Agitator element for vacuum cleaner

Abstract

An agitator element (22, 24) for a vacuum cleaner includes a support member (50) having opposing first and second end surfaces (51, 52) at first and second ends of the agitator element, respectively. An elongate surface extends between the first and second end surfaces. An agitation material (40) extends away from the first end surface of the support member such that an outermost end of the agitation material defines an outermost end of the first end of the agitator element.

Description

Technical Field

[0001] The invention relates to an agitator element for a cleaner head of a vacuum cleaner, as well as to a cleaner head comprising such an agitator element and a vacuum cleaner comprising such a cleaner head. Background Art

[0002] A vacuum cleaner typically includes a cleaner head having a housing defining a suction chamber. The housing is configured to move over a floor or other surface to be cleaned while air is drawn into the suction chamber along with dust, hair and other dirt to be removed from the surface. An outlet of the housing is connected to a motor via a wand or hose. The motor provides the suction required to generate an airflow through the suction chamber. In many modern vacuum cleaners, the cleaner head includes one or more brush bars or other types of agitator elements that rotate as the housing moves over the surface to be cleaned. The agitator elements serve to separate dirt from the surface and increase the chances of dirt being picked up, thereby improving the cleaning performance of the vacuum cleaner.

[0003] Typically, vacuum cleaner heads experience some degree of hair ingress during use, which means that hair can become lodged in or between parts of the cleaner head. Hair can also become entangled in agitator elements, which can damage the agitator elements and also reduce their ability to separate dirt and hair from the floor, particularly if a thick layer of hair becomes entangled in the agitator elements.

[0004] The vacuum cleaner needs to pick up as much dirt as possible from the floor surface. Therefore, it is desirable that the vacuum cleaner head can collect dirt from the edges of the room or furniture so that no part of the floor is left uncleaned.

[0005] It is in this context that the present invention has been developed. Summary of the invention

[0006] In a first aspect, the present invention provides an agitator element for a vacuum cleaner, the agitator element comprising: a support member having opposing first and second end surfaces and an elongated surface extending between the first and second end surfaces, wherein the first end surface is located near a first end of the agitator element, and wherein the second end surface is located near a second end of the agitator element; and an agitated material extending away from the first end surface of the support member such that the outermost end of the agitated material defines the outermost end of the first end of the agitator element.

[0007] The agitator element of the present invention is advantageous because the agitator material extends beyond the end of the support element, which means that the width of the floor that can be cleaned is greater than the elongated width of the support element.

[0008] Optionally, the agitating material comprises a fabric covering at least a portion of the first end surface. Many different fabrics having many different aesthetic and functional characteristics may be selected as the agitating material. The fabric may be readily applied to the support element as a complete covering or a partial covering. The fabric agitating material may be used alone or in combination with other agitating materials such as bristles.

[0009] The first end surface optionally surrounds a recessed portion of the support member.The recessed portion may be a closed-ended hole in the support member, or it may be a through hole extending along the entire length of the support member.

[0010] At least a portion of the fabric agitating material may extend from the first end surface into the recessed portion to help secure the fabric to the support member and prevent the fabric from flaking or falling off the first end surface.

[0011] In one example, the agitator element includes a post located within the recessed portion, wherein an exterior of the post engages the fabric agitating material located within the recessed portion to help secure the fabric to the support member. Optionally, for ease of manufacturing and reduced part count, the post is integral with the support member.

[0012] The agitating material optionally includes a plurality of upstanding bristles, either used alone or in combination with other agitating materials, such as a fabric agitating material.

[0013] The support member may include a body and an end cap having an outer surface, wherein the outer surface of the end cap defines at least a portion of the first end surface of the support member. The provision of the end cap may facilitate rapid assembly of the stirring element. In one example, the stirring material may cover the outer surface of the end cap.

[0014] Optionally, the agitating material extends away from the elongated surface of the support member. At least a portion of the agitating material extending away from the elongated surface may optionally be continuous with at least a portion of the agitating material extending away from the first end surface, so that the same fabric can be used on the first end surface and the elongated surface, thereby providing material continuity between the two surfaces.

[0015] The composition of the agitating material extending away from the elongate surface may be different from the composition of the agitating material extending away from the first end surface, so that the agitating material most suitable for positioning on the first end surface can be selected independently of the agitating material selected for the elongate surface.

[0016] In one example, the agitating material extends away from the second end surface of the support member, thereby further increasing the effective width of the agitating member. This may be particularly useful when two or more agitating members are used end to end, because any gap between the agitating members is at least partially spanned by the agitating material.

