a filter bag. The vacuum cleaner 10 can also be provided with one or more
additional
filters upstream or downstream of the collection system 18.
[0031] The upright body 12 is pivotally mounted to the base 14 for movement
between an upright storage position, shown in FIG. 3, and a reclined use
position (not
shown). The vacuum cleaner 10 can 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 detent
pedal 24 are
known in the art, and will not be discussed in further detail herein.
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[0032] The upright body 12 also has an elongated handle 26 extending
upwardly
from the main support section 16 that is provided with a hand grip 28 at one
end that can
be used for maneuvering the vacuum cleaner 10 over a surface to be cleaned. A
motor
cavity 30 is formed at a lower end of the support section 16 and contains a
conventional
suction source, such as a motor/fan assembly 36, positioned therein in fluid
communication with the collection system 18. The vacuum cleaner 10 can also be
provided with one or more additional filters upstream or downstream of
motor/fan
assembly.
[0033] In FIG. 3, a lower portion of the vacuum cleaner 10 is cut away to
show
features of the base 14. The base 14 can include an upper housing 32 that
couples with a
lower housing 34 to create a partially enclosed space therebetween. An
agitator chamber
38 can be provided at a forward portion of the lower housing 34 for receiving
a brushroll
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 can
be provided on the base 14 for maneuvering the vacuum cleaner 10 over a
surface to be
cleaned.
[0034] The brushroll 60 is positioned within the agitator chamber 38 for
rotational
movement about a central rotational axis X. A single brushroll 60 is
illustrated; however,
it is within the scope of the present disclosure for dual rotating brushrolls
to be used.
Moreover, it is within the scope of the present disclosure for the brushroll
60 to be
mounted within the agitator chamber 38 in a fixed or floating vertical
position relative to
the chamber 38 and lower housing 34.
[0035] The brushroll 60 can be operably coupled to and driven by the
motor/fan
assembly 36 in the motor cavity 30. The motor/fan assembly 36 can comprise a
motor
shaft 46 which is oriented substantially parallel to the surface to be cleaned
and protrudes
from the motor cavity 30 into a rear portion of the base 14. A drive belt 48
operably
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) can be provided within the base 14 to drive the brushroll
60.
[0036] The base 14 can further include an optional suction nozzle height
adjustment
mechanism for adjusting the height of the suction nozzle opening 42 with
respect to the
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surface to be cleaned. A rotatable knob 54 for actuating the adjustment
mechanism can be
provided on the exterior of the base 14. In another variation, the suction
nozzle height
adjustment mechanism can be eliminated.
[0037] In operation, the vacuum cleaner 10 draws in debris-laden air
through the base
14 and into the collection system 18 where the debris, which can include, but
is not
limited to, dirt, dust, hair, and other debris, is substantially separated
from the working air
flow, which is generated by the motor/fan assembly 36. The spinning motor
shaft 46 of
the motor/fan assembly 36 rotates the brushroll 60 via the drive belt 48 that
is operably
connected therebetween. Alternatively, a separate, dedicated agitator drive
motor can
rotate the brushroll 60. As the brushroll 60 rotates, the bristles sweep
across the surface to
be cleaned to release and propel debris into the working air flow generated by
the
motor/fan assembly 36, which carries the debris into the collection system 18.
The
working air flow then passes through the motor cavity 30 and past the
motor/fan
assembly 36 prior to being exhausted from the vacuum cleaner 10. The
collection system
18 can be periodically emptied of debris.
[0038] FIG. 4 is a perspective view of the brushroll 60. The brushroll 60
includes a
brush dowel 62 configured to be mounted for rotation about a central
rotational axis X
extending longitudinally through the dowel 62. The brush dowel 62 is mounted
on an
elongated shaft 64 that extends through the center of the dowel 62 and defines
the central
rotational axis X around which the brushroll 60 rotates, The brushroll 60
illustrated is
configured to be rotationally driven in the direction indicated by arrow R. A
bearing 66 is
mounted on each end of the shaft 64. In operation, the dowel 62 rotates about
the shaft 64
on the bearings 66. A belt engagement surface 68 extends around the
circumference of
the dowel 62 near one end, and communicates with the belt 48 (FIG. 3). The
belt
engagement surface 68 may comprise a pulley.
