SURFACE CLEANER

Abstract

A surface cleaner including a cleaning head with a rotatable brushroll assembly. The cleaning head further includes a cutting member configured to cut debris from the brushroll assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International Patent Application No. PCT/US2022/031937, filed Jun. 2, 2022, which claims priority to U.S. Provisional Patent Application No. 63/195,945, filed Jun. 2, 2021, the entire contents of all which are hereby incorporated by reference herein.

FILED OF THE INVENTION

The present invention relates to surface cleaners including a brushroll assembly.

SUMMARY

The present invention relates to a surface cleaner. The cleaning head includes a housing including a brushroll chamber, a brushroll assembly, a suction inlet, a suction source, and a cutting member. The brushroll chamber has a front side, a rear side, an upper side, and a lower side with an opening adjacent a surface to be cleaned. The brushroll assembly is rotatably mounted in the brushroll chamber. The brushroll chamber includes one or more agitating members. The one or more agitating members are positioned to extend through the opening to agitate the surface to be cleaned. The suction inlet is positioned in the front side of the brushroll chamber and is in communication with a brushroll chamber outlet in the rear side of the brushroll chamber. The suction source is in fluid communication with the suction inlet and the brushroll chamber outlet for generating a working air flow through the housing. The cutting member extends from the rear side of the brushroll chamber toward the brushroll assembly. The cutting member extends parallel to the brushroll axis 100 and does not engage the one or more agitating members. The cutting member is positioned adjacent the brushroll chamber outlet and is configured to cut debris off the brushroll assembly to facilitate debris intake through the brushroll chamber outlet.

In another embodiment, the surface cleaner includes a housing including a brushroll chamber, a brushroll assembly, a suction inlet, a suction source, and a cutting member. The brushroll chamber has a front side, a rear side, an upper side, and a lower side with an opening adjacent a surface to be cleaned. The brushroll assembly is rotatably mounted in the brushroll chamber. The brushroll assembly has a first agitating portion, a second agitating portion, and a track portion positioned between the first agitating portion and the second agitating portion. The first agitating portion and the second agitating portion extend through the opening to agitate the surface to be cleaned. The suction inlet is positioned in the front side of the brushroll chamber and is in communication with a brushroll chamber outlet in the rear side of the brushroll chamber. The suction source is in fluid communication with the suction inlet and the brushroll chamber outlet for generating a working air flow through the housing. The cutting member extends from the rear side of the brushroll chamber and includes a gear portion. The gear portion is positioned to engage the track portion. The cutting member is configured to inhibit debris wrap around the first agitating portion and the second agitating portion when the brushroll assembly rotates.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cleaning device or floor cleaner according to one embodiment of the invention.

FIG. 2 is a cross-section view of taken along line X of FIG. 1.

FIG. 2a is a front view of a cleaning head of FIG. 1, shown with an upper portion of a housing and a brushroll removed, according to one embodiment.

FIG. 2b is a detail view of the cutting member of FIG. 2a.

FIG. 3 is a cross-section view of taken along line X of FIG. 1.

FIG. 3a is a front view of a cleaning head of FIG. 1, shown with an upper portion of a housing and a brushroll removed, according to one embodiment.

FIG. 3b is a detail view of the cutting member of FIG. 3a.

FIG. 4 is a cross-section view of taken along line X of FIG. 1.

FIG. 4a is a front view of a cleaning head of FIG. 1, shown with an upper portion of a housing and a brushroll removed, according to one embodiment.

FIG. 4b is a detail view of the cutting member of FIG. 4a.

FIG. 5 is a cross-section view of taken along line X of FIG. 1.

FIG. 5a is a front view of a cleaning head of FIG. 1, shown with an upper portion of a housing and a brushroll removed, according to one embodiment.

FIG. 5b is a detail view of the cutting member of FIG. 5a.

FIG. 6 is a cross-section view of taken along line X of FIG. 1.

FIG. 6a is a front view of a cleaning head of FIG. 1, shown with an upper portion of a housing and a brushroll removed, according to one embodiment.

FIG. 6b is a detail view of the cutting member of FIG. 6a.

FIG. 7 is a cross-section view of taken along line X of FIG. 1.

