VACUUM NOZZLE AND BRUSHROLL DESIGN

Abstract

A nozzle assembly for use on a vacuum cleaner includes a base unit, an outlet coupled to the base unit and pivotable with respect to the base unit, one or more wheels coupled to the base unit, and a suction chamber coupled to the base unit. The outlet is configured for engagement with a suction tube of the vacuum cleaner. The suction chamber includes a first agitator configured to rotate in a first direction, a second agitator configured to rotate in a second direction opposite from the first direction, and a suction port arranged between the first agitator and the second agitator.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional application No. 63/653,391, filed May 30, 2024, and the benefit of provisional application No. 63/520,716, filed Aug. 21, 2023, the disclosures of which are each incorporated by reference herein in their entirety.

BACKGROUND

Cleaning tools such as vacuum cleaners have been used for decades to aid in cleaning dirt and other debris from floors. Most vacuum cleaners have a built-in motor to facilitate air suction and a chamber to collect dirt, but the units are often heavy and bulky, thus making it difficult to deftly maneuver the unit around a given floorspace. The vacuum cleaner may also not pick up debris from every surface as effectively. Accordingly, there exist some drawbacks and other unsolved issues that limit the convenience of vacuum cleaners.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of embodiments of the claimed subject matter will become apparent as the following Detailed Description proceeds, and upon reference to the Drawings, in which:

FIG. 1 illustrates an isometric, three-dimensional view of a vacuum cleaner, in accordance with some embodiments of the present disclosure.

FIGS. 2A-2D illustrate various views of a nozzle assembly with a tiltable suction chamber, in accordance with some embodiments of the present disclosure.

FIG. 3 illustrates a cross-section view of the nozzle assembly, in accordance with some embodiments of the present disclosure.

FIG. 4 illustrates a view from below the nozzle assembly, in accordance with some embodiments of the present disclosure.

FIGS. 5A and 5B illustrate front and back views of the nozzle assembly, in accordance with some embodiments of the present disclosure.

FIG. 6 illustrates a view of the nozzle assembly with a portion of the housing on the suction chamber removed, in accordance with some embodiments of the present disclosure.

FIG. 7A illustrates a three-dimensional view of the nozzle assembly with the suction chamber removed, in accordance with some embodiments of the present disclosure.

FIG. 7B illustrates a three-dimensional view of a suction chamber removed from the nozzle assembly, in accordance with some embodiments of the present disclosure.

FIG. 8 illustrates a cross-section view through the nozzle assembly showing a pivot axis through the suction chamber, in accordance with some embodiments of the present disclosure.

FIGS. 9A and 9B illustrate tilting of the suction chamber in response to moving the nozzle assembly across a surface in a forward or backward direction, in accordance with some embodiments of the present disclosure.

FIGS. 10A and 10B illustrate tilting of the suction chamber in response to moving the nozzle assembly against a wall, in accordance with some embodiments of the present disclosure.

FIG. 11 illustrates a view of the nozzle assembly showing various optical sources on the nozzle assembly, in accordance with some embodiments of the present disclosure.

FIGS. 12A and 12B illustrate different views of one of the rollers used within the suction chamber, in accordance with some embodiments of the present disclosure.

FIGS. 13A-13D illustrate different views of rollers having an anti-hair wrap design, in accordance with some embodiments of the present disclosure.

FIG. 14 illustrates views of a compliant element folded into a shape that can be coupled to a roller, in accordance with some embodiments of the present disclosure.

FIG. 15 illustrates a view of a roller having compliant elements that overlap across a portion of a length of the roller, in accordance with some embodiments of the present disclosure.

FIGS. 16A-16F illustrate views of a compliant element having various possible designs and features, in accordance with some embodiments of the present disclosure.

FIG. 17 illustrates a view of a roller having compliant elements and bristles between the compliant elements, in accordance with some embodiments of the present disclosure.

FIGS. 18A-18D illustrate different views of front and back debriding edges on the bottom of the suction chamber, in accordance with some embodiments of the present disclosure.

Although the following Detailed Description will proceed with reference being made to illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent in light of this disclosure.

DETAILED DESCRIPTION

As noted above, there are some non-trivial issues with the designs of most vacuum cleaners. Many of the issues pertain to matters of convenience for the user. For example, vacuum cleaners include a nozzle assembly having a brush roll or similar agitation member to facilitate the collection of debris off of a surface. Often times, the brush roll does not effectively clean all of the dirt or debris on a given surface, causing the user to run the vacuum multiple times over a given area in an effort to collect all of the dirt or debris. Furthermore, many vacuums are designed to pick up the dirt or debris on the forward stroke of the nozzle assembly but are usually less efficient at picking up the dirt or debris on the backstroke. Additionally, in cases where multiple agitators are incorporated into the nozzle assembly, the force to move the vacuum forward or backward may be greater than desired and can lead to user fatigue.

In addition to the issues mentioned above, typical brush roll designs utilize various features that may protrude from the brush roll to facilitate the collection of dirt and debris. However, the brush rolls also easily pick up long strand-like objects like hair or string that wraps itself around such elements and can cause clogging or jamming to the rotation of the brush roll.

Thus, a vacuum cleaner nozzle assembly is disclosed that provides a greater ability to lift up dirt and debris from various surface types while minimizing user fatigue due to its design. According to some embodiments, the nozzle assembly includes a suction chamber that houses at least two agitators where the suction chamber is designed to rotate about a tilt axis passing through a central portion of the suction chamber. Accordingly, the tilt axis runs between at least one agitator positioned near a front of the suction chamber and at least one agitator positioned near a rear of the suction chamber, according to some embodiments. In some examples, the agitators are brush rollers and the tilt axis extends parallel to a central axis of each of the at least two brush rollers. In a design having two agitators (one arranged near the front of the suction chamber and the other near the rear of the suction chamber), pushing the nozzle assembly forward across a surface (e.g., a forward stroke) causes the first agitator to engage more closely with the surface and tilts the suction chamber about the tilt axis such that the back of the suction chamber lifts away from the surface. Similarly, pulling the nozzle assembly backward across the surface (e.g., a backstroke) causes the rear agitator to engage more closely with the surface and tilts the suction chamber about the tilt axis such that the front of the suction chamber lifts away from the surface. This tilting action increases the engagement of the agitators with the surface and picks up more debris compared to previous designs. Additionally, a rotational direction of the agitators coupled with their enhanced engagement with the surface reduces the forces required to push or pull the vacuum and reduces the fatigue on the user.