[0017] Optionally, the agitating material extending away from the second end surface includes fabric covering at least a portion of the second end surface, wherein the second end surface surrounds a second recessed portion in the support member, and wherein at least a portion of the fabric agitating material extends from the second end surface into the second recessed portion to help secure the fabric to the support member and prevent the fabric from peeling or falling off the second end surface.

[0018] The agitator element may optionally taper from its first end to its second end, or vice versa. A tapered agitator element is beneficial because any hair or other long fibers picked up by the agitator element tend to migrate along the length of the agitator element toward the tapered end where the hair or other long fibers can be removed. This helps prevent hair and other long fibers from becoming tightly entangled on the agitator element.

[0019] In a second aspect, the invention provides a cleaner head for a vacuum cleaner comprising an agitator element as described above.

[0020] In a third aspect, the invention provides a cleaner head for a vacuum cleaner, the cleaner head comprising a housing defining a suction chamber including an outlet, and an agitator element as described above mounted for rotation within the housing.

[0021] Optionally, the cleaner head comprises a second agitating element, wherein the housing comprises a first side and a second side, and wherein the agitator element is mounted for rotation on the first side of the housing, and the second agitator element is mounted for rotation on the second side of the housing, wherein the respective first ends or second ends of the agitator elements are positioned adjacent to each other.

[0022] In a fourth aspect, the present invention provides a vacuum cleaner comprising a cleaner head as described above.

[0023] Features described in conjunction with the first aspect of the invention are equally applicable to the second, third and fourth aspects of the invention, and vice versa. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a perspective view of an example embodiment of a vacuum cleaner;

[0025] Figure 2 yes Figure 1 a perspective view of a cleaner head of a vacuum cleaner;

[0026] Figure 3 yes Figure 1 a perspective view of an agitator element of the illustrated cleaner head;

[0027] Figure 4 yes Figure 3 a cross-sectional view of an agitator element;

[0028] Figure 5 is a perspective view of an alternative agitator element;

[0029] Figure 6 yes Figure 5 a cross-sectional view of an agitator element;

[0030] Figure 7 is a cross-sectional view of another alternative agitator element;

[0031] Figure 8a is similar to Figure 7 A partial cross-sectional view of an alternative agitator element to the agitator element of ;

[0032] Figure 8b yes Figure 8a a partial perspective view of an agitator element;

[0033] Figure 9a is a partial cross-sectional view of other alternative agitator elements.

[0034] Figure 9b yes Figure 9a a partial perspective view of an agitator element;

[0035] Fig.10a is a partial cross-sectional view of yet another alternative agitator element;

[0036] Fig.10b yes Fig.10a a partial perspective view of an agitator element; and

[0037] Figures 11a to 11b is a partial perspective view of another alternative agitator element. DETAILED DESCRIPTION

[0038] Figure 1 A handheld vacuum cleaner 2 is shown, comprising a main body 4, a wand 6 and a cleaner head 20. The main body 4 comprises a separation system 10 in the form of a cyclonic separator, a motor and impeller (not visible) arranged to draw air through the separation system 10, and a power supply 12 in the form of a battery for powering the motor. The main body 4 has a handle 14 for gripping by a user and a clean air outlet 16 through which air that has passed through the separation system 10 is discharged. The wand 6 is attached to the main body 4 at one end and to the cleaner head 20 at the other end. The wand 6 provides fluid communication between the cleaner head 20 and the separation system 10 and supports the cleaner head 20 during use.

[0039] Figure 2A cleaner head 20 of a vacuum cleaner 2 is shown. The cleaner head 20 has a housing 32 at least partially defining a suction chamber including an outlet 34 for exhausting air and debris towards the vacuum cleaner 2. The cleaner head 20 comprises a first agitator element 22 and a second agitator element 24. In this embodiment, the agitator elements 22, 24 are realized as frustoconical agitator elements 22, 24, which will be described in more detail below.

[0040] The first and second agitator elements 22, 24 are each mounted to rotate around their respective axes R1, R2. Each agitator element 22, 24 includes a first free end 26a, 26b and a second end 28a, 28b, which are mounted to the cleaner head 20 at the second end 28a, 28b. In this embodiment, the agitator elements 22, 24 have a truncated cone shape, which tapers toward the first end 26a, 26b in the direction along the axis of rotation R1, R2. The two agitator elements 22, 24 are cantilevered from opposite sides of the hub portion 30 of the cleaner head 20 at their respective second ends 28a, 28b. It should be understood that a portion of one or both of the agitator elements 22, 24 may not be conical. For example, the shape of one or both of the agitator elements 22, 24 may include a cylindrical portion combined with a truncated cone portion. In other embodiments, the agitator elements 22, 24 may be completely cylindrical.

