Bladed disk brush roller assembly for a vacuum cleaner

Abstract

A brush roller assembly for a vacuum cleaner includes a spindle rotatable within a vacuum cleaner housing. A first airflow enhancing device (AED) may be attached to the first end of the spindle. When rotated, the spindle may increase the flow of air from the end of the spindle toward the central portion of the spindle and thereby improve the vacuum cleaner's edge cleaning capability.

Description

This application is a continuation-in-part application claiming priority from utility patent application Ser. No. 10/222,673, filed on Aug. 16, 2002, now U.S. Pat. No. ______ which is incorporated herein by reference.

I. BACKGROUND OF THE INVENTION

A. Field of Invention

The present invention relates generally to new and novel improvements in a bladed disk brush roller assembly for a vacuum cleaner. More particularly, the present invention relates to methods and apparatuses related to a brush roller assembly for a vacuum cleaner that generates direct and/or indirect force that moves air and debris, such as dirt and dust, away from the ends of the spindle and toward the middle of the spindle where it is removed by the suction of the vacuum cleaner.

B. Description of Related Art

Brush roller assemblies for vacuum cleaners are well known and have been described in numerous references, including a number of issued United States patents. A typical brush roller assembly includes a rotatably mounted and motor driven spindle having a brush on a cylindrical or non-cylindrical outer surface thereof and a non-rotatable mounting structure at each end to mount the brush roller assembly to a vacuum cleaner housing. While the mounting structure may vary considerably, one type of known mounting structure includes end assemblies at each end of the spindle, the end assemblies including a rotatable stub shaft, a bearing and an end cap member which is fixedly secured to the vacuum cleaner housing.

Certain problems are known to exist with known prior art brush roller assemblies for vacuum cleaners. In particular, debris, such as dirt and dust, tends to collect in such known prior art brush roller assemblies. Further discussion of this problem is commonly owned U.S. Pat. No. 6,314,611 which is incorporated herein by reference. This debris collection problem is thought to be due, at least in part, to the lack of movement of air from the ends of the brush roller assembly to the central portion of the brush roller assembly where debris, such as dirt and dust, can be removed from the brush roller assembly by the vacuum of the vacuum cleaner.

II. SUMMARY OF THE INVENTION

According to one embodiment of this invention, a vacuum cleaner includes a housing having a top, a bottom and first and second side walls. An intake aperture is provided in the bottom of the housing and first and second openings are provided in the first and second side walls, respectively. A drive motor may be supported to the housing. The vacuum cleaner may also include: (a) a spindle operatively connected to the drive motor and selectively rotatable within the housing, the spindle having a central portion and first and second ends juxtaposed to the first and second openings in the housing, respectively; (b) a first airflow enhancing device positioned on the first end of the spindle, the first airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the intake aperture and first opening to the central portion of the spindle; and, (c) a second airflow enhancing device positioned on the second end of the spindle, the second airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the intake aperture and second opening to the central portion of the spindle.

According to another embodiment of this invention, the spindle may have pins extending from the spindle ends. The pins may be adapted to be rotatably received by the housing and to be received by holes formed in the first and second airflow enhancing devices.

According to another embodiment of this invention, the spindle may have first and second recesses formed in the first and second ends of the spindle. At least a portion of the first and second airflow enhancing devices may be positioned within the first and second recesses.

According to another embodiment of this invention, the spindle may have a driven pulley adapted to engage a belt driven by the drive motor.

According to another embodiment of this invention, first and second adjustment mechanisms may be used to adjust the size of the first and second openings, respectively.

According to another embodiment of this invention, a device may include: (a) a spindle having first and second ends and a central portion, the spindle is adapted to be driven by a vacuum cleaner motor and rotated within a vacuum cleaner housing; and, (b) first and second airflow enhancing devices fixed on the first and second ends, respectively, of the spindle. The first and second airflow enhancing devices may be selectively rotatable by the spindle to increase the flow of air from the first and second ends of the spindle to the central portion of the spindle.

According to another embodiment of this invention, a method may include the following steps: (a) providing a vacuum cleaner comprising: (1) a housing having an intake aperture and a first opening; and, (2) a drive motor; (b) providing a device comprising a spindle operatively connected to the drive motor and selectively rotatable within the housing, the spindle having a central portion and a first end juxtaposed to the first opening in the housing; and, (c) operating the drive motor to rotate the spindle thereby drawing air through the first opening and along the longitudinal axis of the spindle from the first end toward the central portion.

According to another embodiment of this invention, prior to the step of, operating the drive motor to rotate the spindle, the method comprises the step of adjusting the size of the first opening.