Additionally, a brush roll design is disclosed that reduces or eliminates the wrapping of hair or other strand-like objects around the brush roll. According to some embodiments, the brush roll includes a plurality of compliant elements that extend from the brush roll core and traverse around the brush roll core in both a longitudinal and circumferential direction. In some embodiments, the plurality of compliant elements extend along the longitudinal direction of the brush roll core. Unlike simple flaps used on conventional brush roll designs, the compliant elements are folded into a given shape (e.g., circular, teardrop, oval, etc.) that may have a hollow interior that runs along the length of the compliant element. For example, the compliant elements may be folded onto themselves into a teardrop shape that extends from the core of the brush roll, or into any other suitable shape. Each compliant element may include a head portion having the folded shape and an anchor portion that is designed to fit into corresponding grooves or tracks in the brush roll core. In some examples, the folded shape of the head portion encloses a hollow interior. In other examples, the folded shape of the head portion encloses a soft material, such as a foam core. According to some embodiments, a plurality of compliant elements may overlap across a portion of the brush roll where the compliant elements also bend towards one another. This design helps to prevent any hair, string, or other similar elements from wrapping tightly around the brush roll.

According to an embodiment, a nozzle assembly for use on a vacuum cleaner includes a base unit, an outlet coupled to the base unit and pivotable with respect to the base unit, one or more wheels coupled to the base unit, and a suction chamber coupled to the base unit. The outlet is configured for engagement with a suction tube of the vacuum cleaner. The suction chamber includes a first agitator configured to rotate in a first direction, a second agitator configured to rotate in a second direction opposite from the first direction, and a suction port arranged between the first agitator and the second agitator.

According to an embodiment, a suction chamber is designed for use on a vacuum cleaner. The suction chamber includes a housing, first and second coupling ports on the housing, a first agitator arranged at a forward position of the housing, a second agitator arranged at a rear position of the housing, and a suction port through a top surface of the housing and between the first agitator and the second agitator. The first and second coupling ports face each other and are spaced apart from each other along an axis. The first and second coupling ports are configured to engage with corresponding coupling structures of a base unit.

According to an embodiment, a vacuum cleaner includes a nozzle assembly at a distal end of the vacuum cleaner, and a brush roll coupled to the nozzle assembly. The brush roll includes a cylindrical core and a compliant element coupled to the cylindrical core and extending away from the cylindrical core in a radial direction. The compliant element extends along a length of the cylindrical core, and the compliant element has an outer surface with a cross-sectional shape around a hollow interior or around a core comprising a compliant material.

According to an embodiment, a brush roll is configured for use within a nozzle assembly of a vacuum cleaner. The brush roll includes a cylindrical core, a first compliant element coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, and a second compliant element coupled to the cylindrical core and extending away from the cylindrical core in a radial direction. The first compliant element extends around at least a portion of a circumference of the cylindrical core while extending along more than 50% of a total length of the cylindrical core starting from a first end of the cylindrical core. The second compliant element extends around at least a portion of a circumference of the cylindrical core while extending along more than 50% of a total length of the cylindrical core starting from a second end of the cylindrical core opposite from the first end. One or both ends of the first compliant element have a taper, and one or both ends of the second compliant element have a taper.

These and other such embodiments will be described in more detail herein.

The description uses the phrases “in an embodiment” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. When used to describe a range of dimensions, the phrase “between X and Y” represents a range that includes X and Y.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

FIG. 1 illustrates a perspective three-dimensional view of a vacuum cleaner 100, according to an embodiment. Vacuum cleaner 100 has the general shape of an upright vacuum, however, it should be understood that the embodiments described herein with regards to the nozzle assembly may be used on any type of vacuum cleaner, such as a stick vacuum cleaner, canister vacuum cleaner, or upright vacuum cleaner. In some embodiments, vacuum cleaner 100 includes a nozzle assembly 102 at a distal end of vacuum cleaner 100 while a handle 104 may be coupled to a proximal end of vacuum cleaner 100. Nozzle assembly 102 can include any number of rotating brush heads for facilitating the gathering of debris from a surface. The surface is typically a floor, but may also include furniture, walls, ceiling, or vehicle interiors.

According to some embodiments, vacuum cleaner 100 also includes at least a motor 106 and a waste receptacle 108. Motor 106 may be any suitable vacuum motor, such as a universal motor, that draws air up through nozzle assembly 102 and into waste receptacle 108.

According to some embodiments, the waste receptacle 108 may have a substantially cylindrical shape to fit with the overall form factor of vacuum cleaner 100. Waste receptacle 108 may have any suitable elongated geometry.

FIG. 2A illustrates a side view of nozzle assembly 102, according to some embodiments. Nozzle assembly 102 includes a base unit 202 and a suction chamber 204 coupled to base unit 202. According to some embodiments, a rear portion of base unit 202 is coupled to an outlet 206 to allow nozzle assembly 102 to engage with the distal end of a vacuum cleaner and connect its air suction tube to that of the vacuum cleaner. Accordingly, outlet 206 may slidably engage with a portion of any type of vacuum cleaner. As mentioned above, nozzle assembly 102 may be designed to engage with any type of vacuum, such as a stick vacuum, cannister vacuum, upright vacuum, or handheld vacuum, to name a few examples. In some examples, outlet 206 may pivot about a ball-in-socket joint and/or other structures involving tube sections that are flexible or rotate into one another to allow for pivotable movement of outlet 206 with respect to base unit 202.