FIG. 7a is a front view of a cleaning head of FIG. 1, shown with an upper portion of a housing and a brushroll removed, according to one embodiment.

FIG. 7b is a detail view of the cutting member of FIG. 7a.

FIG. 8 is a rear view of a cleaning head of FIG. 1, shown with a transparent housing, according to one embodiment.

FIG. 9 is a side view of the cleaning head shown in FIG. 8.

FIG. 10 is a rear view of a cleaning head of FIG. 1, shown with a transparent housing, according to one embodiment.

FIG. 11 is a side view of the cleaning head shown in FIG. 10.

DETAILED DESCRIPTION

The disclosure relates to a floor cleaner such as a vacuum cleaner, an extractor, or the like, and more specifically, a cleaning head 12 for a floor cleaner 10. FIG. 1 illustrates a floor cleaner 10. The floor cleaner 10 includes a cleaning head 12 having a housing 14 including a brushroll chamber 16 formed in the housing 14, the brushroll chamber extending along a brushroll axis 100. The brushroll chamber 16 includes a front side 30, a rear side 32, an upper side 34, and a lower side 36. The lower side 36 has an opening 38 adjacent a surface to be cleaned 50 forming a suction inlet 15. A brushroll chamber outlet 17 is formed in the rear side 32, and a brushroll assembly 20 is rotatably mounted in the brushroll chamber 16. The brushroll assembly 20 rotates about the brushroll axis 100.

The suction inlet 15 is positioned in a front portion 26 of the housing 14 and is in communication with the brushroll chamber outlet 17 in the rear side 32 of the brushroll chamber 16. A suction source 18 is in fluid communication with the suction inlet 15 and the brushroll chamber outlet 17 for generating a working air flow along an air flow path through the housing 14. Air enters the housing 14 through the suction inlet 15, through the brushroll chamber outlet 17 and along the air flow path to the suction source 18 and an exhaust outlet. In the illustrated embodiments, the brushroll chamber outlet 17 is centrally positioned on the rear side 32 of the brushroll chamber 16. The brushroll chamber outlet 17 has a width 84 measured along the brushroll axis 100.

The brushroll assembly 20 includes one or more agitating member 22. The agitating members 22 are positioned to extend through the opening 38 to agitate the surface to be cleaned 50 during operation. In the illustrated embodiments, the agitating members 22 are vanes extending between a first longitudinal end of the brushroll assembly and a second end, and are spaced around the circumferential surface of an agitator body. In one embodiment, the vanes 22 extend along the agitator body in a helical arrangement. In one embodiment, the vanes 22 extend along the agitator body in a chevron arrangement. In other embodiments the agitating members 22 may be bristles, cloth, microfiber, semi-rigid protrusions or the like. The agitating members 22 extend outwardly from the agitator body to an agitating tip 24. The agitating tip 24 forms an outer perimeter of the brushroll assembly 20. The agitating tip 24 is configured to contact the surface to be cleaned 50 through the opening 38. In one embodiment, the agitating tip 24 is positioned to be spaced a distance from the housing 14.

As illustrated in the embodiments shown in FIGS. 2-7 and 10, a cutting member 40 extends from the rear side 32 of the brushroll chamber 16 toward the agitating members 22. The cutting member 40 includes a proximal end 62 attached to the housing 14 and a distal end 64 extending toward the brushroll assembly 20. The cutting member 40 extends along the brushroll axis 100 spaced from the one or more agitating member 22. The cutting member 40 extends toward the agitating members 22 but does not engage the agitating tip 24. As longer debris, such as hair or thread, accumulates and wraps around the brushroll assembly 20, the cutting member 40 is positioned to cut the debris off the brushroll assembly 20 to inhibit wrapping of the longer debris around the brushroll assembly. Debris and hair wrapping around the brushroll assembly tends to decrease cleaning performance and requires the user to clean the hair and debris from the brushroll. As used in this application including the appended claims, the words cut or cutting are not limited to severing or cutting but includes rubbing, removing, dislodging, tearing, pulling, grinding, and the like.