Other advantages and novel features of the present invention will become apparent in the following detailed description of the invention when considered in conjunction with the accompanying drawings.

III. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective side view of a vacuum cleaner than may use one or more of the various brush roller assemblies of this invention.

FIG. 2 is a schematic representation showing how the spindle of this invention may be driven by a motor.

FIG. 3 is a perspective view of an AED brush roller assembly for a vacuum cleaner in accordance with one embodiment of the present invention.

FIG. 4 is a perspective view of an AED brush roller assembly for a vacuum cleaner in accordance with another embodiment of the present invention.

FIG. 5 is a perspective assembly view of one end of the AED brush roller assembly embodiment shown in FIG. 3.

FIG. 6 is a perspective assembly view of the end of the AED brush roller assembly embodiment shown in FIG. 5 but shown from the opposite side.

FIG. 7 is a perspective view of one housing embodiment.

FIG. 8 is a perspective view showing how the spindle may be positioned within the housing.

FIG. 9 is a perspective view showing how debris may be vacuumed into the housing.

FIG. 10 is an enlarged perspective view of one end of the spindle embodiment shown in FIG. 3.

FIG. 11 is an enlarged perspective view of one end of the spindle embodiment shown in FIG. 4.

FIG. 12 is a perspective view showing the direction of airflow for one embodiment of this invention.

FIG. 13 is a perspective view showing the direction of airflow for another embodiment of this invention.

FIG. 14 is a perspective view showing the direction of airflow for still another embodiment of this invention.

FIG. 15 is a perspective view showing the direction of airflow for yet another embodiment of this invention.

FIG. 16 is an exploded perspective view of another embodiment of the present invention showing an adjustment mechanism used to adjust the size of the openings in the sidewalls of the housing.

FIG. 17 is a side view of the adjustment mechanism shown in FIG. 16 with the openings uncovered to permit airflow into the housing.

FIG. 18 is a side view of the adjustment mechanism shown in FIG. 16 similar to that shown in FIG. 17 but with the openings covered to prevent airflow into the housing.

FIG. 19 is a perspective view of a modified end cap attached to a housing.

FIG. 20 is an exploded bottom cut-away view of the end cap shown in FIG. 19.

FIG. 21 is an exploded cut-away front elevation view of the end cap shown in FIG. 19.

FIG. 22 is an exploded bottom perspective view of the end cap attached to the housing.

FIG. 23 is a perspective view of another embodiment brush roller assembly.

FIG. 24 is a perspective assembly view of one end of the brush roller assembly embodiment shown in FIG. 23.

FIG. 25 is a perspective assembly view of the end of the brush roller assembly embodiment shown in FIG. 24 but from the opposite side.

FIG. 26 is a top plan view of the testing pattern that may be used with the embodiments shown in FIGS. 19-25.

IV. DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings wherein the showings are for purposes of illustrating one or more embodiments of the invention only and not for purposes of limiting the same, FIG. 1 shows a vacuum cleaner 1 that may use the brush roller assembly 10 of this invention. The vacuum cleaner 1 shown is of the type known to those of skill in the art as an upright vacuum cleaner. However, it is to be understood that the brush roller assembly 10 of this invention may work equally well with canister type vacuum cleaners, as the end or wand portion of a vacuum cleaner, with wet/dry vacuum cleaners, and with other vacuum cleaners as well. The vacuum cleaner may include a cleaner main body or housing 40, a handle 2, and a dust collector 3. The handle 2 may be pivoted to a rear portion of the main body 40. The dust collector 3 shown is in the form of a bag and communicates at its lower end with the interior of the housing 40. The brush roller assembly 10 is positioned within the housing 40 as will be described in more detail below.

With reference now to FIGS. 1-2, the housing 40 may have an intake aperture A formed in the front portion of the bottom of the housing 40. One or more floor engaging wheels 4 may support the housing 40 for easy movement of the vacuum cleaner 1. The dust collector 3 may be connected to the opposite end of the housing 40, as shown. A motor 6 may be supported to the housing 40 in any conventional manner and may serve as a fan motor to provide vacuum suction as is well known in the art. The motor 6 may also serve as a drive motor for the brush roller assembly 10. In another embodiment, the brush roller assembly 10 is driven by a motor with a sole purpose of driving the brush roller assembly 10 while the fan is driven by a separate motor with a sole purpose of driving the fan. A belt 8 for transmitting a drive force to the brush roller assembly 10 couples a drive pulley 5 and a driven pulley 1 1 defined on a spindle 12. The particular designs for the drive and driven pulleys 5, 11 can be of any design chosen with sound engineering judgment. Thus, as non-limiting examples: either or both pulleys 5, 11 may have a frustoconical shape; either or both pulleys 5, 11 may have a constant diameter; both pulleys 5, 11 may have the same diameter; the pulleys 5, 11 may have different diameters thereby providing a gear reduction or gear increase design; etc. It should be noted that the particular position of the driven pulley 11 along the axis of the spindle can be any location chosen with sound engineering judgment. It should also be noted that the driven pulley 11 is not shown in the remaining drawings for purposes of clarity. With the vacuum cleaner 1 thus constructed, the motor 6, when operated, rotates the fan and rotates the spindle 12 of the brush roller assembly 10 within the housing 40, whereby dust is removed from a carpet or floor surface and then drawn into the dust collector 3.