[0039] The brush dowel 62 further includes one or more bristle supports 70
which
project into the dowel 62. Bristles 72 protrude from the bristle supports 70,
and can be
provided in a series of discrete tufts or in a continuous strip. The bristles
72 can be
arranged in various patterns on the dowel 62, including straight, angled,
helical, or
combinations thereof.
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[0040] The brushroll 60 is designed to prevent or greatly reduce the amount
of hair
wrap during operation by providing a shroud surface 74 for wrapping hair. The
shroud
surface 74 is provided adjacent to the bristles 72 in order to establish a
more shallow hair
wrap angle, as described in further detail below.
[0041] In the illustrated aspect, two bristle supports 70 and two
corresponding rows
of bristle tufts 76 are provided on the dowel 62, each tuft 76 containing a
plurality of
bristles 72, and extend in a generally helical pattern around the
circumference of the
dowel 62. The outer surface of the brush dowel 62 includes opposing curved
sections,
shown herein as convex curved surfaces 86, defining the shroud surface 74 and
opposing
flat sections defining mounting surfaces 78 of the bristle supports 70 from
which the tufts
76 project.
[0042] FIG. 5 is a cross section of the brushroll 60 taken through line V-V
of FIG. 4.
The brush dowel 62 can define a hollow interior 80 that extends along the
length of the
dowel 62. The shaft 64 is received within the hollow interior 80. The bristle
supports 70
further include bristle support platforms 82 which project from the mounting
surfaces 78
into the hollow interior 80 of the dowel 62. Bristle holes 84 for the bristle
tufts 76 can be
formed in the mounting surface 78 and can extend at least partially into the
platfoliiis 82.
[0043] In one non-limiting example, to produce the brushroll 60 shown in
FIG. 5, the
outer contour of the dowel 62 can be formed using a two-part mold, while the
interior of
the dowel 62, including the platforms 82, can be cored out using an unscrewing
core. It is
noted that, in order to form the brushroll 60 in a two-part mold, the bristle
supports 70
and shroud surfaces 74 may extend 180 degrees or less along the length of the
dowel 62
in order to be in the line of draw. The bristle holes 84 can be formed in the
dowel 62 by
drilling into the dowel 62 after molding, or can be integrally molded with the
dowel 62.
The bristle tufts 76 can be assembled with the dowel 62 by pressing bristles
72 into the
bristle holes 84 and securing the bristles 72 using a fastener (not shown),
such as, but not
limited to, a staple, wedge, or anchor. The dowel 62 can comprise a polymeric
material,
such as polypropylene, acrylonitrile butadiene styrene (ABS), or styrene. The
bristles 72
can comprise a polymeric material, such as nylon or polyester, for example,
which allows
the bristles 72 to flex and deflect when brought into contact with a surface
to be cleaned
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during normal operation. Other manufacturing methods can also be used to
produce the
brushroll 60 shown in FIG. 5.
[0044] As noted above, the brushroll 60 is designed to prevent or greatly
reduce the
amount of hair wrap during operation by providing the shroud surface 74 for
wrapping
hair. In the illustrated aspect, the brush dowel 62 defines a major diameter
D1, which is
the diameter defined by the smallest circle that can enclose the shroud
surface 74 of the
dowel 62. The bristle tufts 76 define a trim diameter D2, which is slightly
larger than the
major diameter Dl. The flat mounting surfaces 78 are recessed below the major
diameter
D1, and therefore below the shroud surface 74, which allows the bristles 72 on
the flat
mounting surfaces 78 to deflect when contacting the surface to be cleaned,
while keeping
any hair at or near the tip of the bristles 72. For example, the bristle
supports 70 define a
minor diameter D3 of the brush dowel 62. The minor diameter D3 can be defined
at the
tufting locations of the bristle tufts 76 in the bristle supports 70. The
minor diameter D3
can be less than the major diameter D1 and the trim diameter D2. In the
illustrated
example, the minor diameter D3 is the diameter defined by the smallest circle
that can
touch both mounting surfaces 78 of the bristle supports 70, at the tufting
locations of the
bristle tufts 76. Other configurations for a brushroll having bristle supports
70 and shroud
surface 74 may have major and minor diameters D1, D3 defined in other manners,
as
long as the shroud surface 74 defines D1 and the bristle supports 70 define
D3.
