Vacuum cleaner with removable agitator assembly

Abstract

A vacuum cleaner includes a first agitator, a second agitator, a suction conduit, a drive motor, and a removable assembly including at least one of the agitators. The removable assembly can include drive components operably connecting the drive motor with one or both of the agitators. The housing can have a removable sole plate that is removed to access the assembly. Methods for user disassembly of a vacuum cleaner with a removable agitator assembly are also provided.

Description

BACKGROUND

[0001] Vacuum cleaners generally include a suction conduit with an opening on the underside of a surface cleaning base for drawing air and debris into and through the cleaning base. A goal with vacuum cleaner design is to effectively loosen debris and capture the debris in the flow of air into the suction conduit. Vacuum cleaners generally use an agitator to aid in this goal. An agitator is often used in the suction conduit of a cleaning base proximate a suction inlet to cause agitated debris to flow into the suction conduit. If the agitator is unable to loosen the debris or if the debris is too small, the suction conduit may pass over the debris without removing the debris from the surface. In other cases, the surface cleaning base may push or plow larger debris forward without ever allowing the debris to be captured in the flow into the suction conduit. To combat these issues, some vacuum cleaners have dual agitators, with a front or leading agitator configured to prevent plowing of larger debris without scattering smaller debris and a rear or trailing agitator located in the suction conduit.

[0002] Challenges with dual agitator vacuum cleaners including accommodating two agitators within the cleaning base and providing a way for the end user to access the agitators and their drive components for servicing and / or replacement of said parts. The steps to access the agitators and their drive components are often numerous and frustrating, leading to user neglect of service needs and poor vacuum cleaner performance. It remains challenging to service and replace components on many dual agitator vacuum cleaners.BRIEF SUMMARY

[0003] A vacuum cleaner with a removable agitator assembly is provided herein. The removable assembly can include an agitator and drive components operably connecting the drive motor with the agitator or with multiple agitators.

[0004] According to one aspect of the disclosure, a vacuum cleaner includes a housing defining an agitator chamber and a suction conduit with a suction conduit opening on an underside of the housing facing a surface to be cleaned, an agitator drive motor, a first agitator rotatable about a first agitator axis, a second agitator rotatable about a second agitator axis, a sole plate removably attached on the underside of the housing, and an agitator assembly removably mounted to the housing as a complete unit, the agitator assembly having the first agitator and a drive module including a first belt coupling the first agitator with the drive motor and a second belt coupling the second agitator with the first agitator.

[0005] According to another aspect of the disclosure, a vacuum cleaner includes a housing, an agitator drive motor, a first agitator rotatable about a first agitator axis, a second agitator rotatable about a second agitator axis, a sole plate removably attached on an underside of the housing, and an agitator assembly removably mounted to the housing as a complete unit, the agitator assembly having the first agitator and a drive module coupling the first agitator directly with the drive motor and coupling the second agitator indirectly with the drive motor via a coupling with the first agitator.

[0006] In these and other aspects of the disclosure, the drive module can be disposed on a lateral side of housing, outboard of a cleaning path of the vacuum cleaner.

[0007] In these and other aspects of the disclosure, the agitator assembly is clamped to the housing by the sole plate to hold the agitator assembly in a working position, whereby the agitator assembly is removable as a complete unit through the underside of the housing after removal of the sole plate from the housing.

[0008] In these and other aspects of the disclosure, the drive module comprises a drive casing having an interior chamber, wherein the drive components for the second agitator are contained entirely within the interior chamber of the drive casing.

[0009] In these and other aspects of the disclosure, the drive module is clamped between the housing and the sole plate to hold the agitator assembly in the working position.

[0010] In these and other aspects of the disclosure, the housing comprises a belt compartment in which a motor pulley is housed, and the belt compartment is sized with a clearance gap next to the motor pulley such that a user can pull a belt off the motor pulley using a finger.

[0011] In this and other aspects of the disclosure, the sole plate has a belt guard configured to close the belt compartment when the sole plate is attached on the underside of the housing, whereby removal of the sole plate from the housing exposes the belt compartment for access from an exterior of the housing.

[0012] In these and other aspects of the disclosure, the vacuum cleaner can have a cord guard pivotally attached to the housing and traversing the suction conduit opening in a working position thereof, wherein the cord guard is held in the working position thereof by the sole plate.

[0013] According to another aspect of the disclosure, a removable agitator assembly for a vacuum cleaner includes a first agitator and a drive module connected to the first agitator. The drive module includes a drive casing having an interior chamber, a cover enclosing the interior chamber, a first belt coupled with the first agitator and extending from the interior chamber to outside of the drive casing to couple the first agitator with a drive motor of the vacuum cleaner, and a second belt coupled with the first agitator and contained entirely within the interior chamber. The first agitator can be freely rotatable relative to at least the drive casing and the cover. The drive module can couple a second agitator indirectly with the drive motor via the second belt. The agitator assembly can be removed as a complete unit from an underside of the vacuum cleaner.