With reference now to FIGS. 3-6, in general the brush roller assembly 10 of this invention provides at least one embodiment of an airflow enhancing device (AED). The AED may take any of a number of embodiments that include, but are note limited to, bladed disks, fans, impellers, and other mechanical structures that increase airflow. The brush roller assembly 10 may include the spindle 12 that may have a generally cylindrical configuration and may have at least one brush 14 extending from the outer surface of the spindle 12, as shown. The particular spindle 12 design can vary according to sound engineering judgment. Thus, for example, the spindle 12 may have any geometric shape, including the alternate embodiments shown in FIGS. 3 and 4. The spindle 12 may have two (2) end portions 16, of which only one (1) is shown in FIGS. 5 and 6, and a central portion 18. The spindle 12 may have a recess 20 in each end portion 16 and opening 22 that removably receives outwardly extending pin 24. The spindle 12 is preferably fabricated from wood, although, if desired, a plastic material or some other material may alternatively be used. The pin 24 is may be fabricated from steel, although, if desired, some other material may be used. The brush roller assembly 10 also may include two (2) bearings 26 that may be positioned in a central portion 30 of each AED 28, as shown. Each pin 24 may be received with one bearing 26 and within a hole 29 formed in each AED 28, as shown, to facilitate the rotation of the spindle 12 with respect to the housing 40.

With continuing reference to FIGS. 3-6, the brush roller assembly 10 may also include two (2) AEDs 28 positioned on each end portion 16 of the spindle 12. It should be noted that the AEDs 28 may be attached at any location along the spindle 12 chosen with sound engineering judgment. Each AED 28 may include a central portion 30 which is positioned substantially perpendicular to the longitudinal axis of the spindle 12 when the AED 28 is placed on the end portion 16 of the spindle 12. At least one fan blade projection 32 may extend outwardly from the periphery of the central portion 30. More specifically, the periphery may define a lip 31 extending from the central portion 30, where the lip has a first side 31a adjacently 30 located to the central portion and a second side 31b, which is distally located from the first side 31a. The one or more fan blade projections 32 of the AEDs 28 are preferably oriented at an angle relative to central portion 30 of the AEDs 28 to facilitate the movement of outside air from end portions 16 of the spindle 12 toward central portion 18 of the spindle 12 where outside air, as well as any debris 70, such as dirt and dust, carried with the outside air, is removed from the brush roller assembly 10 by the airflow of the vacuum cleaner. Each blade projection 32 has a top 54 and a bottom 56. Further each blade 32 has a first face 58, which is flush with the second side 32b of the lip 31. Each blade 32 also has a second face 60, which may extend approximately midway across the lip 31. The angle of one or more fan blade projections 32 of AEDs 28 relative to central portion 30 of AEDs 28 is preferably in the range of zero (0) to ninety (90) degrees and is most preferably approximately twenty (20) degrees. Each blade projection 32 may have substantially the same cross sectional shape from the top 54 of the blade 32 to the bottom 56 of the blade 32. The angle of the top 54 and bottom 56 of the blade projections 32 relative to the central portion 30 may be equal. The AEDs 28 are preferably fabricated from a plastic material, or alternatively, are fabricated as sheet metal stampings, although, if desired, other materials may be used.