[0041] In the illustrated embodiment, the hub portion 30 is located at a laterally central position relative to the entire cleaner head 20, although this may not always be the case. For example, if the first and second agitator elements 22, 24 have different lengths, the hub portion 30 may be laterally offset relative to the laterally central portion of the cleaner head 20. The hub portion 30 is used to rotatably support the second ends 28a, 28b of the agitator elements 22, 24, and may include a drive housing that holds a drive mechanism for rotating the agitator elements 22, 24. In alternative embodiments, the agitator elements may be cantilevered from a separate hub located at the first ends 26a, 26b of the agitator elements 22, 24, or the agitator elements 22, 24 may be supported by hubs located at the first ends 26a, 26b and the second ends 28a, 28b of the agitator elements 22, 24.

[0042] Figure 3 and 4 A perspective view and a cross-sectional view are shown respectively of the first agitator element 22. It should be understood that all features described below with respect to the first agitator element 22 are equally applicable to the second agitator element 24, and for the sake of brevity, only the first agitator element 22 is described in detail below.

[0043] like Figure 4As shown, the agitator element 22 includes a fabric agitating material 40 supported by a support member 50. The support member 50 includes an elongated surface 53 extending between a first end surface 51 of the support member 50 located near the first end 26a of the agitator element 22 and a second end surface 52 of the support member 50 located near the second end 28a of the agitator element 22. The support member 50 has a recessed portion 58 located near the first end 26a of the agitator element 22 and a second recessed portion 59 located near the second end 28a of the agitator element 22, so that the first and second end surfaces 51, 52 of the support member 50 are annular.

[0044] The fabric agitating material 40 includes a textile material having a fluffy outer layer 46 and a backing layer 45. The backing layer 45 is attached to the support member 50 with an adhesive so that the entire elongated surface 53 and the first and second end surfaces 51, 52 are covered with the agitating material 40. The agitating material is wrapped around the ends of the support member 50 so that the agitating material 40 extends from the first and second end surfaces 51, 52 into the recessed portion 58 and the second recessed portion 59. In an alternative example (not shown), the agitating material 40 may terminate at the radially innermost edge of the first and / or second end surfaces 51, 52 so that it does not extend into one or both of the recessed portion 58 or the second recessed portion 59.

[0045] The agitated material 40 extends away from the elongated surface 53 and away from the first and second end surfaces 51, 52 such that the outermost extremities of the agitated material 40 define the outermost extremities of the agitator element 22. Thus, the outermost extremities of the agitated material 40 at the first end 26a of the agitator element 22 define the outermost extremities 60 of the first end 26a of the agitator element 22, and the outermost extremities of the agitated material 40 at the second end 28a of the agitator element 22 define the outermost extremities 61 of the second end 28a of the agitator element 22.

[0046] Figure 5 and Figure 6 A perspective view and a cross-sectional view, respectively, of an alternative arrangement of an agitator element 22 are shown. Figure 5 and 6 The agitator element 22 is similar in all respects to Figure 3 and 4 The agitator elements shown are identical except that the agitated material 40 comprises a common backing layer 45 having two distinct outer layers 46 , 47 .

[0047] The outer layer includes Figure 3 and 4The fluffy outer layer 46 is the same as the first outer layer 46 and the second outer layer 47. The material properties of the second outer layer 47 are different from the material properties of the first outer layer 46, so that the agitator element 22 can perform two functions at the same time. For example, the first outer layer 46 can be selected based on its ability to separate dirt, while the second outer layer 47 is selected based on its polishing ability.

[0048] The first and second outer layers 46, 47 of the agitator element 22 may include any suitable material. For example, both outer layers 46, 47 may be fluffy, but have fibers with different orientations, and / or fibers with different stiffnesses. Alternatively, one of the outer layers may be fluffy and the other may not be fluffy. It should be understood that Figure 5 and 6 The embodiment shown is merely an example and it is not essential that the fluff layer is located in the region of the agitator head indicated by reference numeral 46 .

[0049] exist Figure 5 and Figure 6 In the embodiment of the present invention, two outer layers 46, 47 of the agitation material 40 are woven together with a common backing layer 45. In alternative embodiments, one or both of the outer layers 46, 47 can be applied to the backing layer 45 with an adhesive. Thus, the outer layers 46, 47 can be flocked, or can include non-woven materials, such as felt or combed natural or synthetic fibers. The backing material 45 can be a woven material or a non-woven material. For some materials, such as felt materials, there can be no backing layer, so that the material is directly attached to the support member 50.