According to some embodiments, base unit 202 includes a rigid or semi-rigid body of a lightweight material (e.g., hard plastic or molded plastic). Suction chamber 204 may be designed to house the cleaning elements of the vacuum cleaner, such as any rollers, brushes, liquid sprayers, etc. According to some embodiments, suction chamber 204 is coupled to base unit 202 by pivot structures that allow suction chamber 204 to rotate about a pivot axis passing through the suction chamber with respect to base unit 202. The range of rotational motion of suction chamber 204 may be limited to less than 15 degrees, less than 10 degrees, or less than 5 degrees in either direction (clockwise or counterclockwise) about the pivot axis. Each of these features will be discussed in more detail herein.

According to some embodiments, base unit 202 includes one or more wheels 210 to balance a rear portion of base unit 202 when placed onto a surface 212. Surface 212 may represent any type of surface that nozzle assembly 102 can be placed upon to perform a cleaning operation. In some examples, surface 212 represents a hard surface such as hardwood or tile. In some examples, surface 212 represents a carpeted surface.

FIG. 2B illustrates a top view of nozzle assembly 102, according to some embodiments. A width of suction chamber 204 along a Y-axis is greater than a width of base unit 202 along the Y-axis. In some examples, the width of suction chamber 204 is at least 1.5×, at least 2×, or at least 2.5× greater than the width of base unit 202.

FIG. 2C illustrates a view from behind nozzle assembly 102, according to some embodiments. Outlet 206 may be seated into a pivot base structure 213 that is coupled to or is an integral part of base unit 202. In some examples, outlet 206 and pivot base structure 213 form a ball-in-socket joint that allows outlet 206 to swivel in any direction as depicted by the arrows. Other types of pivotable joints may be used as well. According to some embodiments, wheels 210 have a concave shape to reduce the amount of surface contact when rolling along a surface, and also to allow debris to pass beneath them during a backstroke of nozzle assembly 102.

FIG. 2D illustrates a top view of nozzle assembly 102, according to some embodiments. According to some embodiments, a top portion of base unit 202 includes an access port 214. A cover may be placed over access port 214 that can be either removed or opened to allow access into access port 214. In some examples, the cover can be slid to open access port 214 or rotated about a hinge to open access port 214. According to some embodiments, access port 214 provides access into the body of base unit 202 or more specifically into an air suction tube passing through base unit 202. Accordingly, dirt or other debris that could be clogged within the air suction tube can be removed via access port 214. In some embodiments, various modular components may be installed into nozzle assembly 102 via access port 214. For example, a sensor package that includes one or more sensors to evaluate debris load or vacuum performance may be swapped into or out of nozzle assembly 102 via access port 214, or any other port on nozzle assembly 102.

FIG. 3 illustrates a cutaway view taken through a central portion of nozzle assembly 102, according to some embodiments. Suction chamber 204 includes a first roller 302 and a second roller 304, according to some embodiments. As used herein, a roller refers to any cylindrical cleaning structure that can include various parts, such as a rigid core and softer cleaning elements such as bristles, fabrics, or foams. Rollers are one example of agitators used to clean a surface. First roller 302 may be arranged at a front of suction chamber 204 while second roller 304 is arranged at a rear of suction chamber 204. According to some embodiments, suction chamber 204 includes a suction port 306 through which dirt or other debris is sucked into off of surface 212. Suction port 204 may be centrally located along a bottom side of suction chamber 204. First roller 302 may have a greater diameter compared to second roller 304. For example, first roller 302 may have a diameter between about 45 mm and about 55 mm while second roller 304 may have a diameter between about 30 mm and about 40 mm. In some embodiments, both first roller 302 and second roller 304 have the same diameter.

According to some embodiments, base unit 202 includes an air suction tube 308 that couples to suction port 306 via a flexible duct 310. Flexible duct 310 may fit over suction port 308 when suction chamber 204 is attached to base unit 202. In a more general sense, flexible duct 310 provides a leak-proof or at least a leak-resistant seal between suction port 306 and air suction tube 308. During operation, dirt or other debris is sucked from surface 212 through suction port 306 and into air suction tube 308 where it can be passed further into the vacuum cleaner coupled to outlet 206. Note that air suction tube 308 may be made up of various segments having different diameters and/or curvatures. For example, tube segment 308a may fit over tube segment 308b to allow for backwards and forwards pivoting of outlet 206. As outlet 206 is pivoted backwards, tube segment 308a slides over tube segment 308b to maintain suction through air suction tube 308. In other examples, tube segments 308a and 308b may be replaced by a flexible, corrugated tube.

According to some embodiments, first roller 302 is designed to rotate in a first direction while second roller 304 is designed to rotate in a second direction opposite from the first direction. For example, in the illustrated view, first roller 302 may rotate in a counterclockwise direction to push and/or lift dirt and debris off of surface 212 and towards suction port 306 during a forward stroke of nozzle assembly 102. Similarly, in the illustrated view, second roller 304 may rotate in a clockwise direction to push and/or lift dirt and debris off of surface 212 and towards suction port 306 during a backstroke of nozzle assembly 102. According to some embodiments, the rotational speed of first roller 302 and/or second roller 304 can be adjusted either manually or dynamically. A velocity and/or acceleration sensor (e.g., an accelerometer) may be used to determine a movement profile of nozzle assembly 102 with the rotational speed of first roller 302 and/or second roller 304 being adjusted accordingly. For example, a motor can increase the rotational speed of first roller 302 in response to an output from the sensor indicating that nozzle assembly 102 is experiencing a forward stroke. In another example, another motor can increase the rotational speed of second roller 304 in response to an output from the sensor indicating that nozzle assembly 102 is experiencing a backstroke. In some embodiments, the sensor may be coupled to or otherwise associated with one or more of wheels 210 to determine the speed and direction (e.g., forward stroke or backstroke) of nozzle assembly 102. In some embodiments, one or more encoders, accelerometers, gyroscopes, or LIDAR sensors may be used to determine speed, direction, and/or angle of nozzle assembly 102.