[0014] According to still another aspect of the disclosure, a method for user disassembly of a vacuum cleaner having a housing and an agitator assembly removably mounted to the housing as a complete unit is provided herein.

[0015] These and other features and advantages of the present disclosure will become apparent from the following description of particular embodiments, when viewed in accordance with the accompanying drawings and appended claims.

[0016] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a side view of a vacuum cleaner including a cleaning base according to one aspect of the disclosure;

[0018] FIG. 2 is a bottom perspective view of the cleaning base of FIG. 1;

[0019] FIG. 3 is a front perspective view of the vacuum cleaner of FIG. 1;

[0020] FIG. 4 is a cross-sectional view of a portion of the cleaning base taken through line IV-IV of FIG. 3;

[0021] FIG. 5 is a bottom perspective, partially exploded view of the cleaning base of FIG. 1, showing a sole plate and a roller disassembled from the cleaning base;

[0022] FIG. 6 is a cross-sectional view of a portion of the cleaning base taken through line VI-VI of FIG. 3;

[0023] FIG. 7 is a perspective view of an agitator assembly according to one aspect of the disclosure; and

[0024] FIG. 8 is an enlarged, partially exploded view of one end of the agitator assembly of FIG. 7;

[0025] FIG. 9 is an exploded view of the agitator assembly of FIG. 7;

[0026] FIG. 10 is a cross-sectional view of the cleaning base taken through line X-X of FIG. 3 to show a brushroll and drive module of the agitator assembly, with break lines indicating that a portion of the cleaning base is not shown for clarity;

[0027] FIG. 11 is a cross-sectional view of the cleaning base taken through line XI-XI of FIG. 3 to show a roller and its connection with the drive module of the agitator assembly, with break lines indicating that a portion of the cleaning base is not shown for clarity;

[0028] FIG. 12 is a bottom perspective view of the cleaning base of FIG. 1, illustrating the movement of a cord guard to an open position;

[0029] FIG. 13 is a bottom perspective view of the cleaning base of FIG. 1, illustrating the initial removal of the agitator assembly out of the cleaning; and

[0030] FIG. 14 is a bottom perspective view of the cleaning base of FIG. 1, illustrating the final removal of the agitator assembly from the cleaning base after disconnection of a drive coupling.BRIEF DESCRIPTION

[0031] The invention generally relates to a vacuum cleaner with a removable agitator assembly. The agitator assembly may include an agitator and drive components for the agitator, and is configured to be disassembled by the end user of the vacuum cleaner for servicing and / or replacement of the assembly or a component of the assembly. Aspects of the disclosure described herein are further related to a vacuum cleaner with dual agitators, including, but not limited to, the vacuum cleaner including a removable agitator assembly having drive components for the dual agitators. Aspects of the disclosure described herein are further related to a cleaning base with a removable agitator assembly and / or dual agitators.

[0032] As used herein, a “cleaning base” refers to a device configured to contact a surface for cleaning the surface by use of suction air flow, agitation, or a combination thereof. A cleaning base may be coupled with an upright body, wand, or handle for directing the base across the surface to be cleaned, and may be pivotably or steeringly coupled by a swivel connection to an upright body, wand, or handle. A cleaning base may also be operable without an upright body, wand, or handle.

[0033] As used herein, the term “user disassembly” and variations thereof refer to intentional disassembly by an end user of the vacuum cleaner without the use of destructive forces, including disassembly with or without the use of commonplace household tools. Unless otherwise noted, user disassembly of components from the vacuum cleaner includes the ability for such components to be reassembled to the vacuum cleaner.

[0034] As used herein, the term “debris” includes dirt, soil, dust, hair, stains, and other debris, unless otherwise noted.

[0035] As used herein, the term “flow path” refers to the path taken by air as it flows into a suction conduit when drawn in by suction.

[0036] As used herein, “seal” or “sealing” refers to preventing a substantial amount of air from passing through to the suction conduit but does not require an airtight seal.

[0037] As used herein, “agitator” refers to any element, member, or structure capable of agitating a surface to facilitate movement of debris into a suction air flow in a surface cleaning base.

[0038] As used herein, “soft” and “softer” refer to the characteristics of a cleaning element being more compliant or pliable than another cleaning element.