[0050] In an alternative embodiment (not shown), the agitator element 22 may include separate agitating materials 40 that do not have a backing layer or do not share a common backing layer 45. Such separate components may be attached to the support member 50 adjacent to each other so that the entire elongated surface 53 and the first and second end surfaces 51, 52 are covered by the agitating material 40. Alternatively, only portions of the elongated surface 53 and the first and second end surfaces 51, 52 may be covered by the agitating material 40. In either case, the agitating material 40 may optionally extend into one or both of the recessed portion 58 or the second recessed portion 59.

[0051] In another alternative example, one or more agitating materials 40 may include a plurality of upright bristles that are supported directly by the support member 50, or are applied to or formed with the backing material 45 of one or more pieces of fabric agitating material 40. The bristles may be used with or in place of the fabric agitating material. The bristles may extend from the support member 50 in any suitable direction.

[0052] The agitator element 22 may include any number and / or configuration of agitating material. The composition of the agitating material 40 on the first and / or second end surfaces 51 , 52 may be different than the composition of the agitating material 40 on the elongated surface 53 .

[0053] Figure 7 is a cross-sectional view of another alternative agitator element 22 . Figure 7 The agitator element 22 is similar in all respects to Figure 3 and 4 The agitator elements shown are identical except that the support member 50 includes an integral strut 54 at the first end 26a of the agitator element 22 and the fabric agitation material 40 has been processed at the second end 28a after being attached to the support member 50 .

[0054] As shown, the struts 54 are connected to the body of the support member 50 by an annular wall 55, thereby defining an annular recessed portion 58 at the first end 26a of the agitator element 22 between the struts 54 and the body of the support member 50. The agitator material 40 extends from the first end surface 51 into the annular recessed portion 58 so that the outer portion 56 of the struts engages the fabric agitating material located within the recessed portion 58. Because the radial depth of the annular recessed portion 58 is less than the thickness of the agitating material 40, the fluffy outer layer 46 of the agitating material 40 is compressed within the annular recessed portion 58. This compression is sufficient to retain the agitating material 40 in the annular recessed portion 58. Alternatively or additionally, an adhesive and / or a retaining structure can be formed in the surface of the recessed annular portion 58 to help hold the agitating material 40 in place.

[0055] After the agitating material 40 at the second end 58a of the agitator element 22 has been attached to the support member 50 by removing the outer layer 46 of the agitating material 40 from within the second recessed portion 59, the agitating material 40 has been processed. The backing layer 45 remains in place within the second recessed portion 59. In another alternative example, the backing layer may also be removed during this process.

[0056] It will be appreciated that by providing an integral support at the second end 28a, an annular recessed portion may be provided at the second end 28a of the agitator element 22 as well as at the first end 26a. Similarly, some or all of the agitating material 40 may be removed from the recessed portion at the first end 26a of the agitator element 22, regardless of whether the recessed portion at the first end 26a is formed. Figure 7 The ring shown is still Figures 3 to 6 Non-circular shown.

[0057] Figure 8a and 8b The partial cross-sectional view and perspective view respectively show alternative arrangements of the first end 26a and / or the second end 28a of the agitator element. Figure 8a and 8b 28a, but it will be appreciated that the same arrangement may also or alternatively be used at the second end 28a.

[0058] Figure 8a and 8b The first end 26a of the agitator element 22 is shown to be similar in all respects to the Figure 7 The agitator element shown is the same except that separate posts 70 are used in place of integral posts 54. After the agitating material 40 has been applied to the support element 50 and clamped in place by engagement of the clip structures 72 at the innermost ends of the posts 70 and the annular wall 55, the posts 70 are positioned in the recessed portion 58. The outermost ends of the posts 70 include radially extending lips 71 that compress the agitating features 40 between the edges of the lip 71 and the body of the support member 50. The agitating material 40 located in the recessed portion 58 may be held in place by the posts 60 alone, or an adhesive may be used with the posts 70.

[0059] Figure 9a and 9b A partial cross-sectional view and an isometric view, respectively, show another alternative arrangement of the first end 26a and / or the second end 28a of the agitator element. Figure 9a and 9b 28a, but it will be appreciated that the same arrangement may also or alternatively be used at the second end 28a.

[0060] In this example, the support member 50 includes a body 49 and an end cap 75. The body 49 of the support member 50 is covered with agitating material, and the outer end 76 of the end cap 75 is covered with agitating material 40. The end cap 75 is held in place by a clip structure 77 located at the innermost end of the end cap 75. The clip structure 77 engages with the annular wall 57 located at the outermost end of the body 49.

[0061] exist Figure 9a and 9b In an alternative arrangement to the arrangement shown, the end cap 75 may include a recessed portion so that the first end 26a of the agitator element is similar to Figure 8a and 8b A first end 26a is shown.