FIG. 4 illustrates a view from below nozzle assembly 102, according to some embodiments. Each of first roller 302 and second roller 304 are shown arranged parallel to one another along nearly an entire width of suction chamber 204. Although first and second rollers 302 and 304 are illustrated as cylindrical, it should be understood that other roller shapes can be used as well, such as conically shaped rollers. Suction chamber 204 includes a housing 402 that defines the rigid shape of suction chamber 204. Housing 402 may include a lightweight but substantially rigid or semi-rigid material, such as a hard plastic or molded plastic. According to some embodiments, the underside of housing 402 includes conduits 404 that lead to suction port 306, which extends through housing 402. Conduits 404 may be upwardly tapered towards suction port 306 such that the vacuum forces can draw the dirt or debris along conduits 404 and into suction port 306.

According to some embodiments, one or more bottom edges of housing 402 include a compliant material 406. In some embodiments, compliant material 406 is provided to seal or otherwise block some of the edges around the bottom of suction chamber 204 when it is placed on a surface to create a better vacuum environment beneath suction chamber 204. Although some air may pass beneath compliant material 406, it is substantially less air than would pass through in the absence of compliant material 406. In some examples, compliant material 406 includes a fabric, such as a felt material that extends away from the bottom edges of housing 402. One or more side rollers 408 may be provided on each side of housing 402 for increased stability. According to some embodiments, when suction chamber 204 is placed on a surface to be cleaned, the only elements of suction chamber 204 that contact the surface are first roller 302, second roller 304, compliant material 406, and side rollers 408.

FIGS. 5A and 5B illustrate front and back views of nozzle assembly 102, according to some embodiments. A front panel 502 of housing 402 is offset from a bottom of first roller 302 by a distance Δd of between about 8 mm and about 15 mm to allow for even larger debris to be engaged by first roller 302 during a front stroke of nozzle assembly 102. Similarly, a back panel 504 of housing 402 is offset from a bottom of second roller 304 by a similar distance Δd of between about 8 mm and about 15 mm to allow for even larger debris to be engaged by back roller 304 during a backstroke of nozzle assembly 102. The front and back offsets may be the same or may be different.

FIG. 6 illustrates a top view of nozzle assembly 102 with a portion of the suction chamber housing removed, according to some embodiments. A first motor 602a may be arranged within suction chamber 204 on one side of base unit 202 while a second motor 602b may be arranged within suction chamber 204 on the opposite side of base unit 202. In other examples, the motors may be arranged in other parts of suction chamber 204. Each of first motor 602a and second motor 602b may use a belt drive system to turn one or more gears 604 that engage with first roller 302 and second roller 304. For example, first motor 602a may provide the power to rotate first roller 302 and second motor 602b may provide the power to rotate second roller 304. In this way, each roller can have its rotational speed independently controlled. In some embodiments, a single motor is used to control the rotation of both rollers together. In some embodiments, a single motor is coupled to a transmission system to provide different rotational speeds to first roller 302 and second roller 304.

FIG. 7A illustrates a view of base unit 202 with suction chamber 204 removed while FIG. 7B illustrates the removed suction chamber 204, according to some embodiments. The underside of base unit 202 may be sloped to provide a clearance where suction chamber 204 fits into when it is coupled to base unit 202. Flexible duct 310 can be seen coupled to an underside of base unit 202 and sized to form a suitable seal over suction port 306 of suction chamber 204. Flexible duct 310 aligns with suction port 306 when suction chamber 204 is coupled to base unit 202.

According to some embodiments, base unit 202 includes any number of coupling structures 701 that engage with any number of corresponding coupling structures 702 on suction chamber 204. In the illustrated example, coupling structures 701 include pegs and coupling structures 702 include ports that are designed to mechanically accept the pegs and allow suction chamber 204 to rotate or pivot about a pivot axis 704 that runs axially through coupling structures 701 and coupling structures 702. Any other shapes or types of coupling structures may be used as well that result in the ability for suction chamber 204 to pivot about pivot axis 704. Electrical wires or connectors may pass through or between coupling structures 701 and coupling structures 702 to provide power to any number of electrical components on suction chamber 204, such as motors, sensors, or optical sources. In some embodiments, the location of coupling structures 702 on suction chamber 204 may be adjustable to raise or lower pivot axis 704.

In some embodiments, suction chamber 204 includes a first motor cover 706a and a second motor cover 706b to protect first motor 602a and second motor 602b, respectively. First and second motor covers 706a/706b may be integral elements of housing 402 or separate panels that can be removed to provide access to either first motor 602a or second motor 602b. Each of first motor 602a and second motor 602b may be modular components that can be removed and replaced with a different motor type.

FIG. 8 illustrates a cutaway view through suction chamber 204 illustrating the position of coupling structure 702 with respect to each of first roller 302 and second roller 304, according to some embodiments. In some examples, first roller 302 has a first central axis 802 and second roller 304 has a second central axis 804 parallel to the first central axis. In some examples, first roller 302 and second roller 304 are angled with respect to each other along the XY plane and/or along the YZ plane such that their central axes are not parallel. Pivot axis 704 that runs through coupling structure 702 is parallel to both first central axis 802 and second central axis 804, according to some embodiments. Pivot axis 704 may be arranged between first central axis 802 and second central axis 804 along the illustrated X-axis, which is parallel to a forward and backward direction of travel of nozzle assembly 102. More generally, pivot axis 704 may be arranged between first roller 302 and second roller 304 along the illustrated X-axis. In some examples, coupling structure and pivot axis 704 is arranged anywhere between a front edge of suction chamber 204 and a rear edge of suction chamber 204 along the X-axis. This arrangement of pivot axis 704 between the rollers allows for suction chamber 204 to pivot on both front stroke and backstroke movements as discussed in more detail with reference to FIGS. 9A-9B. According to some embodiments, pivot axis 704 is also located above both first central axis 802 and second central axis 804 (or above first roller 302 and/or above second roller 304) along the illustrated Z-axis.