[0039] As used herein, the terms “outboard” and “inboard” refer to being located farther and nearer, respectively, the center of the surface cleaning base in an orientation of the surface cleaning base on a surface to be cleaned. For reference, the center of the surface cleaning base is defined by a longitudinal axis C of the surface cleaning base (see FIGS. 2 and 3) passing through the middle of the base and that is generally parallel to a direction that a user pushes the surface cleaning base on a surface being cleaned (i.e., back to front).

[0040] As used herein, the terms “above” and “below” and derivatives thereof are used relative to an orientation of the surface cleaning base on a surface to be cleaned and the terms “front” and “back” and derivatives thereof are used relative to a direction that a user pushes the surface cleaning base on a surface being cleaned (i.e., back to front).

[0041] As used herein, the term “leading” refers to a position in front of at least another component but does not necessarily mean in front of all other components.

[0042] Referring to FIGS. 1-2, a vacuum cleaner 10 according to one aspect of the present disclosure is shown and described. As discussed in further detail below, the vacuum cleaner 10 has a cleaning base 12 having dual agitators and a removable assembly including at least one of the agitators and drive components for at least one of the agitators, which is described in further detail below. The vacuum cleaner 10 can include at least one cleaning system, including, but not limited to, a vacuum collection system that removes debris from the surface to be cleaned and stores the collected debris within the vacuum cleaner 10.

[0043] The cleaning base 12 is adapted to move over a surface to be cleaned and includes a housing 14 with a front side 16F, and a back side 16B, lateral or left and right sides 18L, 18R, an upper side 20, and a lower or underside 22 between the front side 16F and the back side 16B. The housing 14 defines a brush chamber 24 and a suction conduit 26 having an opening 28 on the underside 22 of the housing 14 (shown schematically in FIG. 1). The housing 14 may comprise a single housing piece, or multiple housing pieces coupled together.

[0044] The suction conduit 26 is fluidly coupled to a dirty air inlet 30, which leads to a suction motor 32 (shown schematically in FIG. 3) either in the base 12 or another location in the vacuum cleaner 10. The suction conduit 26 is the interior space defined by interior walls in the housing 14, which receives and directs air drawn in by suction, and the opening 28 is where the suction conduit 26 meets the underside 22 of the housing 14. The suction conduit 26 can pass through at least a portion of the brush chamber 24. Although an embodiment of the housing 14 is described herein for illustrative purposes, the housing 14 and components thereof may have other shapes and configurations.

[0045] The cleaning base 12 includes dual agitators, for example, a first agitator 36 and a second agitator 38 configured to rotate about first and second rotating axes X, Y, respectively, that generally extend perpendicular to the intended direction of the vacuuming movement of the cleaning base 12 and / or generally parallel to the front side 16F. The rotating axes X, Y may further be perpendicular to the longitudinal axis C of the cleaning base 12. In at least some embodiments, the first agitator 36 is a brushroll 36 and the second agitator 38 is a leading roller 38, and will be referred to herein as such, although it is understood that alternative agitators are possible. The rotating brushroll 36 and / or the leading roller 38 may be coupled to, and rotated about the rotating axes X, Y, by one or more motors. According to one aspect of the disclosure, as described in further detail below, the agitators are rotated by a single drive motor 60.

[0046] The cleaning base 12 can include a cord guard 34 configured to prevent large objects (e.g., a power cord) from being drawn into the suction conduit 26. The cord guard 34 is coupled to the housing 14 and traverses the opening 28 to the suction conduit 26. As used herein, “traverses” or “traversing” refers to extending across or over. As such, the cord guard 34 can block the opening 28, but does not seal the opening 28 against air and debris ingestion. In another embodiments, a cord guard is not included with the base 12.

[0047] The cleaning base 12 includes removable agitator assembly 40 including at least one of the agitators and drive components for at least one of the agitators. The removable assembly 40 is removably coupled to the housing 14 and is removable from the housing 14 by an end user of the vacuum cleaner 10 without the use of destructive forces. The removable assembly 40 can be disassembled from the housing 14 with or without the use of commonplace household tools. The same removable assembly 40 can be reassembled to the housing 14, or may be replaced with a new assembly 40. In the present embodiment, the agitator assembly 40 includes the brushroll 36 and drive components for both the brushroll 36 and the roller 38.

[0048] Referring to FIGS. 1 and 3, and consistent with an embodiment of the present disclosure, the vacuum cleaner 10 can be an upright vacuum cleaner having upright body 42 coupled with the cleaning base 12 to direct the base 12 over the surface to be cleaned. The various systems and components described for the vacuum cleaner 10 can be supported by either or both the base 12 and the upright body 42, except where expressly specified to the contrary. Alternatively or additionally to the upright body 42, the vacuum cleaner 10 can have a wand and / or handle.