[0045] The outer surface of the brush dowel 62 shown in FIG. 5 further
includes
outside corners 88 where the convex curved surfaces 86 defining the shroud
surface 74
intersect the opposing flat sections defining mounting surfaces 78. The
outside corners 88
are where the two converging surfaces 78, 86 meet. Further, the brush dowel 62
shown in
FIG. 5 is symmetrical about multiple axes, including a first axis of symmetry
extending
generally along where the minor diameter D3 is defined, and second axis of
symmetry
that is orthogonal to the first axis of symmetry, generally where the trim
diameter D2 is
shown in FIG. 5.
[0046] FIGS. 6-7 show an exemplary operation of the brushroll 60. The
brushroll 60
is designed to have a hair wrap angle A2 that is less than or equal to the
deflection angle
Al (in other words, where A2 < Al). During operation, the brushroll 60 rotates
in
direction R and debris including, but not limited to, dirt, dust, and hair on
the surface to
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be cleaned is swept up by the brushroll 60. In the present example, for
purposes of simple
illustration, a single hair H on the surface is shown as being picked up by
the brushroll 60
in FIG. 6 by the bristle tuft 76 in contact with the surface. The bristle tuft
76 lifts the hair
H off the surface and around the dowel 62 as the brushroll 60 rotates. In some
cases, the
hair H may be pulled off the brushroll 60 by the suction force of the vacuum
cleaner. In
other cases, as the bristle tuft 76 holding the hair H continues along the
rotational path
determined by the dowel 62, the hair H can wrap around the shroud surface 74,
as shown
in FIG. 7, extending from the attachment point P to the bristle tuft 76 and
around the
dowel 62. Because the hair wrap angle A2 is more shallow, the hair H remains
at or near
the tip of the bristle tuft 76 and the hair H is not pulled toward the root of
the bristles 72,
nor does the hair H wrap tightly around the dowel 62. As the bristle tuft 76
holding the
hair H again comes into contact with the surface to be cleaned, the hair H can
be pulled
off the bristle tuft 76 by frictional contact with the surface to be cleaned
and the resulting
deflection of the bristle tuft 76. Though the hair H may be returned to the
surface, as the
vacuum cleaning operation continues, the same hair H may be picked up again by
the
brushroll 60 and pulled off the brushroll 60 by the suction force of the
vacuum cleaner. It
is also noted that the brushroll 60 may make one or more revolutions before
hair H is
pulled off the brushroll 60 by suction force or releasing hair back onto the
surface to be
cleaned.
[0047] In one example, the hair wrap angle A2 of the brushroll 60 can be
approximately half of the bristle deflection angle Al. Keeping the minor
diameter D3 less
than the major diameter D1 essentially pulls the bristle tips in closer to the
shroud surface
74, such that the trim diameter D2 remains slightly larger than the major
diameter D1,
and hair wrap can be prevented. If the hair wrap angle A2 becomes too shallow,
essentially by the major diameter D1 of the shroud surface 74 becoming larger
relative to
the trim diameter D2, the shroud surface 74 may prevent the bristle tufts 76
from
engaging the surface to be cleaned.
[0048] FIG. 8 is a perspective view of a brushroll 90 according to a second
aspect of
the present disclosure. The brushroll 90 can be used with the vacuum cleaner
10 of FIG.