FIG. 9A illustrates a pivoting rotation of suction chamber 204 in response to a forward stroke motion of nozzle assembly 102, and FIG. 9B illustrates a pivoting rotation of suction chamber 204 in response to a backstroke motion of nozzle assembly 102, in accordance with some embodiments. Turning to FIG. 9A, a forward stroke of nozzle assembly 102 across surface 212 as denoted by the while arrow causes first roller 302 to engage more strongly with surface 212 as first roller 302 is actuated in a counterclockwise direction to push debris towards the center of suction chamber 204. The force of this engagement causes suction chamber 204 to pivot forward about pivot axis 704 (counterclockwise in the illustrated view), thus raising the back end of suction chamber 204 further from surface 212 and reducing the engagement between second roller 304 and surface 212. Air is drawn into suction port 306 from between first roller 302 and second roller 304 and may also be drawn from beneath second roller 304, as denoted by the arrows, according to some embodiments. Turning to FIG. 9B, a backstroke of nozzle assembly 102 across surface 212 as denoted by the while arrow causes second roller 304 to engage more strongly with surface 212 as second roller 304 is actuated in a clockwise direction to push debris towards the center of suction chamber 204. The force of this engagement causes suction chamber 204 to pivot backward about pivot axis 704 (clockwise in the illustrated view), thus raising the front end of suction chamber 204 further from surface 212 and reducing the engagement between first roller 302 and surface 212. Air is drawn into suction port 306 from between first roller 302 and second roller 304 and may also be drawn from beneath first roller 302, as denoted by the arrows, according to some embodiments. Base unit 202 may exhibit some pivoting around its own pivot axis near or through wheels 210 during a forward stroke or backstroke of nozzle assembly 102. But suction chamber 204 pivots about pivot axis 704 with respect to base unit 202 and independently of base unit 202.

By allowing suction chamber 204 to pivot about pivot axis 704 during both the forward stroke and backstroke, a more efficient retrieval of dirt and debris from surface 212 on both the forward stroke and backstroke can be achieved. It should be noted that the illustrated pivoting movement of suction chamber 204 is most observable when surface 212 is a compliant surface (such as carpet). The pivoting movement may be less pronounced or not observed at all when surface 212 is a hard surface. In any case, wheels 210 of base unit 202 may remain in their same orientation on surface 212 for both the forward stroke and backstroke. Additionally, the enhanced engagement between rollers 302/304 and surface 212 on the forward stroke and backstroke, respectively, coupled with the counter-rotational directions of rollers 302/304 allow nozzle assembly 102 to be driven forward on a front stroke and driven backward on a backstroke, thus reducing the amount of force required by the user to push or pull nozzle assembly 102 across surface 212.

According to some embodiments, suction chamber 204 may include motorized actuation about pivot axis 704. According to some embodiments, suction chamber 204 may rotate about pivot axis 704 in response to some mechanism unrelated or related to the travel direction of nozzle assembly 102. In either case, the pivoting of suction chamber 204 about pivot axis 704 may be controlled irrespective of the number or type of rollers within suction chamber 204. In some examples, the pivoting of suction chamber 204 about pivot axis 704 may be controlled in designs where suction chamber 204 does not include any rollers.

FIGS. 10A and 10B illustrate the tiling motion of suction chamber 204 when it encounters a wall, according to some embodiments. Housing 402 of suction chamber 204 includes a nose structure 1002 that extends beyond first roller 302 out in front of suction chamber 204 along the X-axis, according to an embodiment. Nose structure 1002 may be an integral part of housing 402 or may be a separate component that is attached to housing 402. In some embodiments, nose structure 1002 includes a compliant material, such as rubber, that is softer than the rest of housing 402.

FIG. 10A illustrates a situation where nozzle assembly 102 approaches a wall 1004 (or any type of obstruction). It can often be difficult for vacuum cleaners to access dirt or debris 1006 at the corner between wall 1004 and surface 212. However, as illustrated in FIG. 10B, nose structure 1002 contacts wall 1004 and is angled such that suction chamber 204 pivots backwards about pivot axis 704, thus raising a front portion of suction chamber 204 further from surface 212 and raising first roller 302 from surface 212. This motion reduces or breaks the suction seal between first roller 302 and surface 212 and creates a better suction path, as shown by the arrow, beneath first roller 302 to collect debris 1006 from in front of first roller 302.

FIG. 11 illustrates the location of various optical sources around nozzle assembly 102, according to some embodiments. In some examples, one or more first optical sources 1102 are located on a front-facing portion of suction chamber 204 and one or more second optical sources are located on a rear-facing portion of suction chamber 204. One or more first optical sources 1102 may provide light on the surface in front of suction chamber 204 while one or more second optical sources 1104 may provide light on the surface to be cleaned behind suction chamber 204. According to some embodiments, one or more first optical sources 1102 may be programmed to only activate during a forward stroke of nozzle assembly 102 and one or more second optical sources 1104 may be programmed to only activate during a backstroke of nozzle assembly 102.

According to some embodiments, a row of optical sources 1106 may be located on a front-facing portion of suction chamber 204 to provide more light on the surface in front of suction chamber 204. Row of optical sources 1106 may be able to produce different colors depending on the state of the vacuum cleaner. For example, row of optical sources 1106 may have a first color when starting the vacuum, a second color to indicate that all components are functioning properly and the vacuum is ready to use, a third color to indicate a clog in the suction path, and a fourth color to indicate a malfunction in one of the nozzle assembly elements, to name a few example conditions. Furthermore, the color produced by row of optical sources 1106 may be adjusted by a user via a switch or button on the vacuum cleaner or nozzle assembly 102.

According to some embodiments, an indicator light 1108 may be present on a top portion of base unit 202. A sensor within base unit 202 may detect the presence of dirt or debris moving through air suction tube 308. Indicator light 1108 may either change color or turn on or off in response to dirt or debris being sensed by the sensor. In this way, a user can tell if an area is clean (e.g., no more dirt or debris is detected) by observing the state of indicator light 1108.

Any of first optical sources 1102, second optical sources 1104, row of optical sources 1106, and indicator light 1108 can include any number of light emitting diodes (LEDs) and color filters to produce any desirable color. According to some embodiments, any of first optical sources 1102, second optical sources 1104, and row of optical sources 1106 can be controlled wirelessly via Bluetooth or Wi-Fi via a PC, laptop, or smartphone device. In some embodiments, a particular application may be installed onto the PC, laptop, or smartphone device to interface with various elements on nozzle assembly 102 and control their operation via Bluetooth or Wifi communication. In some examples, the application may control what colors are produced by any of first optical sources 1102, second optical sources 1104, and row of optical sources 1106, or may control when they are turned on. Other functions may include receiving and/or controlling the RPM speed of first roller 302 or second roller 304.