[0049] The vacuum collection system can include the suction conduit 26, the dirty air inlet 30, the suction motor 32, which is in fluid communication with the suction conduit 26 for generating a working air stream, a collection container 44 for separating and collecting debris from the working airstream for later disposal, and a clean air outlet (not shown). When the suction motor 32 is activated, debris-laden working air is drawn in through the suction conduit 26 and into the downstream collection container 44, where the debris is substantially separated from the working air. The airstream then passes through the suction motor 32 prior to being exhausted from the vacuum cleaner 10 through the clean air outlet.

[0050] A separator (not shown) can be formed in a portion of the collection container 44 for separating entrained debris from the working airstream. The separator can include, but is not limited to, a cyclonic separator having one or more cyclonic separation stages, a bulk separator, a filter bag, or a combination thereof. The collection container 44 can be removable from the upright body 42 or from the base 12 for emptying collected debris.

[0051] The suction motor 32 and other electrical components of the vacuum cleaner 10 can be electrically coupled to a power source, such as a power cord 46 plugged into a household electrical outlet. Alternatively, the power source may be a battery. While not shown for clarity, the vacuum cleaner 10 may also include one or more controllers and / or sensors disposed within and / or coupled to the upright body 42 or the base 12.

[0052] Referring to FIG. 4, a cross-sectional view of a portion of the base 12 is shown on a surface to be cleaned S. The brushroll 36 is mounted to the housing 14 within the brush chamber 24, and can be at least partially disposed within the suction conduit 26, which can pass through at least a portion of the brush chamber 24. The brushroll 36 is exposed to the flow path (e.g., arrows F) into the opening 28 and through the suction conduit 26. At least a portion of the brushroll 36 can extend through the suction conduit opening 28 to engage the surface to be cleaned. In some embodiments, the suction conduit 26 can also define at least a portion of the brush chamber 24 itself, including, but not limited to, a lower portion of the brush chamber 24.

[0053] The leading roller 38 is mounted to the housing 14 in front of the brushroll 36. The leading roller 38 can preferably be positioned in front of and spaced from the brushroll 36 and at least substantially outside the suction conduit 26. In certain embodiments, at least some of the inner upper portion of the leading roller 38 may not be exposed to the flow path F into the opening 28 of the suction conduit 26 while at least an inside of the bottom portion of the leading roller 38 is exposed to the flow path F into the opening 28 of the suction conduit 26. The leading roller 38 is received in a leading roller chamber 48, which may prevent portions of the inside upper quadrant of the leading roller 38 from being exposed to the flow path F. Other variations are possible with different portions of the leading roller 38 being exposed and not exposed to the flow path. A space between lower portions of the leading roller 38 and the brushroll 36 forms an inter-roller air passageway 50 that may provide at least a portion of the flow path F into the opening 28 of the suction conduit 26 and allow debris to be carried into the suction conduit 26.

[0054] The leading roller 38 may be spaced apart a distance L (which is greater than 0 mm) from the brushroll 36 such that the leading roller 38 does not contact the brushroll 36. The distance L allows for the passageway 50 between lower portions of the brushroll 36 and the leading roller 38, which provides at least a portion of the flow path F into the opening 28 of the suction conduit 26. The passageway 50 allows for debris that is either picked up by (and / or removed from) the leading roller 38 to be entrained in the flow path F and / or to be picked up by the brushroll 36.

[0055] The housing 14 is open at the front side 16F such that a debris opening 52 is defined by a clearance H between a lower end of the front side 16F and the surface S, wherein the clearance is greater than 0 mm, and optionally less than 15 mm, alternatively less than 11 mm. A space between an outside of the bottom portion of the leading roller 38 and the debris opening 52 forms a debris passageway 54 that allows debris to pass into the housing 14 and not be pushed or plowed forward. The roller 38 can substantially seal the debris passageway 54 from the flow path F into the opening 28 of the suction conduit 26 to mitigate, or prevent, suction loss at the front side 16F of the housing 14. As discussed further below, in at least some embodiments the roller 38 is soft or compressible to roll over the debris that enters through the debris opening 52.

[0056] The leading roller 38 may be positioned within the housing 14 such that a bottom contact surface 56 thereof is disposed closer to the surface S compared to a bottom contact surface 58 of the brushroll 36. This arrangement allows the leading roller 38 to contact a surface (e.g., a hard surface) without the brushroll 36 contacting the surface. The brushroll 36 is intended to primarily contact a carpet surface This arrangement allows the leading roller 38 to form a seal with the hard surface, thereby enhancing airflow and suction with the hard surface. As may be appreciated, the leading roller 38 may pick up some debris from surface while the brushroll 36 is intended to primarily move debris into the suction conduit 26.