In the embodiments shown in FIGS. 2-7 and 10, the cutting member 40 includes a blade edge 42 at the distal end 64, extending nearest the agitating tip 24. The blade edge 42 helps facilitate cutting of debris from the brushroll assembly 20. In one embodiment, the blade edge 42 is spaced between 0 and 1.5 millimeters from the agitating tip 24. In one embodiment, the blade edge 42 is spaced between 1 and 3 millimeters from the agitating tip 24. In one embodiment, the blade edge 42 is spaced between 3 and 5 millimeters from the agitating tip 24. The blade edge 42 being spaced from the agitating members 22 and agitating tip 24 allows debris to be removed, while reducing wear on the agitating members 22 from repeated engagement with the blade edge 42. In various embodiments the blade edge 42 may be sharp, semi-sharp, blunt, serrated, or abrasive as desired for the application.

The cutting member 40 is positioned adjacent the brushroll chamber outlet 17 in order to cut debris wrapped around the brushroll assembly 20 and facilitate debris intake through the brushroll chamber outlet 17. In the embodiments illustrated in FIGS. 2-5, the cutting member 40 extends over a portion of the brushroll chamber outlet 17. In one embodiment, the cutting member 40 is positioned at a top portion of the brushroll chamber outlet 17 or above the brushroll chamber outlet 17. The cutting member 40 is disposed above the lower side 36 of the brushroll chamber 16 and above the opening 38. The cutting member 40 is not configured to contact the surface to be cleaned 50.

In the embodiment illustrated in FIGS. 10 and 11, the cutting member is positioned at a bottom portion of the brushroll chamber outlet 17 or below the brushroll chamber outlet 17. In the embodiment illustrated in FIGS. 10 and 11, the blade edge 42 at the distal end 64 is disposed on a flange 66 extending upwardly at an angle toward the brushroll assembly 20.

In the illustrated embodiments, the length 80 of the cutting member 40 between the first end 58 and the second end 60 is equal to or greater than the width 84 of the brushroll chamber outlet 17. In one embodiment, the length 80 of the cutting member 40 between the first end 58 and the second end 60 is a length less than the width 84 of the brushroll chamber outlet 17. In one embodiment, the length 80 of the cutting member 40 between the first end 58 and the second end 60 extends a length between 30% and 70% of the length 82 of the brushroll chamber 16. In one embodiment, the length 80 of the cutting member 40 between the first end 58 and the second end 60 extends a length between 70 and 100% of the length 82 of the brushroll chamber 16.

In the embodiments illustrated in FIGS. 2-6 and 10, the cutting member 40 is stationary. The cutting member 40 extends from a first side 58 to a second side 60, opposite the first side 58. The cutting member 40 extends a length 80 between the first side 58 and the second side 60.

In the embodiment illustrated in FIG. 2, the blade edge 42 extends in a straight line between the first side 58 and the second side 60. In this embodiment, the blade edge 42 extends parallel to the brushroll axis 100 disposed at an elevation between the lower side 36 and the brushroll axis 100. In this embodiment, the blade edge 42 is disposed in the airpath in front of the brushroll chamber outlet 17.

In the embodiment illustrated in FIGS. 10 and 11, the cutting member 40 has an angled blade as defined by the angled extending flange 66. The angled blade arrangement may provide added flexibility and durability for the cutting member 40.

In the embodiment illustrated in FIGS. 3 and 5, the cutting member 40 extends in a polygonal shape varying the elevation of the blade edge 42 between the first side 58 and the second side 60. As illustrated in FIGS. 3b and 5b, the cutting member 40 includes a first side portion 70 extending from the first side 58. The first side portion 70 connects to a first connector portion 74 that extends at a steeper angle than the first side portion 70. The first connector portion 74 connects to a generally flat plateau portion 78. The flat plateau portion 78 is a part of the blade edge 42 and extends generally parallel to the brushroll axis 100. The plateau portion 78 extends across the brushroll chamber outlet 17. The plateau portion 78 then connects to a second connector portion 76, which connects to a second side portion 72 at the second side 60. In the embodiment illustrated in FIG. 3, the plateau portion 78 is disposed at an elevation between the lower side 36 and the brushroll axis 100. In this embodiment, the blade edge 42 is disposed in the airpath in front of the brushroll chamber outlet 17. In the embodiment illustrated in FIG. 5, the plateau portion 78 is disposed at an elevation above the brushroll axis 100. In this embodiment, the blade edge 42 is disposed in the airpath along an upper portion of the brushroll chamber outlet 17. In the embodiments of FIGS. 3 and 5, the blade edge 42 at the first side 58 and at the second side 60 is disposed at an elevation between the lower side 36 and the brushroll axis 100. The cutting member 40 shown in both FIGS. 3 and 5 is generally symmetrical. The first connector portion 74 and the second connector portion 76 are longer in FIG. 5 compared to FIG. 3. The length and angle of the cutting member 40, and specifically the first connector portion 74 and the second connector portion 76 can be modified based on desired cleaning performance.