It should be understood that any of the optical sources discussed above may be modular components that can be removed and/or replaced with different types of optical sources.

FIG. 12A illustrates a perspective view of first roller 302 or second roller 304, and FIG. 12B illustrates a cross-section view of first roller 302 or second roller 304, according to some embodiments. In some examples, first roller 302 and second roller 304 have the same design with the same materials (although they may have different sizes). Accordingly, the illustrated elements of FIGS. 12A and 12B may be describing first roller 302, second roller 304, or both rollers. It should also be understood that the illustrated rollers in FIGS. 12A and 12B could also be rollers in any vacuum cleaner and are not exclusively designed for use within suction chamber 204. The illustrated rollers could be used in vacuum cleaners that use a single roller design, a two-roller design, or a multi-roller design.

Roller 302/304 includes a core 1202 having one or more compliant elements 1204 wrapped around an outside surface of core 1202, according to some embodiments. Core 1202 may be a substantially rigid material, such as metal or hard plastic, and may be solid or have a hollow interior. Compliant elements 1204 may wrap in a spiral pattern across the outer surface of core 1202 to help remove hair off of the bristles around core 1202. According to some embodiments, compliant elements 1204 are anchored to core 1202 using a lobe structure 1206 that is embedded within core 1202. Compliant elements 1204 may include a foam interior protected by an outer polymer shell.

FIG. 12B illustrates a cross section of roller 302/304 showing a first set of bristles 1208 and a second set of bristles 1210 coupled to the outer surface of core 1202 between compliant elements 1204. First set of bristles 1208 may have a greater density and a greater softness compared to second set of bristles 1210. In some examples, second set of bristles 1210 are shorter than first set of bristles 1208. Different types of bristles may exhibit better cleaning ability depending on the surface being cleaned. For example, first set of bristles 1208 can be used to buff a hard surface while the shorter second set of bristles 1210 are kept away from the hard surface to avoid scratching it. However, second set of bristles 1210 help to provide a deeper clean on a carpeted surface.

FIG. 13A illustrates a view of another roller 1300 having a plurality of compliant elements 1302 around the outside of core 1202, according to some embodiments. Compliant elements 1302 may be an elastomeric material, such as a suitable polymer material, that is folded into a given shape around a hollow interior or foam core, as will be discussed in more detail herein. According to some embodiments, compliant elements 1302 include a circular, oval, or teardrop cross-sectional shape.

Compliant elements 1302 extend both longitudinally and circumferentially along the outside surface of core 1202, according to some embodiments. In other embodiments, compliant elements 1302 extend longitudinally but not circumferentially along the outside surface of core 1202. A given compliant element 1302 may start at a first or opposite second end of core 1202 and extend towards the opposite end. In some examples, each compliant element 1302 extends along more than 50% of the entire length of core 1202, such as at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% the entire length of core 1202.

According to some embodiments, one or both ends of compliant elements 1302 include a taper 1304. According to some embodiments, the cross-sectional shape of compliant elements 1302 is maintained through taper 1304, but with a reduction in its size.

FIG. 13B illustrates a view of core 1202 with compliant elements 1302 removed to reveal grooves 1306, according to some embodiments. Grooves 1306 may act like tracks through which compliant elements 1302 are fed and held in place. Accordingly, grooves 1306 may include recessed features of a given shape, as will be discussed in more detail herein. Grooves 1306 define the locations for compliant elements 1302, according to some embodiments.

FIG. 13C illustrates another example roller 1300 with compliant elements 1302 that extend along the entire length of core 1202 in straight lines (e.g., not circumferentially). FIG. 13D illustrates another example roller 1300 with compliant elements 1302 that extend along the entire length of core 1202 in a helix pattern.

FIG. 14 illustrates views of a given compliant element 1302 that is folded together to form a head portion 1402 and an anchor portion 1404, according to some embodiments. Compliant element 1302 may be a continuous sheet that is bent and folded towards itself (as indicated by the arrows on the left) about an axis 1406 passing through the center of compliant element 1302 to produce a structure with head portion 1402 and anchor portion 1404 along an entire length of compliant element 1302, as shown on the right. According to some embodiments, head portion 1402 may have a cross-sectional shape around a hollow interior 1408. The cross-sectional shape of hollow interior 1408 may have a circular, oval, or tear drop shape, to name a few examples. In some embodiments, hollow interior 1408 is filled or substantially filled with a compliant material, such as a foam core or other similar material.

According to some embodiments, the ends of compliant element 1302 are brought together (e.g., folded towards each other) as illustrated by the arrows on the right to form anchor portion 1404. As such, anchor portion 1404 may have a symmetrical shape about axis 1406, such as a ‘T’ shape. According to some embodiments, anchor portion 1404 slides into groove 1306 around core 1202 to attach compliant element 1302 to core 1202. Thus, groove 1306 may have the same corresponding shape of anchor portion 1404.

FIG. 15 illustrates another view of roller 1300 with a first compliant element 1302a extending from a first end 1502a of core 1202 and a second compliant element 1302b extending from a second end 1502b of core 1202, according to some embodiments. As noted above, each compliant element 1302 may extend along more than 50% of the total length of core 1202, such that there will be overlap in the circumferential direction between the compliant elements along the length of core 1202. In the illustrated example, first compliant element 1302a and second compliant element 1302b overlap within a midsection along the length of core 1202. According to some embodiments, the twisting pattern of first compliant element 1302a and second compliant element 1302b is repeated across any number of other compliant elements around core 1202. In some examples, three compliant elements extend from first end 1502a and three compliant elements extend from second end 1502b. Any number of compliant elements may extend from either end using the illustrated twisting pattern of first compliant element 1302a and second compliant element 1302b. According to some embodiments, second compliant element 1302b twists around core 1202 towards first compliant element and may, or may not, contact first compliant element 1302a. Similarly, first compliant element 1302a twists around core 1202 towards a lower compliant element and may, or may not, contact the lower compliant element, and the pattern repeats around the circumference of core 1202. Due to the overlapping design and presence of taper 1304 at the ends of each of first compliant element 1302a and second compliant element 1302b, hair or other strand-like objects naturally migrate towards the center of roller 1300 and away from ends 1502a/1502b where it could get stuck in the bearings or other mechanical linkages made to roller 1300. The hair can then be easily removed from around roller 1300 once concentrated at or near the midpoint.