3, as described above, or with other vacuum cleaners and accessory tools, and
is designed
to accommodate a secondary device for cutting wrapped hair. In one aspect, the
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secondary device includes scissors or another hand-held cutting implement. The
brushroll
90 includes a brush dowel 92 configured to be mounted for rotation about a
central
rotational axis X extending longitudinally through the dowel 92. The brush
dowel 92 is
mounted on an elongated shaft 94 that extends through the center of the dowel
92 and
defines the central rotational axis X around which the brushroll 90 rotates.
The brushroll
90 illustrated is configured to be rotationally driven in the direction
indicated by arrow R.
A bearing 96 is mounted on each end of the shaft 94. In operation, the dowel
92 rotates
about the shaft 94 on the bearings 96. A belt engagement surface 98 extends
around the
circumference of the dowel 92 near one end, and can communicate with a belt,
such as
belt 48 (FIG. 3). The belt engagement surface 98 may comprise a pulley.
[0049] The brush dowel 92 further includes a cylindrical core 100 and one
or more
bristle supports 102 projecting from the core 100. Bristles 104 protrude from
the bristle
supports 102, and can be provided in a series of discrete tufts or in a
continuous strip. The
bristles 104 can be arranged in various patterns on the dowel 92, including
straight,
angled, helical, or combinations thereof
[0050] The brushroll 90 is designed to accommodate a secondary device for
cutting
wrapped hair by providing at least one standing rib 106 adjacent to the
bristles 104 which
defines a channel 108 into which scissors or another cutting implement can be
inserted to
cut hair that is wrapped around the dowel 92.
[0051] In the illustrated aspect, two rows of bristle supports 102 and two
corresponding rows of bristle tufts 110, each tuft 110 containing a plurality
of bristles
104, are provided on the dowel 92. The rows extend in a generally helical
pattern around
the circumference of the dowel 92. Further, two opposing sets of standing ribs
106
project radially from the dowel 92, though only one set of visible in FIG. 8.
The ribs 106
can extend axially along the core 100 of the dowel 92 in one or more rows to
define the
channel 108. Alternatively, the channel 108 can be formed between one standing
rib 106
and the bristle support 102.
[0052] Circumferential gaps 112 can extend around the dowel 92 to separate
adjacent
bristle supports 102 and ribs 106, and further allow the rotating brushroll 90
to clear ribs
on the lower housing 34 that prevent carpet from getting drawn into the
suction nozzle
opening 42 (FIG. 4).
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[0053] FIG. 9 is a cross section of the brushroll 90 taken through line IX-
IX of FIG.
8. The brush dowel 92 can define a hollow interior 114 that extends along the
length of
the dowel 92. The shaft 94 is received within the hollow interior 114. Bristle
holes 116
for the bristle tufts 110 can be formed in the bristle supports 102.
[0054] In one non-limiting example, to produce the brushroll 90 shown in
FIG. 9, the
outer contour of the dowel 92, including the bristle supports 102 and the ribs
106, can be
formed using a two-part mold, while the interior of the dowel 92 can be cored
out using
an unscrewing core. The ribs 106 are oriented in the line of draw. The bristle
holes 116
can be formed in the dowel 92 by drilling into the dowel 92 after molding, or
can be
integrally molded with the dowel 92. The bristle tufts 110 can be assembled
with the
dowel 92 by pressing bristles 104 into the bristle holes 116 and securing the
bristles 104
using a fastener (not shown), such as, but not limited to, a staple, wedge, or
anchor. The
dowel 92 can comprise a polymeric material, such as polypropylene, ABS, or
styrene.
The bristles 104 can comprise a polymeric material, such as nylon or
polyester, for
example, which allows the bristles 104 to flex and deflect when brought into
contact with
a surface to be cleaned during normal operation. Other manufacturing methods
can also
be used to produce the brushroll 90 shown in FIG. 9.