[0057] The brushroll 36 may have bristles, fabric, or other cleaning elements, or any combination thereof around the outside of the brushroll 36. The size and shape of the bristles may be selected based on the intended application. For example, the brushroll 36 may include bristles having a length of between 15-19 mm, alternatively around 17 mm, and may be grouped in tufts having a diameter of around 6 mm at the outer end of the tuft. The bristles may be made on any material such as, but not limited to, nylon.

[0058] The leading roller 38 may include a relatively soft material (e.g., soft bristles, fabric, felt, nap, or pile). The leading roller 38 may be selected to be substantially softer than the brushroll 36. The softness, length, diameter, arrangement, and resiliency of the bristles and / or pile of the leading roller 38 may be selected to form a seal with a hard surface (e.g., but not limited to, a hard wood floor, tile floor, laminate floor, or the like), whereas the bristles of the brushroll 36 may selected to agitate carpet fibers or the like. Softness may be determined, for example, based on the pliability of the bristles or pile being used.

[0059] The size and shape of the bristles and / or pile for the leading roller 38 may be selected based on the intended application. For example, the leading roller 38 may include pile having a length of between 8-12 mm, alternatively around 10 mm, and may have a diameter of 0.01-0.04 mm. The pile may be made of any material such as, but not limited to, microfiber, silk, cotton, wool, synthetic fibers, or a combination of materials.

[0060] The leading roller 38 may have an outside diameter DL that is smaller than the outside diameter DB of the brushroll 36. For example, the roller diameter DL may be greater than zero and less than 1X× the brushroll diameter DB, or in the range of 0.5× to 0.75× the brushroll diameter DB. As an illustrative example, the brushroll 36 may have an outside diameter of 50-80 mm, alternatively 57-70 mm, alternatively 67 mm and the leading roller 38 may have an outside diameter of 40-50 mm, alternatively 45 mm. In other embodiments, the roller diameter DL may be equal to or greater than the brushroll diameter DB.

[0061] In at least one embodiment, the brushroll 36 and the leading roller 38 rotate in the same direction, for example clockwise when viewed from the perspective of FIG. 4. The brushroll 36 and the leading roller 38 may rotate at same speed or at different speeds.

[0062] Referring to FIGS. 2, 4, and 5, according to an embodiment, the cleaning base 12 includes a sole plate 62 removably attached on the underside 22 of the housing 14. The sole plate 62 defines at least a portion of the suction conduit 26, for example at least a portion of the opening 28 on the underside 22 of the housing 14. The sole plate 62 can be fully removable from the housing 14, or may be partially removable, such as by being hingedly coupled with the housing 14. The sole plate 62 faces the surface to be cleaned S (e.g., the floor, FIG. 4) when in a working position.

[0063] According to some embodiments, the sole plate 62 is removable by the use of simple tools, such as a screwdriver, or without the use of tools. The removability of the sole plate 62 with simple or no tools allows for the end user of the vacuum cleaner 10 to clean, service, and / or replace components of the cleaning base 12, rather than having a service expert perform such operations. For example, removable of the sole plate 62 can permit access to one or more of the brushroll 36, roller 38, brush chamber 24, suction conduit 26, leading roller chamber 48, and / or agitator drive mechanism(s). In one embodiment, the sole plate 62 is attached on the underside 22 of the housing 14 by one or more fasteners 64, e.g., screws (FIG. 5).

[0064] Referring to FIGS. 2 and 5, in one embodiment, the sole plate 62 includes a rear frame wall 66, a left side frame wall 68, and a right side frame wall 70, which can form a generally U-shaped frame that is open toward the front. The U-shaped frame is beneficial for a dual agitator cleaning base since the sole plate 62 does not block or impede airflow through the inter-roller air passageway 50. Although an embodiment of the sole plate 62 is described herein for illustrative purposes, the sole plate 62 may have other shapes and configurations.

[0065] The suction conduit opening 28 to the suction conduit 26 can be bordered by the rear frame wall 66 and the side frame walls 68, 70, and the space between the frame walls 66, 68, 70, can define the opening 28. The rear frame wall 66 can have a leading edge 66L that defines a rear peripheral edge of the suction conduit opening 28.

[0066] The rear frame wall 66 can, in some embodiments, extend partially below the brushroll36. For example, as shown in FIG. 4, the brushroll 36 has a radius from the first agitator axis X to an outer surface of the brushroll 36, and the rear frame wall 66 can extend beyond a trailing side of the brushroll 36 a distance less than or equal to the radius, alternatively a distance greater than 0 mm and less than the radius.