[0062] Fig.10a and 10b A partial cross-sectional view and an isometric view, respectively, show yet another alternative arrangement of the first end 26a and / or the second end 28a of the agitator element. Fig.10a and 10b 28a, but it will be appreciated that the same arrangement may also or alternatively be used at the second end 28a.

[0063] In this example, the support member 50 includes a wall 63 at its outermost end, which is proximate to the first end 26a of the agitator element, wherein the outermost surface of the wall 63 includes the first end surface 51 of the support member 50. The elongated surface 53 of the support member is covered by the first agitating material 40, and the first end surface 51 is covered by the second agitating material 48. Alternatively, the agitating material on the first end surface 51 may be the same as the agitating material on the elongated surface 53.

[0064] The annular rim 64 surrounds the covered portion of the first end surface 51 so that a portion of the support element 50 is not covered by the agitating material 40, 48. This is not required, and in another example, the agitating material 40, 48 may cover the entire first end surface 51.

[0065] Fig.11a and 11b is a partial perspective view of another alternative arrangement of the first end 26a and / or the second end 28a of the agitator element. Fig.11a and 11b 28a, but it should be understood that the same arrangement can also be used at the second end 28a or alternatively at the second end 28a.

[0066] exist Fig.11a In the example of FIG. 5 , only a portion of the first end surface 51 of the support member is covered by the agitated material 40, while in Fig.11b In the example shown in FIG. 4 , a plurality of upright bristles 90 extend from a first end surface of the support member, and the elongated surface is covered with the fabric agitating material 40 .

Claims

1. An agitator element for a vacuum cleaner, the agitator element comprising: a support member having opposing first and second end surfaces and an elongated surface extending between the first and second end surfaces, wherein the first end surface is located proximate a first end of the agitator element, and wherein the second end surface is located proximate a second end of the agitator element; and An agitating material extends away from the first end surface of the support member such that an outermost end of the agitating material defines an outermost end of the first end of the agitator element.

2. The agitator element of claim 1, wherein the agitating material comprises a fabric covering at least a portion of the first end surface.

3. An agitator element according to claim 2, wherein the first end surface surrounds a recessed portion of the support member.

4. An agitator element according to claim 3, wherein at least a portion of the fabric agitating material extends from the first end surface into the recessed portion.

5. An agitator element according to claim 4, comprising a post located within the recessed portion, wherein an exterior of the post engages the fabric agitating material located within the recessed portion.

6. An agitator element according to claim 4, wherein the struts are integral with the support member.

7. An agitator element according to any one of the preceding claims, wherein the agitating material comprises a plurality of upstanding bristles.

8. An agitator element according to any one of the preceding claims, wherein the support member comprises a body and an end cap having an outer surface, wherein the outer surface of the end cap defines at least a portion of the first end surface of the support member.

9. An agitator element according to claim 8, wherein the agitating material covers an outer surface of the end cap.

10. An agitator element according to any preceding claim, wherein the agitated material extends away from the elongate surface of the support member.

11. An agitator element according to claim 10, wherein at least a portion of the agitating material extending away from the elongated surface is continuous with at least a portion of the agitating material extending away from the first end surface.

12. An agitator element according to claim 10 or 11, wherein the composition of the agitating material extending away from the elongate surface is different to the composition of the agitating material extending away from the first end surface.

13. An agitator element according to any preceding claim, wherein the agitating material extends away from the second end surface of the support member.

14. An agitator element according to claim 13, wherein the agitating material extending away from the second end surface includes fabric covering at least a portion of the second end surface, wherein the second end surface surrounds a second recessed portion in the support member, and wherein at least a portion of the fabric agitating material extends from the second end surface into the second recessed portion.

15. An agitator element according to any one of the preceding claims, wherein the agitator element tapers from its first end towards its second end, or tapers from its second end towards its first end.

16. A cleaner head for a vacuum cleaner, the cleaner head comprising an agitator element according to any preceding claim.

17. A cleaner head for a vacuum cleaner, the cleaner head comprising: a housing defining a suction chamber including an outlet; and 16. An agitator element as claimed in any one of claims 1 to 15, mounted for rotation within the housing.

18. A vacuum cleaner head according to claim 17, comprising a second agitating element according to any one of claims 1 to 15, wherein the housing comprises a first side and a second side, and wherein the agitator element is mounted for rotation on the first side of the housing and the second agitator element is mounted for rotation on the second side of the housing, wherein the respective first ends or second ends of the agitator elements are positioned adjacent to each other.

19. A vacuum cleaner comprising a cleaner head according to claim 17 or 18.

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