[0055] During operation, the brushroll 90 rotates in direction R and debris
including,
but not limited to, dirt, dust, and hair on the surface to be cleaned is swept
up by the
brushroll 90. In some cases, hair can wrap around the dowel 92 rather than
being pulled
off the brushroll 90 by suction force of the vacuum cleaner. In this case,
scissors or
another cutting implement can be inserted into the channel 108 defined by the
ribs 106 to
cut that hair that is wrapped around the dowel 92.
[0056] In a further aspect, the height of the standing ribs 106 can be
increased so that
the outer perimeter defined by the top of the standing ribs 106 forms a shroud
surface to
minimize the hair wrap angle A2, as described for the first aspect.
[0057] It should be understood that the brushroll 60 of FIGS. 4-7 can
further be
designed to accommodate a secondary device, such as scissors or another hand-
held
cutting implement, for cutting wrapped hair in a manner similar to the
brushroll 90 of
FIGS. 8-9. In one aspect, ribs 106 and/or channel 108 can be provided in the
dowel 62.
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[0058] FIGS. 10-11 show a brushroll 120 according to a third aspect of the
present
disclosure. The brushroll 120 can be used with the vacuum cleaner 10 of FIG.
3, as
described above, or with other vacuum cleaners and accessory tools, and
differs from the
first aspect of the brushroll 60 by having concave, rather than flat, tufting
surfaces, as
described in further detail below.
[0059] The brushroll 120 includes a brush dowel 122 configured to be
mounted for
rotation about a central rotational axis X extending longitudinally through
the dowel 122.
The brush dowel 122 is mounted on an elongated shaft 124 that extends through
the
center of the dowel 122 and defines the central rotational axis X around which
the
brushroll 120 rotates. The brushroll 120 illustrated is configured to be
rotationally driven
in the direction indicated by arrow R. A bearing 126 is mounted on each end of
the shaft
124. In operation, the dowel 122 rotates about the shaft 124 on the bearings
126. A belt
engagement surface 128 extends around the circumference of the dowel 122 near
one
end, and can communicate with a belt, such as belt 48 (FIG. 3). The belt
engagement
surface 128 may comprise a pulley.
[0060] The brush dowel 122 further includes one or more bristle supports
130 which
project into the dowel 122. Bristles 132 protrude from the bristle supports
130, and can
be provided in a series of discrete tufts or in a continuous strip. The
bristles 132 can be
arranged in various patterns on the dowel 122, including straight, angled,
helical, or
combinations thereof.
[0061] The brushroll 120 is designed to prevent or greatly reduce the
amount of hair
wrap during operation by providing a shroud surface 134 for wrapping hair. The
shroud
surface 134 is provided adjacent to the bristles 132 in order to establish a
more shallow
hair wrap angle, the benefits of which are discussed above with respect to the
first aspect
of the brushroll 60.
[0062] In the illustrated aspect, two bristle supports 130 and two
corresponding rows
of bristle tufts 136 are provided on the dowel 122, each tuft 136 containing a
plurality of
bristles 132, and extend in a generally helical pattern around the
circumference of the
dowel 122. The overall outer surface of the brush dowel 122 includes opposing
convex
curved surfaces 138 which together define the shroud surface 134 and opposing
concave
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curved surfaces 140 defining mounting surfaces of the bristle supports 130
from which
the tufts 136 project.
[0063] FIG. 11 is a cross section of the brushroll 120 taken through line
XI-XI of
FIG. 10. The brush dowel 122 can define a hollow interior 142 that extends
along the
length of the dowel 122. The shaft 124 is received within the hollow interior
142. The
bristle supports 130 further include bristle support platforms 144 which
project from the
concave curved surfaces 140 into the hollow interior 142 of the dowel 122.
Bristle holes
146 for the bristle tufts 136 can be formed in the concave curved surfaces 140
and can
extend at least partially into the platforms 144.