[0067] The cleaning base 12 may include one or more wheels 72, 76 for supporting the housing 14 on the surface to be cleaned and maneuvering the vacuum cleaner 10 over a surface to be cleaned. At least one set of wheels 72 can be mounted to the sole plate 62 for rollably supporting the cleaning base 12 on the surface to be cleaned. A set of larger wheels 76 can be mounted at or near the back side 18 of the housing 14. Other arrangements for the wheels of the vacuum cleaner 10 are possible.

[0068] The front wheel(s) 72 and rear wheel(s) 76 may provide the primary contact with the surface being cleaned and thus primarily support the cleaning base 12. When the cleaning base 12 is positioned on the surface being cleaned, the cord guard 34 and / or the sole plate 62 may sit above the surface being cleaned. When the cleaning base 12 is positioned on the surface being cleaned, the leading roller 38 may also rest on the surface being cleaned. In other embodiments, the leading roller 38 may be positioned such that the leading roller 38 sits just above the surface being cleaned.

[0069] According to an embodiment, a sealing strip 78 is located on the sole plate 62 on a rear side of the opening 28 to the suction conduit 26. The sealing strip 78 may contact the surface to be cleaned behind the brushroll 36 to seal against the surface together with the leading roller 38 contacting the surface in front of the brushroll 36. The sealing strip 78 may include soft bristles, fabric material, rubber material, or other material capable of contacting the surface being cleaned to substantially prevent air flow into the opening 28 from the rear side. The sealing strip 78 may also include a combination of elements or materials. The sealing strip 78 may enhance sealing between the base 12 and the floor, thereby enhancing the vacuum efficiency. Providing the sealing strip 78 on the removable sole plate 62 allows the sealing strip 78 to be cleaned, serviced, or replaced conveniently. In one embodiment, the sealing strip 78 extends from the rear frame wall 66 of the sole plate 62, and can be disposed on the rear frame wall 66 adjacent the leading edge 66L. Other arrangements for the sealing strip are possible.

[0070] The sole plate 62 can secure the agitator assembly 40 in a working position on the housing 14. As described in further detail below, in one embodiment the leading roller 38 can be removed from housing 14 without removing the sole plate 62, although in other embodiments the sole plate 62 can also secure the roller 38 in a working position on the housing 14.

[0071] Optionally, the sole plate 62 can also secure the cord guard 34, if present, in a working position on the housing 14. In such a case, the cord guard 34 is a component separate from the sole plate 62. In another embodiment, the sole plate 62 can comprise the cord guard 34, such as by the cord guard 34 being attached to, formed with, or otherwise joined to the sole plate 62, such that removal of the sole plate 62 from the housing 14 also removes the cord guard 34.

[0072] In one embodiment the cord guard 34 is component separate from the sole plate 62 and can be at least partially removable from the housing 14 for accessing and / servicing the agitator assembly 40. For example, the cord guard 34 can be pivotable between a closed or working position and an open position. In the open position, the agitator assembly 40 can be removed from the housing 14. One non-limiting example of the open position is shown in FIGS. 12 and 13. One non-limiting example of the working position is shown in FIGS. 2 and 5 and includes the cord guard 34 traversing the suction conduit opening 28 and crossing the brushroll 36.

[0073] The cord guard 34 may remain attached to the housing 14 in the open position. For example, the cord guard 34 can be hinged to the housing 14, and pivots between the working position and the open position.

[0074] The sole plate 62 can include features that secure the agitator assembly 40 in a working position on the housing 14. For example, the sole plate 62 may include at least one cradle 80, 82, 84 that presses against at least one non-rotating portion of the agitator assembly 40 to support the agitator assembly 40 horizontally and hold the agitator assembly 40 in its working position within the housing 14. In one embodiment, a left cradle 80 is formed on or otherwise coupled with the left side frame wall 68 of the sole plate 62 and supports a left end of the agitator assembly 40, a right rear cradle 82 is formed on or otherwise coupled with the right side frame wall 70 of the sole plate 62 and supports a right rear end of the agitator assembly 40, and a right front cradle 84 is formed on or otherwise coupled with the right side frame wall 70 in front of the rear cradle 82 and supports a right forward end of the agitator assembly 40.

[0075] The sole plate 62 may further include a belt guard 86 configured to protect a drive belt of the drive transmission for the agitator assembly 40. As described in further detail below, a drive belt 102 of the agitator assembly 40 that is coupled with a drive motor 60 may be accessed by the end user in order to remove the agitator assembly 40. The drive belt 102 is protected by the belt guard 86 and is exposed to the user's view upon removal of the sole plate 62 from the housing 14. In one embodiment, the belt guard 86 can be an extension of the right side wall 70, or can be formed on or otherwise coupled to the sole plate 62.