FIGS. 16A-16E illustrate various examples of compliant element 1302 having different features, according to some embodiments. FIG. 16A illustrates compliant element 1302 including an outer layer 1602 and an inner layer 1604 that are folded together into head portion 1402 around hollow interior 1408, according to some embodiments. Outer layer 1602 may be a hard polymer shell coupled to the outside of inner layer 1604, which may be a softer polymer or foam-based material. In some examples, inner layer 1604 has a greater flexibility compared to outer layer 1602. Both inner layer 1604 and outer layer 1602 may be generally compliant materials, with outer layer 1602 have a higher degree of stiffness compared to inner layer 1604. Outer layer 1602 may be a fabric material, or at least a portion of outer layer 1602 includes a fabric material. For example, half of outer layer 1602 may include a fabric material, such as the leading side of compliant element 1302 that contacts the floor surface based on the rotation direction of roller 1300. Inner layer 1604 may be thicker than outer layer 1602, as generally illustrated in FIG. 16A. In some examples, inner layer 1604 is at least 2 times, 3 times, 4 times, or 5 times thicker than outer layer 1602. The thickness of the layers does not need to remain constant along the entire profile of compliant element 1302. For example, inner layer 1604 may be thicker within anchor portion 1404 and thinner within head portion 1402 to provide greater structural rigidity in anchor portion 1404. In some embodiments, outer layer 1602 is present around head portion 1402, but is absent around anchor portion 1404.

FIG. 16B illustrates compliant element 1302 folded together to form a more compressed oval shape, according to some embodiments. As such, hollow interior 1606 takes on the oval shape as opposed to the teardrop or circular shape illustrated in FIG. 16A. Any number of different shapes can be realized through the bending or folding of compliant element 1302.

FIG. 16C illustrates compliant element 1302 having a rib structure 1608 that protrudes from an outer surface of head portion 1402, according to some embodiments. Rib structure 1608 may extend along at least a portion of a length of compliant element 1302, or along an entire length of compliant element 1302. Although only one rib structure 1608 is illustrated, any number of similar rib structures 1608 may be provided on the outside surface of head portion 1402. Rib structures 1608 may be used to provide further agitation of a surface to be cleaned.

FIG. 16D illustrates compliant element 1302 having any number of relief features 1610 formed within a flexible material layer (such as inner layer 1604), according to some embodiments. Relief features 1610 may be any recesses or cuts made through the inner surface of the flexible material layer. Such relief features 1610 may be provided to aid in the folding or bending of compliant element 1302 and their pattern may dictate the shape of compliant element 1302. Example relief features 1610 include thin cuts through inner layer 1604 that extend longitudinally along the inner surface of head portion 1402 or one or more recesses formed by removing portions of the material of inner layer 1604.

FIG. 16E illustrates compliant element 1302 having any number of inner ribs 1612, according to some embodiments. FIG. 16F illustrates a cross-section view through compliant element 1302 showing multiple inner ribs 1612. Inner ribs 1612 may impart greater structural integrity to head portion 1402. In some examples, inner ribs 1612 are equally spaced from one another along the length of compliant element 1302. Each of inner ribs 1612 may extend around a majority of the inner circumference of head portion 1402, such as at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the inner circumference. Inner ribs 1612 may be formed from the same material as compliant element 1302, or may be a different, stiffer polymer material.

FIG. 17 illustrates another example of roller 1300 having compliant elements 1302 arranged in a chevron configuration along the length of core 1202, according to some embodiments. Compliant elements 1302 may each extend along an entire length of core 1202 in the chevron configuration. According to some embodiments, regions of core 1202 not occupied by compliant elements 1302 include bristles 1702. In some examples, bristles 1702 are densely packed soft filament material. In the illustrated example, bristles 1702 substantially fill the entire outer surface of core 1202 adjacent to compliant elements 1302. In other examples, bristles 1702 are present in specific regions on the outer surface of core 1202. For two-roller or multi-roller nozzle designs (e.g., having more than two rollers), the presence of bristles 1702 can aid in forming a vacuum seal beneath the nozzle between the rollers. In some examples, the presence of bristles 1702 can also provide vacuum chamber sealing in a single roller configuration.

FIGS. 18A-18D illustrate various views of suction chamber 204 both with and without roller 1300, according to some embodiments. FIGS. 18A and 18B illustrate a first roller 1300a and a second roller 1300b arranged within suction chamber 204. The illustrated rollers have the chevron configuration, although any other configuration (e.g., overlapping helix of FIG. 15, straight lines of FIG. 13C, or full helix of FIG. 13D) can be used as well for either the front roller, back roller, or for both rollers. According to some embodiments, a first debriding edge 1802a may be coupled to an underside of suction chamber 204 and designed to contact at least a portion of compliant elements 1302 as first roller 1300a rotates. Similarly, a second debriding edge 1802b may be coupled to an underside of suction chamber 204 and designed to contact at least a portion of compliant elements 1302 as second roller 1300b rotates. Each of first debriding edge 1802a and second debriding edge 1802b may also contact bristles 1702 as they pass by first debriding edge 1802a and second debriding edge 1802b. The debriding edges may be any hard plastic, rigid, semi-rigid, or flexible material to help remove debris that may be stuck to the outer surface of compliant elements 1302 and/or bristles 1702. In some examples, the stiffness of first debriding edge 1802a and second debriding edge 1802b varies along its length to provide a more robust contact to compliant elements 1302 as they pass by. In some embodiments, first debriding edge 1802a and/or second debriding edge 1802b include a dense felt material.