Still referring to FIGS. 3-6, the brush roller assembly 10 may also include two (2) end caps 34 attached to the bearings 26 in such a manner as to permit rotation of spindle 12 and the AEDs 28. Each end cap 34 preferably includes at least one opening, and more preferably a plurality of openings 36 elongated in a radial direction and positioned in a circular configuration approximately corresponding to the position of the one or more fan blade projections 32 on the AEDs 28. This positioning of the openings 36 facilitates the movement of outside air from the end portions 16 of the spindle 12 toward central portion 18 of the spindle 12. Thus, any debris 70 (FIG. 7) such as dirt and dust carried with the outside air, is removed by the airflow created by the vacuum cleaner 1 and the brush roller assembly 10. End caps 34 preferably include recess 38 and AEDs 28 are preferably positioned, at least in part, within recess 38 of end caps 34. In addition, a portion of central portion 30 of the AEDs 28 may be positioned in recess 20 in end portions 16 of spindle 12. The AED 28 may be operationally connected in a variety of ways, including but not limited to, insertion in recess 20, screwed onto the brush roller assembly 10 and/or molded into the brush roller assembly 10. End caps 34 are preferably fabricated from a plastic material, although, if desired, other materials may be used to fabricate end caps 34. In addition, if desired, spindle 12 and AEDs 28 could be fabricated as an integral integrated assembly.

With reference now to FIGS. 7-18, several alternative embodiments of the present invention will now be described. It should be understood that the end caps 34 previously described may be utilized in connection with the embodiments described below if desired. The housing 40 may have a top 42, a bottom 44 and a pair of sidewalls 46. The housing 40 may also have at least a first opening 48 in sidewall 46a and a second opening 50 in sidewall 46b. The first end 16a of the spindle 12 is laterally spaced from the first opening 48, and the second end 16b of the spindle 12 is laterally spaced from the second opening 50. As such, air is adapted to enter the housing through the first and second openings 48, 50 and travel along the longitudinal axis towards the central portion 18 of the spindle 12 so as to increase airflow and aid in the removal of debris 70, which is best seen in FIG. 12. It should be noted that the air entering the first and second openings 48, 50 will generally be clean, meaning substantially uncontaminated by debris 70. Airflow through the first and second openings 48, 50, may alternately be redirected to collect debris near the sidewalls 46 and the bottom 44, and the debris is conveyed to the central portion 18, thus, enhancing edge cleaning.

With reference now to FIGS. 12 and 13, another embodiment of the present invention is shown. In this embodiment, the bottom 44 of the housing 40 has one or more openings or apertures 52 in addition to the primary intake aperture A. Although not required, it is preferred that the openings 52 in the bottom 44 of the housing 40 be positioned in close proximity to the sidewalls 46. With this configuration, air enters through the bottom apertures 52 outboard of the AEDs 28 and travels along the longitudinal axis of the spindle 12 to the central portion 18. Air entering the housing 40 from the bottom aperture 52 will most likely be contaminated with debris 70. In this embodiment, the sidewalls 46a, 46b, may have the first and second openings 48, 50 to simultaneously draw in clean air 72 during operation. Further, this embodiment may utilize the AED 28 as previously described or no AED. Edge cleaning is also enhanced in this embodiment.

FIG. 14 shows yet another embodiment of the present invention. In this embodiment the first and second openings 48, 50 are completely open, meaning there are no subdivisions as shown in FIG. 7. Further, there are no obstructions, such as a brush, between the sidewall openings 48, 50 and the ends 16 of the spindle 12. Air entering the housing enters the openings 48, 50 and flows directly to an area in close proximity to one of the corresponding end 16a, 16b, of the spindle 12 toward the central portion 18. In this configuration, airflow input is greatly enhanced.

With reference to FIG. 15, another embodiment of the present invention is illustrated. In this embodiment, an airflow adjustment mechanism 62 takes the form of a pressurization mechanism, such as but not limited to a pressurized fan. The airflow adjustment mechanism 62 is in airflow communication with one of the ends 16 of the spindle 12. The airflow adjustment mechanism 62 may be attached to the housing or the spindle 12 through any means known in the art. The forced airflow may utilize the normal exhaust from the main vacuum in combination with appropriate ducting (not shown). As with the other embodiments, this embodiment increases forced airflow from outside the housing, down the longitudinal axis of the spindle 12 towards the central portion 18.

FIGS. 16-18 show yet another embodiment of the present invention. In this embodiment the first and second openings 48, 50 are adjustable. An adjustment mechanism 100 is shown which varies the size of the openings 48, 50. The adjustment mechanism 100 may be any device, but not limited to a movable plate 102, as shown in FIG. 17. The movable plate 102 may be rotated to vary the size of the openings 48, 50. When the adjustment mechanism 100 is in a first position, as shown in FIG. 17, air entering the housing enters the openings 48, 50 and flows directly to an area in close proximity to one of the corresponding end 16a, 16b, of the spindle 12 toward the central portion 18. Whereas, when the adjust mechanism 100 is in a second position, as shown in FIG. 18, the openings 48, 50 are closed an air cannot pass through. The adjustment mechanism 100 may be moved to any position between completely open and completely closed in order vary and achieve the desired airflow.