In the embodiment illustrated in FIG. 4 and the cutting member 40 extends in an arc shape varying the elevation of the blade edge 42 between the first side 58 and the second side 60. As illustrated in FIG. 4b, the cutting member 40 includes the first side portion 70 extending from the first side 58. The first side portion 70 connects to the first connector portion 74 that extends at a steeper angle than the first side portion 70. The first connector portion 74 connects to an arc portion 90. The arc portion 90 extends across the brushroll chamber outlet 17. The arc portion 90 then connects to the second connector portion 76, which connects to the second side portion 72 at the second side 60.

In the embodiment illustrated in FIG. 6, the cutting member 40 extends in an arc shape between the first side 58 and the second side 60. As illustrated in FIG. 6b, the cutting member includes a first side portion 70 extending from the first side 58. The first side portion 70 extends to an arc portion 90. The arc portion 90 generally extends around the brushroll chamber outlet 17. As shown in FIG. 6, the highest point of the arc portion 90 is disposed at an elevation above the brushroll axis 100. In the embodiment of FIG. 6, the blade edge 42 at the first side 58 and at the second side 60 is disposed at an elevation between the lower side 36 and the brushroll axis 100. The angle and length of the arc portion 90 can be modified based on desired cleaning performance.

In the embodiment illustrated in FIG. 7, the cutting member 40 is a cylindrical blade roll 40 extending from the rear side 32 of the brushroll chamber 16. The cylindrical cutting member 40 includes a plurality of blade edges 42 spaced from the agitating tip 24. When the space is greater than 0 mm and no debris is wrapped around the brushroll assembly 20, the cylindrical spinning blade roll 40 is generally stationary. Once debris begins to wrap around the brushroll assembly 20, the debris fills the space between the agitating tip and the cutting member 40 engaging the cylindrical blade roll 40 causing it to rotate, resulting in cutting debris on the brushroll assembly 20. In this embodiment, the spinning blade roll 40 is rotatable about an axis 102 extending between the first end 58 and the second end 60. The spinning blade roll 40 is able to rotate about the axis 102 but does not move toward or away from the agitating member 22. In the embodiment of FIG. 7b, the surface of the cylindrical blade roll 40 is knurled forming the plurality of blade edges 42. In the embodiment of FIGS. 8 and 9, the plurality of blade edges 42 is formed by cutting edges. In the embodiment illustrated in FIG. 7, the cylindrical blade roll 40 engages the agitating tip 24 enabling the rotating brushroll assembly to rotate the cutting member. In one embodiment, the cylindrical blade roll 40 is spaced from the agitating tip 24 and does not engage the agitating tip 24. In one embodiment, the spinning blade roll 40 is spaced between 0 and 1.5 millimeters from the agitating tip 24. In one embodiment, the spinning blade roll 40 is spaced between 1 and 3 millimeters from the agitating tip 24.

In the embodiment illustrated in FIGS. 8 and 9, the brushroll assembly 20 includes a first agitating portion 44, a second agitating portion 46, and a geared track portion 48 positioned between the first agitating portion 44 and the second agitating portion 46. The cutting member 40 is a cylindrical blade roll 40 extending from the rear side 32 of the brushroll chamber 16. In this embodiment, the cylindrical blade roll 40 includes a gear portion 52. The gear portion 52 is positioned to align with and engage the track portion 48. The gear portion 52 is rotatable about an axis 104. The gear portion 52 is configured to engage the track portion 48 such that the brushroll assembly rotates the gear portion 52. The cutting roll is configured to cut or grind debris accumulated on the brushroll assembly 20. In one embodiment, the track portion and the gear portion 52 include friction surfaces instead of gear teeth and the gear portion is driven by friction rather than with teeth. In one embodiment, the gear portion 52 is driven by a motor, rather than driven by the rotation of the brushroll assembly.