FIG. 18C illustrates the underside of suction chamber 204 with the rollers removed to provide a better view of first debriding edge 1802a, according to some embodiments. As can be observed in this example, first debriding edge 1802a may be a straight sheet extending across substantially the entire width of suction chamber 204 to contact any portion of compliant elements 1302 as they rotate past first debriding edge 1802a. Although not shown in this view, second debriding edge 1802b may have substantially the same straight sheet design as first debriding edge 1802a. FIG. 18D illustrates another example of first debriding edge 1802a having a gull wing design that slopes downwards towards a central point. Although not shown in this view, second debriding edge 1802b may have substantially the same gull wing design as first debriding edge 1802a. In some embodiments, first debriding edge 1802a has the straight sheet design and second debriding edge 1802b as the gull wing design or vice versa.

It should be understood that the nozzle assembly 102 illustrated, for example, in any of FIGS. 2A-11 and the roller design illustrated, for example, in any of FIGS. 12-18 can be utilized within any type of vacuum cleaner. For example, the illustrated nozzle assembly 102 and/or roller 1300 can be used within any standard upright vacuum cleaner, any stick vacuum cleaner, or any canister vacuum cleaner. Furthermore, the suction chamber 204 described herein can be used with any other nozzle assembly designs without substantially altering the design or operation of suction chamber 204.

Numerous specific details have been set forth herein to provide a thorough understanding of the embodiments. It will be understood in light of this disclosure, however, that the embodiments may be practiced without these specific details. In other instances, well known operations and components have not been described in detail so as not to obscure the embodiments. It can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments. In addition, although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described herein. Rather, the specific features and acts described herein are disclosed as example forms of implementing the claims.

Claims

1. A nozzle assembly configured for use on a vacuum cleaner, the nozzle assembly comprising:

a base unit;

an outlet coupled to the base unit and pivotable with respect to the base unit, wherein the outlet is configured for engagement with a suction tube of the vacuum cleaner;

one or more wheels coupled to the base unit; and

a suction chamber coupled to the base unit, and comprising: a first agitator configured to rotate in a first direction, a second agitator configured to rotate in a second direction opposite from the first direction, and a suction port arranged between the first agitator and the second agitator.

2. The nozzle assembly of claim 1, wherein the suction chamber comprises a housing, and the suction port is through a top surface of the housing.

3. The nozzle assembly of claim 2, wherein the suction port is centrally located on the top surface of the housing.

4. The nozzle assembly of claim 3, wherein the suction chamber comprises a first conduit extending from a first side of the suction port to a first side of the suction chamber and a second conduit extending from a second side of the suction port opposite from the first side of the suction chamber to a second side of the suction chamber opposite from the first side of the suction chamber.

5. The nozzle assembly of claim 4, wherein each of the first conduit and the second conduit are upwardly tapered towards the suction port.

6. The nozzle assembly of claim 1, wherein a bottom surface of the suction chamber comprises a structure extending below the suction port and between the first agitator and the second agitator.

7. The nozzle assembly of claim 1, wherein the first agitator is arranged in a forward position of the suction chamber and the second agitator is arranged parallel to the first agitator in a rear position of the suction chamber.

8. The nozzle assembly of claim 1, wherein the suction chamber comprises a first motor configured to rotate the first agitator in a first direction and a second motor configured to rotate the second agitator in a second direction opposite from the first direction, the first and second motors being located between the first agitator and the second agitator.

9. The nozzle assembly of claim 8, wherein the first motor is configured to change the speed of the first agitator or the first and second motors are configured to change the speed of the first and second agitators, respectively, in response to the nozzle assembly moving in a forward direction, and wherein the second motor is configured to change the speed of the second agitator or the first and second motors are configured to change the speed of the first and second agitators, respectively, in response to the nozzle assembly moving in a reverse direction.

10. The nozzle assembly of claim 9, wherein the base unit comprises a sensor, and wherein the sensor is configured to determine a direction of travel of the nozzle assembly.

11. The nozzle assembly of claim 1, wherein the suction chamber is coupled to the base unit about a pivot axis such that the suction chamber is configured to rotate about the pivot axis with respect to the base unit.

12. The nozzle assembly of claim 11, wherein the first and second agitators are first and second rollers, and wherein the pivot axis runs parallel to and between a central axis of the first roller and a central axis of the second roller.

13. The nozzle assembly of claim 1, wherein a geometry of a bottom surface of the suction chamber is mirrored across an axis passing through a center of the suction port and along a length of the suction port.

14. A vacuum cleaner comprising:

the nozzle assembly of claim 1;

a handle at a proximal end of the vacuum cleaner;

a waste receptacle; and

a motor configured to draw air through the nozzle assembly and into the waste receptacle.

15. A suction chamber configured for use on a vacuum cleaner, the suction chamber comprising:

a housing;

first and second coupling ports on the housing, the first and second coupling ports facing each other and spaced apart from each other along an axis, wherein the first and second coupling ports are configured to engage with corresponding coupling structures of a base unit;

a first agitator arranged at a forward position of the housing;

a second agitator arranged at a rear position of the housing; and

a suction port through a top surface of the housing and between the first agitator and the second agitator.

16. The suction chamber of claim 15, wherein the suction port is centrally located on the top surface of the housing.

17. The suction chamber of claim 15, wherein the axis is a pivot axis such that the housing is configured to rotate about the pivot axis relative to the base unit, the pivot axis being arranged between the first agitator and the second agitator.

18. The suction chamber of claim 15, further comprising:

a first motor configured to rotate the first agitator in a first direction; and

a second motor configured to rotate the second agitator in a second direction opposite from the first direction, the first and second motors being located between the first agitator and the second agitator.

19. The suction chamber of claim 18, wherein the first motor is configured to change the speed of the first agitator in response to the suction chamber moving in a forward direction, and wherein the second motor is configured to change the speed of the second agitator in response to the suction chamber moving in a reverse direction.

20. The suction chamber of claim 15, wherein a geometry of a bottom surface of the suction chamber is mirrored across an axis passing through a center of the suction port and along a length of the suction port.