FIGS. 19-25 illustrate yet another embodiment of the present invention. In this embodiment, a modified end cap 200 is utilized as the pressurization mechanism. “Pressurization mechanism” means any mechanical or electro-mechanical means operatively connected to the housing that increases or decreases pressure to affect vacuum performance. The pressurization mechanism may take the form of duct work. An example of such duct work is the modified end cap 200. More specifically, the vacuum cleaner includes the housing 40, as previously described. The housing 40 has a first sidewall 46a and a second sidewall 46b. The spindle 12 is positioned within the housing 40. The spindle 12 has a longitudinal axis, a first end 16a, a second end 16b and a central portion 18. The first end 16a is laterally spaced from the first sidewall 46a of the housing 40. The second end 16b is laterally spaced from the second sidewall 46b of the housing 40. The airflow enhancing device 28, such as a bladed disk discussed above, has a central portion which is positioned substantially perpendicular to the longitudinal axis of the spindle 12 when the airflow enhancing device 28 is placed on one of the ends of the spindle 12. The pressurization mechanism, such as the end cap 200, is operatively connected to the housing 40, wherein the pressurization mechanism is adapted to direct airflow from the bottom edge of the housing 40 to the airflow enhancing device 28 in order to improve edge cleaning. The housing 40 may comprise an opening in the first sidewall 46a and another opening in the second sidewall 46b to allow end caps 200 to extend outward beyond the sidewalls 46a, 46b.

The cap 200 may also include a body 202 operatively connected to the housing 40 through the first opening such that the first opening is substantially covered. Likewise, the body 202 of end cap 200 is also adapted to connect to the housing 40 through the second opening in the second sidewall 46b such that the second opening is substantially covered. The body 202 of the cap 200 further comprises a body having a top 240, sidewalls 242, an inner member 204 and an outer member 206, which defines a cavity therebetween. As shown in the FIGURES, the top 240 may be semi-circular in shape, but this is not required. Any shape may be chosen in accordance with sound engineering judgment as long as the openings in the sidewalls 46a, 46b are covered.

With continuing reference to FIGS. 19-25, the outer member 206 may be slightly longer than the inner member 204. The inner member 204 and outer member 206 each have a bottom edge 207, 208. The bottom edge 208 of the outer member 206 and a bottom edge of the housing define an inlet 210. The AED draws air through the inlet 210 causing pressure to decrease within the cavity 227 to increase a vacuum effect, which improves edge cleaning.

As shown in FIGS. 22-25, the inner member 204 of the body 202 is positioned within the housing 40. The bottom edge 207 of the inner member 204 may contact the bottom of the housing 40. The outer member 206 is positioned substantially outside the housing. This is enabled by a slot 225 defined in the sidewalls 242, which is adapted to receive a portion of the sidewalls 46a, 46b of the vacuum cleaner housing 40. In other words, the bottom edge of the sidewalls of the housing is adapted to fit in lower portions of the inner and outer members 204, 206. A plurality of lips 212 may be positioned about the circumference of the end cap 200. The lips 212 are utilized to secure the cap 200 to the vacuum housing 40. While lips are preferred, any other means of attachment may be utilized that is chosen with sound engineering judgment.

With reference to FIGS. 19-25, the body 202 further comprises a protruding flange member 214 that is operatively connected to an inner wall 216 of the outer member 206. The protruding flange member 214 may take any shape chosen in accordance with sound engineering judgment, but as shown in the present embodiment, it takes the form of an angular ring. The protruding flange member 214 is adapted to receive the airflow enhancing device 28. The airflow enhancing device 28 is adapted to rotate around the protruding flange member 214. The outer member 206 has an indentation 220. This aids in the attachment of the cap 200 to the housing 40. The indentation 220 is oppositely disposed from the protruding flange member 214. A bearing 26 is positioned between the airflow enhancing device 28 and the protruding flange member 214. A pin 24 is adapted to fit within an opening in the airflow enhancing device and the bearing 26. The pin 24 is connected to the spindle 28.

With continuing reference to FIGS. 19-25, the bottom 44 of the housing has an opening 230. Laterally spaced from the bottom opening 230 is the inlet 210. The inlet 210 and the bottom opening 230 each have a cross sectional area. The cross sectional area of the inlet 210 is less than the cross sectional area of the bottom opening 230. Because of the smaller cross sectional area of the inlet 210, airflow is increased, which acts on the airflow enhancing device 28 to improve edge cleaning.