In the embodiments of FIGS. 7-9, the cylindrical blade roll 40 is positioned adjacent the brushroll chamber outlet 17 so that removed debris leaves the brushroll chamber 16 through the brushroll chamber outlet 17 once it is removed from the brushroll assembly 20. The cutting member 40 extends parallel to the brushroll axis 100 disposed at an elevation between the lower side 36 and the brushroll axis 100. The cylindrical blade roll 40 is disposed in the airpath in front of the brushroll chamber outlet 17.

It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. The details set out above are merely exemplary.

Claims

1. A surface cleaner comprising:

a housing including a brushroll chamber, the brushroll chamber having a front side, a rear side, an upper side, and a lower side with an opening adjacent a surface to be cleaned;

a brushroll assembly rotatably mounted in the brushroll chamber, the brushroll assembly including one or more agitating members;

the one or more agitating members are positioned to extend through the opening to agitate the surface to be cleaned;

a suction inlet positioned in the front side of the housing and in communication with a brushroll chamber outlet in the rear side of the housing;

a suction source in fluid communication with the suction inlet and the brushroll chamber outlet for generating a working flow through the housing;

a cutting member extending from the rear side of the brushroll chamber toward the brushroll assembly, the cutting member extending parallel to the brushroll axis and spaced from the one or more agitating members;

wherein the cutting member is positioned adjacent the brushroll chamber outlet, the cutting member configured to cut debris to facilitate debris intake through the brushroll chamber outlet.

2. The surface cleaner of claim 1, wherein the cutting member includes a blade edge extending toward the agitating members.

3. The surface cleaner of claim 2, wherein the blade edge includes a flat portion extending parallel to the brushroll axis.

4. The surface cleaner of claim 2, wherein the blade edge includes a flange extending at an angle toward the agitating member.

5. The surface cleaner of claim 1, wherein the cutting member extends over a portion of the brushroll chamber outlet.

6. The surface cleaner of claim 1, wherein the cutting member is between the brushroll axis and the lower side of the brushroll chamber.

7. The surface cleaner of claim 1, wherein the cutting member includes a flat plateau portion.

8. The surface cleaner of claim 1, wherein the cutting member includes an arc shaped portion.

9. The surface cleaner of claim 1, wherein the cutting member is a cylindrical blade roll.

10. The surface cleaner of claim 1, wherein the cutting member is positioned above the brushroll chamber outlet.

11. The surface cleaner of claim 1, wherein the cutting member is positioned below the brushroll chamber outlet.

12. The surface cleaner of claim 1, wherein the cutting member includes a proximal end attached to the housing and a distal end extending toward the brushroll assembly, wherein the distal end includes a flange extending an angle toward the brushroll assembly.

13. A surface cleaner comprising:

a housing including a brushroll chamber, the brushroll chamber having a front side, a rear side, an upper side, and a lower side with an opening adjacent a surface to be cleaned;

a brushroll assembly rotatably mounted in the brushroll chamber, the brushroll assembly a first agitating portion, a second agitating portion, and a track portion positioned between the first agitating portion and the second agitating portion;

the first agitating portion and the second agitating portion extending through the opening to agitate the surface to be cleaned a suction inlet positioned in the front side of the brushroll chamber and in communication with a brushroll chamber outlet in the rear side of the brushroll chamber;

a suction source in fluid communication with the suction inlet and the brushroll chamber outlet for generating a working flow through the housing;

a cutting member extending from the rear side of the brushroll chamber, the cutting member including a gear portion positioned to engage the track portion configured to rotate the cutting member when the brushroll assembly rotates;

wherein the cutting member is configured to cut debris wrapped around the first agitating portion and the second agitating portion when the brushroll assembly rotates.

14. The surface cleaner of claim 13, wherein the gear portion is driven by the rotation of the brushroll assembly.

15. The surface cleaner of claim 13, wherein the gear portion includes teeth.

16. The surface cleaner of claim 13, wherein the cutting member includes a cutting blade.