[0064] In one non-limiting example, to produce the brushroll 120 shown in
FIGS. 10-
11, the outer contour of the dowel 122 can be formed using a two-part mold,
while the
interior of the dowel 122, including the platforms 144, can be cored out using
an
unscrewing core. It is noted that, in order to form the brushroll 120 in a two-
part mold,
the bristle supports 130 and shroud surfaces 134 may extend 180 degrees or
less along
the length of the dowel 122 in order to be in the line of draw. The bristle
holes 146 can be
formed in the dowel 122 by drilling into the dowel 122 after molding, or can
be integrally
molded with the dowel 122. The bristle tufts 136 can be assembled with the
dowel 122 by
pressing bristles 132 into the bristle holes 146 and securing the bristles 132
using a
fastener (not shown), such as, but not limited to, a staple, wedge, or anchor.
The dowel
122 can comprise a polymeric material, such as polypropylene, acrylonitrile
butadiene
styrene (ABS), or styrene, for example. The bristles 132 can comprise a
polymeric
material, such as nylon or polyester, for example, which allows the bristles
132 to flex
and deflect when brought into contact with a surface to be cleaned during
normal
operation. Other manufacturing methods can also be used to produce the
brushroll 120
shown in FIGS. 10-11.
[0065] The concave curved surfaces 140 intersect the convex shroud surfaces
138 at
outside corners 148 where the two converging surfaces 138, 140 meet. Further,
the brush
dowel 122 shown in FIG. 11 is symmetrical about multiple axes, including a
first axis of
symmetry extending generally along where the minor diameter D3 is defined, and
second
axis of symmetry that is orthogonal to the first axis of symmetry, generally
where the
trim diameter D2 is shown in FIG. 11.
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[0066] As noted above, the brushroll 120 is designed to prevent or greatly
reduce the
amount of hair wrap during operation by providing the shroud surface 134 for
wrapping
hair. For example, the concave curved surfaces 140 are recessed below the
major
diameter D1, and therefore below the shroud surface 134, which allows the
bristles 132
on the concave curved surfaces 140 to deflect when contacting the surface to
be cleaned,
while keeping any hair at or near the tip of the bristles 132.
[0067] In the illustrated aspect, the brushroll 120 further includes
bristle supports
130 that are defined by concave curved surfaces 140, rather than flat surfaces
78 as for
the first aspect of the brushroll 60 (FIG. 5). Having concave curved surfaces
140 defining
the tufting surfaces of the brushroll 120, i.e. the surfaces to which the
bristle tufts 136 are
mounted or secured, can offer improved hair wrap reduction. The concave curved
surfaces 140 intersect the convex shroud surfaces 138 at outside corners 148,
shown
herein as raised edges 148 which can prevent hair from being wedged at the
base of the
bristles tufts 136. With a flat mounting surface, hair may be pulled tight
across the
mounting surface and toward or to the base of the bristle tuft. However, with
the concave
curved surfaces 140 defining trough-shaped tufting surfaces prevent hair from
being
wedged at the base of the tufts 136 because the hair bridging the raised edges
148 create a
gap that spaces the hair from the base of the tufts 136. For the purposes of
this
description, the term concave curved surface refers to a surface that curves
inwardly
toward the central rotational axis X, forming a tufting surface that is
recessed from the
outside corners 148. Although the concave curved surfaces 140 are shown in the
figures
symmetric incurvate shapes, non-unifol in and non-symmetric inwardly curved
recesses
are also contemplated. Additionally, non-arcuate recesses are also
contemplated, such as
planar tufting surfaces or V-shaped tufting surfaces, which are recessed
inwardly toward
the central rotational axis X, for example.
[0068] The illustrated aspect of the brushroll 120 further has the bristle
tufts 136
positioned equidistant from the raised edges 148, and projecting radially from
the dowel
122 at a midpoint of the concave curved surfaces 140.
[0069] It should be understood that the brushroll 120 of FIGS. 10-11 can
further be
designed to accommodate a secondary device, such as scissors or another hand-
held
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cutting implement, for cutting wrapped hair in a manner similar to the
brushroll 90 of
FIGS. 8-9. In one aspect, ribs 106 and/or channel 108 can be provided in the
dowel 122.