FIG. 26 illustrates the testing path used for the vacuum cleaners. Testing occurred with this embodiment of the present invention to prove that improved edge cleaning 10 does occur with the above described configuration. Initial testing was performed to verify that two new unmodified vacuum cleaners were similar in performance. Testing consisted of normal ASTM F608-01 for general cleaning and a modified test designed for edge cleaning. Vacuums were labeled as A and B. Results indicated that these two vacuums were reasonably identical. Next, the vacuums were modified as follows. On both units, a standard brush roller, having a single row of bristles in a spiral pattern and opposing beater bars, was replaced with brush rollers with two rows of bristles in a chevron pattern and no beater bars. Unit B was also modified to include the end cap 200 described herein. The two units were then compared to determine the net effect of only the edge cleaning end cap 200. Test results were as follows:

	F608	Edge	Description
A	42.94%	21.75%	Modified Bristle Pattern
B	38.09%	23.88%	Modified Bristle Pattern, Turbo-Charged

The improved edge cleaning is about ten percent (10%). These results indicate an increase in edge cleanability but a decrease in general cleanability. The improved edge cleaning can be attributed to the edge cleaning concept but the decrease in general cleanability may be explained because the overall effective width of the model B is wider than the standard model A. The available suction airflow is distributed over a wider area. Performance may therefore be improved by either narrowing model B to be the same as model A, or by increasing the airflow proportionally in model B. In either event, the relative edge cleaning of a model with the end caps 200 should be superior to a standard model while maintaining comparable overall cleanability. Testing by Intertek ETL SEMKO, having its principal place of business at 3933 US Route 11, Cortland, N.Y. 13045, tested this embodiment of the invention on Apr. 13, 2004.

The test specimens supplied by the applicant were received assembled. Testing was performed using an ASTM approved plush carpet panel and standard test soil supplied by Intertek. All testing was performed in an environmentally controlled room maintained at 70+5° F. (21+3° C.) and 45% to 55% relative humidity. All components involved with the testing, except the test specimens and bags, were exposed in the controlled environment for a minimum of sixteen hours prior to testing. In order to provide a uniform basis for measuring the capability of the upright vacuum cleaner to remove household embedded dirt, standardized test soil was employed from Annex Al of the referenced specification. Carpet-embedded dirt removal effectiveness testing was conducted in accordance with Section 10 of ASTM F608-03 with client specified modifications. Two (2) runs were conducted on each sample.

To provide a basis for measuring the ability of a vacuum to clean along an edge, 20 grams of standard test soil (⅕th of ASMT F608 test load) was evenly spread in 1-inch strips along each inside edge of the test load application frame (test area) of an ASTM approved plush carpet segment. The strips of soil were 54-inches in length and stopped 2-inches from the front edge. The test area was isolated using a cardboard template supplied by the client. The frame was removed and two, (2) embedment strokes were applied to the soiled segment using the standard embedment tool at 4.8 ft/sec. The frame was then replaced in its original location, and the sample was operated 8 strokes at 4.8 ft/sec on each inside edge. Sample A was run a total of two times; sample B was run a total of four times (brush agitator was replaced after first two runs).

Specimen: (A & B)	Cleaner Height Adj. Setting: (‘1’ Lowest)	Carpet Under Test: (Plush)
	Voltage	Temp.	R.H.			Temp.	R.H.			Avg.
Test	and	Before	Before	Bag Weight	Carpet Weight	After	After	Delta	Delta	Percent
Sample-	Frequency	Test	Test	(grams)	(grams)	Test	Test	Bag	Carpet	Clean.
Run No.	(Vac/Hz)	(° F.)	(%)	Before	After	Before	After	(° F.)	(%)	(grams)	(grams)	(%)
A1	120/60	71.3	53.8	41.03	85.61	4001.00	4059.68	69.7	54.3	44.58	58.68	42.94
A2	120/60	69.8	54.1	40.98	82.28	3999.81	4057.48	72.1	50.5	41.3	57.67
Delta Bag Range = 44.58 − 41.30 = 3.28 grams
B1	120/60	69.1	54.4	40.98	80.73	4002.06	4063.96	68.4	56.5	39.75	61.9	38.09
B2	120/60	68.3	48.0	41.23	77.66	4000.74	4062.30	68.7	50.9	36.43	61.56
Delta Bag Range = 39.75 − 36.43 = 3.32 grams
Legend:
Sample “A” - Model A
Sample “B” - Model A with inventive end cap