[0076] Optionally, the cleaning base 12 can include one or more agitator combs 88, 90 configured to remove debris (such as, but not limited to, hair, string, and the like) that may be wrapped around and / or entrained in / on one or more of the agitators as the cleaning base 12 is being operated to clean a surface and without the user having to manually remove the debris from the agitators. For example, a brushroll comb 88 may be configured to contact the brushroll 36 and a roller comb 90 may be configured to contact the leading roller 38. While combs 88, 90 are provided both the brushroll 36 and roller 38 in the illustrated embodiment, other variations are possible such as only the leading roller 38 having a comb or only the brushroll 36 having a comb. In yet other embodiments, combs are not included.

[0077] In this embodiment, the combs 88, 90 may include a plurality of teeth (e.g., spaced projections or tines) that provide numerous contact points with the brushroll 36 and roller 38, respectively, to remove debris therefrom, while also reducing potential damage to the bristles and / or pile thereof. The leading comb 90 may also substantially prevent air flow to a top of the leading roller 38 such that the top of the leading roller 38 is not exposed to the flow path F to the suction conduit 26.

[0078] The combs 88, 90 may contact a surface of the brushroll 36 and the leading roller 38, respectively, at a distance above the bottom contact surface 56, 58 thereof to facilitate debris removal. In one non-limiting example, the combs 88, 90 contact the brushroll 36 and roller 38 above the rotational axis X, Y thereof.

[0079] One embodiment of the agitator assembly 40 is shown in FIGS. 6-8 and includes the brushroll 36 and a drive module 92. The drive module 92 and brushroll 36 are removable as a complete unit from the base 12. One non-limiting example of the complete unit as removed from the base 12 is shown in FIG. 7. The drive module 92 can include some or all of the drive components necessary to drive the brushroll 36. The drive module 92 can further include some or all of the drive components necessary to drive the leading roller 38.

[0080] The brushroll 36 can have any rotating agitator design, such as a generally cylindrical spindle 94 with a plurality of agitating elements extending radially therefrom. In one embodiment, the brushroll 36 has a plurality of bristles 96 that extend radially outward from a sidewall 98 of the spindle 94. An axle shaft 100 passes through the spindle 94, and is coincident with the rotational axis X.

[0081] In one aspect of the disclosure, the brushroll 36 and the roller 38 are both driven to rotate by the drive module 92. The drive module 92 may be coupled to an electrical drive motor 60 (either AC or DC) to cause the brushroll 36 to rotate about the first rotational axis X and the roller 38 to rotate about the second rotational axis Y. A portion of FIG. 6 is cut away to show the drive motor 60, which may be housed within the cleaning base 12, such as within a motor chamber of the housing 14.

[0082] The drive module 92 can operably connect the drive motor 60 with the agitators 36, 38 and can comprise one or more drive belts, pulleys, gears, or the like for transmitting rotational motion of the motor 60 to the agitators 36, 38. In one embodiment, the brushroll 36 is directly coupled to the motor 60 by the drive module 92 and the leading roller 38 may be indirectly driven by the motor 60 by being directly coupled with the brushroll 36 by the drive module 92.

[0083] In one embodiment, the drive module 92 includes a first belt 102 coupling the brushroll 36 with the drive motor 60 and a second belt 104 coupling the roller 38 with the brushroll 36. The motor 60 includes a motor shaft 106 carrying a motor pulley 108. The motor pulley 108 can define a drive surface, such as a smooth or toothed surface, which engages the belt 102.

[0084] The drive module 92 is disposed on a lateral side of housing 14, e.g., on the right side 18R, outboard of a cleaning path of the housing 14, where the cleaning path is defined by the portion of the agitators 36, 38 exposed to the surface to be cleaned. With the belts 102, 104 part of the drive module 92, the belts 102, 104 are outside the cleaning path and do not interrupt the provision of agitating features (bristles, microfiber, etc.) across width of the agitators, including and particularly in the area of the agitators exposed to the surface to be cleaned, e.g. through the suction conduit opening 28 in the case of the brushroll 36. See, for example, FIGS. 2 and 5, where the drive module 92 is tucked into the lateral side of the housing 14 outboard of the cleaning path and enclosed by the sole plate 62. The provides for efficient, effective cleaning. There is no gap in agitating features on the agitators 36, 38, and consequently there are no gaps of unagitated surface in the cleaning path.

[0085] The drive module 92 includes a drive casing 110, and the second belt 104 can be contained entirely within an interior chamber 112 of the drive casing 110. Optionally the drive casing 110 can comprise a cooperating cover 114 that encloses the interior chamber 112. The cover 114 may or may not be removable from the casing 110 by the end user. In one non-limiting example, the cover 114 can be secured to the drive casing 110 by one or more fasteners 116, e.g., screws. Alternatively, these parts may instead be attached by adhesives, a snap-fit, or other interlocking or engaging features.