[0070] FIGS. 12-13 show a brushroll 150 according to a fourth aspect of the
present
disclosure. The brushroll 150 can be used with the vacuum cleaner 10 of FIG.
3, as
described above, or with other vacuum cleaners and accessory tools, and
differs from the
third aspect of the brushroll 120 by having offset, swept bristle tufts that
are tufted at an
acute angle, as described in further detail below.
[0071] The brushroll 150 includes a brush dowel 152 configured to be
mounted for
rotation about a central rotational axis X extending longitudinally through
the dowel 152.
The brush dowel 152 is mounted on an elongated shaft 154 that extends through
the
center of the dowel 152 and defines the central rotational axis X around which
the
brushroll 150 rotates. The brushroll 150 illustrated is configured to be
rotationally driven
in the direction indicated by arrow R. A bearing 156 is mounted on each end of
the shaft
154. In operation, the dowel 152 rotates about the shaft 154 on the bearings
156. A belt
engagement surface (not shown) can extend around the circumference of the
dowel 152
and can communicate with a belt, such as belt 48 (FIG. 3).
[0072] The brush dowel 152 further includes one or more bristle supports
160 which
project into the dowel 152. Bristles 162 protrude from the bristle supports
160, and can
be provided in a series of discrete tufts or in a continuous strip. The
bristles 162 can be
arranged in various patterns on the dowel 152, including straight, angled,
helical, or
combinations thereof.
[0073] The brushroll 150 is designed to prevent or greatly reduce the
amount of hair
wrap during operation by providing a shroud surface 164 for wrapping hair. The
shroud
surface 164 is provided adjacent to the bristles 162 in order to establish a
more shallow
hair wrap angle, the benefits of which are discussed above with respect to the
first aspect
of the brushroll 60.
[0074] 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 extend in a generally helical pattern around the
circumference of the
dowel 152. The overall outer surface of the brush dowel 152 includes opposing
convex
curved surfaces 168 which together define the shroud surface 164 and opposing
concave
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curved surfaces 170 defining mounting surfaces of the bristle supports 160
from which
the tufts 166 project.
[0075] FIG.
13 is a cross section of the brushroll 150 taken through line XIII-XIII of
FIG. 12. The brush dowel 152 can define a hollow interior 172 that extends
along the
length of the dowel 152. The shaft 154 is received within the hollow interior
172. Bristle
holes 176 for the bristle tufts 166 can be formed in the concave curved
surfaces 170.
[0076] In
one non-limiting example, to produce the brushroll 150 shown in FIGS. 12-
13, the outer contour of the dowel 152 can be formed using a two-part mold,
while the
interior of the dowel 152 can be cored out using an unscrewing core. It is
noted that, in
order to form the brushroll 150 in a two-part mold, the bristle supports 160
and shroud
surfaces 164 may extend 180 degrees or less along the length of the dowel 152
in order to
be in the line of draw. The bristle holes 176 can be formed in the dowel 152
by drilling
into the dowel 152 after molding, or can be integrally molded with the dowel
152. The
bristle tufts 166 can be assembled with the dowel 152 by pressing bristles 162
into the
bristle holes 176 and securing the bristles 162 using a fastener (not shown),
such as, but
not limited to, a staple, wedge, or anchor. The dowel 152 can comprise a
polymeric
material, such as polypropylene, acrylonitrile butadiene styrene (ABS), or
styrene. The
bristles 162 can comprise a polymeric material, such as nylon or polyester,
for example,
which allows the bristles 162 to flex and deflect when brought into contact
with a surface
to be cleaned during normal operation. Other manufacturing methods can also be
used to
produce the brushroll 150 shown in FIGS. 12-13.
[0077] As
noted above, the brushroll 150 is designed to prevent or greatly reduce the
amount of hair wrap during operation by providing the shroud surface 164 for
wrapping
hair. For example, the concave curved surfaces 170 are recessed below the
major
diameter D1, and therefore below the shroud surface 164, which allows the
bristles 162
on the concave curved surfaces 170 to deflect when contacting the surface to
be cleaned,
while keeping any hair at or near the tip of the bristles 162.