Specimen: (A & B)	Cleaner Height Adj. Setting: (‘1’ Lowest)	Carpet Under Test: (Plush)
	Voltage	Temp.	R.H.			Temp.	R.H.			Avg.
Test	and	Before	Before	Bag Weight	Carpet Weight	After	After	Delta	Delta	Percent
Sample-	Frequency	Test	Test	(grams)	(grams)	Test	Test	Bag	Carpet	Clean.
Run No.	(Vac/Hz)	(° F.)	(%)	Before	After	Before	After	(° F.)	(%)	(grams)	(grams)	(%)
A1	120/60	74.1	45.8	41.04	63.40	3999.28	4016.60	72.7	46.5	22.36	17.32	21.75
A2	120/60	73.5	51.5	40.84	61.98	3996.91	4015.26	73.9	49.5	21.14	18.35
Delta Bag Range = 22.36 − 21.14 = 1.22 grams
B1	120/60	73.9	49.3	40.88	64.44	3996.49	4012.99	71.9	50.1	23.56	16.50	23.88
B2	120/60	72.1	53.3	40.98	65.17	3997.03	4013.77	73.7	52.7	24.19	16.74
Delta Bag Range = 24.19 − 23.56 = 0.63 grams
BB1	120/60	73.8	49.4	40.73	63.83	3996.27	4013.12	73.9	51.8	23.10	16.85	23.07
BB2	120/60	74.5	48.6	40.74	63.77	3995.10	4011.98	73.7	52.3	23.03	16.88
Delta Bag Range = 23.10 − 23.03 = 0.07 grams
Legend:
Sample “A” - Model A
Sample “B” - Model A with Inventive End Cap
Sample “BB” - Model A with Inventive End Cap & Replacement Brush Agitator

In order to utilize the present invention, the following steps are taken. The embodiment herein described and shown in FIGS. 19-25 is provided. The pressurization mechanism is operatively connected to the housing. A vacuum is created within the housing. Airflow is directed through the opening in the bottom. Increased air flow occurs through the inlet by the airflow enhancing means and the pressurization mechanism. The debris is cleaned at an edge of a cleaning path of the vacuum cleaner. The step of increasing airflow through the inlet by the airflow enhancing means further comprises the steps of directing air through the inlet, decreasing pressure within the cavity of the cap, and increasing the vacuum effect within the cavity of the cap. By following this method, improved edge cleaning occurs with the vacuum cleaner.

Accordingly, although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. It is apparent to those having a level of ordinary skill in the relevant art that other variations and modifications in the brush roller assembly for a vacuum cleaner in accordance with the present invention, as described and shown herein, could be readily made using the teachings of the present invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims.

Claims

1. A vacuum cleaner comprising:

a housing having a top, a bottom and first and second side walls, an intake aperture is provided in the bottom of the housing, first and second openings are provided in the first and second side walls, respectively;

a drive motor supported to the housing; and,

a device comprising: (a) a spindle operatively connected to the drive motor and selectively rotatable within the housing, the spindle having a central portion and first and second ends juxtaposed to the first and second openings in the housing, respectively; (b) a first airflow enhancing device positioned on the first end of the spindle, the first airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the intake aperture and first opening to the central portion of the spindle; and, (c) a second airflow enhancing device positioned on the second end of the spindle, the second airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the intake aperture and second opening to the central portion of the spindle.

2. The vacuum cleaner of claim 1 wherein:

the spindle comprises first and second pins extending from the first and second ends of the spindle, respectively, the first and second pins are adapted to be rotatably received by the housing; and,

the first and second airflow enhancing devices have first and second holes, respectively, that receive the first and second pins, respectively.

3. The vacuum cleaner of claim I wherein the spindle comprises:

first and second recesses formed in the first and second ends of the spindle, respectively, wherein at least a portion of the first and second airflow enhancing devices are positioned within the first and second recesses, respectively.

4. The vacuum cleaner of claim 1 wherein the spindle comprises:

a driven pulley adapted to engage a belt driven by the drive motor; and,

at least one brush extending from the outer surface of the spindle.

5. The vacuum cleaner of claim 1 wherein:

the housing has third and fourth openings provided in the bottom of the housing juxtaposed to the first and second ends of the spindle, respectively;

the first airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the third opening to the central portion of the spindle; and, the second airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the fourth opening to the central portion of the spindle.

6. The vacuum cleaner of claim 1 further comprising:

first and second adjustment mechanisms selectively adjustable to adjust the size of the first and second openings, respectively.

7. The vacuum cleaner of claim 6 wherein the first and second adjustment mechanisms are pressurization mechanisms.

8. A vacuum cleaner comprising:

a housing having an intake aperture and a first opening;

a drive motor; and,

an assembly comprising: (a) a spindle operatively connected to the drive motor and selectively rotatable within the housing, the spindle having a central portion and a first end juxtaposed to the first opening in the housing; and, (b) a first airflow enhancing device positioned on the first end of the spindle, the first airflow enhancing device is selectively rotatable by the spindle to increase the flow of air from the intake aperture and first opening to the central portion of the spindle.