[0078] In
the illustrated aspect, the brushroll 150 further includes bristle supports
160
that are defined by concave curved surfaces 170 which intersect the convex
shroud
surfaces 168 at outside corners 178 where the two converging surfaces 168, 170
meet.
The outside corners 178 are shown herein as raised edges 178, the benefits of
which are
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discussed above with respect to the third aspect of the brushroll 120. Still
further in the
illustrated aspect, the brushroll 150 includes bristle tufts 166 that are
tufted at an acute
angle relative to the concave tufting surfaces 170, i.e. the tufting surfaces
to which the
bristle tufts 166 are mounted or secured, rather than radially 78 as for the
third aspect of
the brushroll 120 (FIG. 11). In particular, the tufts 166 define and lie on a
centerline axis
180 extending orthogonally through the center of the tufts 166 and the concave
tufting
surfaces 170 define a centerline axis 182 extending orthogonally through the
center of the
concave tufting surfaces 170, and the axes 180, 182 intersect outward of the
dowel 152 at
an acute angle 184. This provides a swept or angled tip or terminal end 186
for each tuft
166 that is angled in the direction of rotation R.
[0079] Further, the bristle tufts 166 are offset on the concave tufting
surface 170, i.e.
tufted closer to one edge 178 than the other, or non-equidistant, or offset
from the
centerline axis 182, rather than being at the center of the concave tufting
surface as for
the third aspect of the brushroll 120 (FIG. 11) or equidistant from the raised
edges 148.
The offset, angled tufts 166 reduce the drive torque required to rotate the
brushroll 150,
which can be useful for particular vacuum cleaner aspects, including
autonomous or
robotic vacuum cleaners. Although the bristle tufts 166 in FIGS. 12-13 are
shown as both
offset from the centerline axis 182, and angled relative to the concave
tufting surface,
other configurations are contemplated. For example, the bristle tufts 166 can
be offset,
but not angled, i.e. oriented parallel to the centerline axis 182.
Alternatively, the bristle
tufts 166 can be tufted at the centerline axis 182, i.e. not offset, but
angled relative to the
centerline axis instead of radial thereto as in FIGS. 10-11.
[0080] It should be understood that the brushroll 150 of FIGS. 12-13 can
further be
designed to accommodate a secondary device, such as scissors or another hand-
held
cutting implement, for cutting wrapped hair in a manner similar to the
brushroll 90 of
FIGS. 8-9. In one aspect, ribs 106 and/or channel 108 can be provided in the
dowel 152.
[0081] While the brushrolls 60, 90, 120, 150 are described herein as being
rotatably
driven by a motor, it is understood that the brushroll 60, 90, 120, 150 can be
driven by
other means, such as, but not limited to, a turbine fan or a mechanical gear
train.
[0082] The vacuum cleaner 10 and various brushrolls 60, 90, 120, 150
disclosed
herein provide an improved brushroll design which addresses the problem of
hair wrap
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Aspects of the present disclosure include brushroll designs in which the hair
wrap angle
A2 is less than or equal to the deflection angle Al (in other words, where A2
< A1). Such
brushrolls release hair that is not pulled off the brushroll by the suction
force of the
vacuum cleaner back on to the surface to be cleaned, rather than tightly
wrapping the hair
on the brushroll. These brushrolls provide the opportunity to prevent or
greatly reduce the
amount of hair wrap during operation. Other aspects of the present disclosure
include
brushroll designs in which hair can easily be cut off the brushroll.
[0083] While
the aspects of the present disclosure have been specifically described in
connection with certain specific aspects thereof, it is to be understood that
this is by way
of illustration and not of limitation. Reasonable variation and modification
are possible
with the scope of the foregoing disclosure and drawings without departing from
the spirit
of the present disclosure which, is defined in the appended 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.
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