9. The vacuum cleaner of claim 8 wherein the first airflow enhancing device comprises:

a central portion; and,

a plurality of blade projections extending from the central portion.

10. The vacuum cleaner of claim 8 wherein:

the spindle comprises a first pin extending from the first end of the spindle, the first pin is adapted to be rotatably received by the housing; and,

the first airflow enhancing device has a first hole that receive the first pin.

11. The vacuum cleaner of claim 8 wherein the spindle comprises:

a first recess formed in the first end of the spindle, wherein at least a portion of the first airflow enhancing device is positioned within the first recess.

12. The vacuum cleaner of claim 8 wherein the spindle comprises:

a driven pulley adapted to engage a belt driven by the drive motor; and,

at least one brush extending from the outer surface of the spindle.

13. The vacuum cleaner of claim 8 further comprising:

an adjustment mechanism selectively adjustable to adjust the size of the first opening.

14. The vacuum cleaner of claim 13 wherein the adjustment mechanism is a pressurization mechanism.

15. The vacuum cleaner of claim 13 wherein the adjustment mechanism comprises:

a plate rotatably attached to the housing.

16. A device comprising:

a spindle having first and second ends and a central portion, the spindle is adapted to be driven by a vacuum cleaner motor and rotated within a vacuum cleaner housing; and,

first and second airflow enhancing devices fixed on the first and second ends, respectively, of the spindle, the first and second airflow enhancing devices are selectively rotatable by the spindle to increase the flow of air from the first and second ends of the spindle to the central portion of the spindle.

17. The device of claim 16 wherein the spindle comprises:

at least one brush extending from the outer surface of the spindle.

18. The device of claim 16 wherein:

the spindle comprises first and second pins extending from the first and second ends of the spindle, respectively, the first and second pins are adapted to be rotatably received by the vacuum cleaner housing; and,

the first and second airflow enhancing devices have first and second holes, respectively, that receive the first and second pins, respectively.

19. The device of claim 16 wherein the spindle comprises:

first and second recesses formed in the first and second ends of the spindle, respectively, wherein at least a portion of the first and second airflow enhancing devices are positioned with the first and second recesses, respectively.

20. The device of claim 16 wherein the first and second airflow enhancing devices are screwed on to the spindle.

21. The device of claim 16 wherein the first and second airflow enhancing devices are molded into the spindle.

22. The device of claim 16 wherein the first and second airflow enhancing devices and the spindle are fabricated as an integrated assembly.

23. The device of claim 16 wherein the spindle comprises:

a driven pulley adapted to engage a belt driven by the vacuum cleaner motor.

24. A method comprising the steps of:

providing a vacuum cleaner comprising: (1) a housing having an intake aperture and a first opening; and, (2) a drive motor;

providing a device comprising a spindle operatively connected to the drive motor and selectively rotatable within the housing, the spindle having a central portion and a first end juxtaposed to the first opening in the housing; and,

operating the drive motor to rotate the spindle thereby drawing air through the first opening and along the longitudinal axis of the spindle from the first end toward the central portion.

25. The method of claim 24 wherein prior to the step of, operating the drive motor to rotate the spindle, the method comprises the step of:

adjusting the size of the first opening.

26. The method of claim 25 further comprising the steps of:

providing an adjustment mechanism comprising a plate rotatably attached to the housing; and,

wherein the step of, adjusting the size of the first opening, comprises the step of rotating the plate.

27. The method of claim 24 further comprising the steps of:

providing the housing with a top, a bottom and a side wall;

providing the intake aperture in the bottom of the housing and the first opening in the side wall;

providing a second opening in the bottom of the housing juxtaposed to the first end of the spindle;

wherein the step of, operating the drive motor to rotate the spindle, comprises the step of drawing air through the second opening and along the longitudinal axis of the spindle from the first end toward the central portion.

28. The method of claim 24 further comprising the steps of:

providing the housing with a top, a bottom and first and second side walls;

providing the intake aperture in the bottom of the housing and the first opening in the first side wall;

providing the spindle with a second end;

providing a second opening in the second side wall juxtaposed to the second end of the spindle;

wherein the step of, operating the drive motor to rotate the spindle, comprises the step of drawing air through the second opening and along the longitudinal axis of the spindle from the second end toward the central portion.

29. The method of claim 24 further comprising the steps of:

providing an airflow enhancing device fixedly attached to the first end of the spindle; and,

wherein the step of, operating the drive motor to rotate the spindle, comprises the step of rotating the airflow enhancing device.