[0086] The first belt 102 can be partially contained within the drive casing 110, and includes a portion contained within the interior chamber 112 of the drive casing 110 and portion outside the drive casing 110 that couples with the drive motor 60. The casing 110 and / or the cover 114 can include a belt opening 118 for the belt 102 to emerge from the interior chamber 112 to couple with the motor pulley 108.

[0087] The drive module 92 includes drive components within the drive casing 110 to transmit the rotational force of the belt 102 to the brushroll 36. In one embodiment, the drive module 92 can include an agitator mount, such as an end cap 120 having a radially extending peripheral wall 122 that abuts a drive end of the spindle 94. The end cap 120 can have a reduced-diameter portion 124 inboard of the peripheral wall 122 that fits into a corresponding opening 126 in the drive end of the spindle 94. The end cap 120 also has a bearing retainer 128 into which a bearing 130 is fitted. The end cap 120 has a central aperture 132 in the bearing retainer 128 through which the axle shaft 100 extends, with the bearing 130 mounted on the axle shaft 100 outboard of the aperture 132.

[0088] The end cap 120 may include an axially-elongated sleeve 134 that extends away the central aperture 132 on the other side of the bearing retainer 128. The central aperture 132 and sleeve 134 has a clearance from the axle shaft 100, so that the end cap 120 can rotate relative to the axle shaft 100 without creating friction. This clearance creates a gap between these parts, and the sleeve 134 can help prevent debris from entering the gap.

[0089] The drive module 92 also includes a first pulley 136 associated with the brushroll 36 and that engages the first belt 102, a second pulley 138 coupled with the first pulley 136, and a third pulley 140 associated with the roller 38. The second belt 104 is wrapped around the second and third pulleys 138, 140. The pulleys 136, 138, 140 can define drive surfaces, such as a smooth or toothed surfaces, which engage said belts102, 104.

[0090] According to one aspect of the disclosure the end cap 120 can carry the first and second pulleys 136, 138. In “carrying” the pulleys 136, 138, the end cap 120 can be integrally formed with the pulleys 136, 138, or be otherwise connected with the pulleys 136, 138 so as to form one inseparable part. Providing the pulleys 136, 138 as one part has the advantage of pre-setting the timing between the two pulleys 136, 138 so that assembly of the drive module 92 is more efficient and takes less time. In other embodiments, the end cap 120 may carry only one of the pulleys 136, 138, or the pulleys 136, 138 may be separate from the end cap 120.

[0091] The pulleys 108, 136, 138, 140 and belts 102, 104 can provide belt drive ratios with an overall design that reduces the speed of the input motor rotation while increasing the torque output. Various belt drive ratios are possible. In one arrangement, the first pulley 136 can have a larger diameter than the motor pulley 108 to operate the brushroll 36 at a decreased speed and increased torque, relative to the motor shaft. The second pulley 138 can have a smaller diameter than the first pulley 136 to increase speed and the third pulley 140 can have the same diameter or larger diameter than the second pulley 138 so that the roller 38 rotates at the same or a slower speed as the brushroll 36. In another embodiment, the pulleys can be sized so that the roller 38 rotates faster than the brushroll 36.

[0092] According to one aspect of the disclosure, the second pulley 138 can comprise the bearing retainer 128, such that the bearing 130 is received within the second pulley 138. Accordingly, the drive surface of the pulley 138 and the end of the second belt 104 wrapped around the second pulley 138 are radially outward of the bearing 130 along an axis that is perpendicular to the rotational axis X.

[0093] A guard cap 142 mounts to the outboard side of the end cap 120 and abuts the first pulley 136. The end cap 120 can have a shoulder 144 between the first pulley 136 and the second pulley 138, and the guard cap 142 can be seated on or around the shoulder 144. The shoulder 144 can have a diameter smaller than that of the first pulley 136 and larger than that of the second pulley 138 so the shoulder 144 is radially outward of the second pulley 138 and radially inward of the first pulley 136. The guard cap 142 includes an annular guard wall 146 that extends radially from the shoulder 144 and has a larger outer diameter than the diameter of the first pulley 136, so that the guard wall 146 extends past the first pulley 136. Preferably, the guard wall 146 has an outer diameter equal to or greater than the combined diameter of the first pulley 136 and first belt 102, such that the guard wall 146 extends to or past the first belt 102. This creates a guard on an outboard side of the belt 102 that prevents the belt 102 from walking off the first pulley 136 and interfering with the second pulley 138.

[0094] The guard cap 142 can have a snap-in connection with the end cap 120 to firmly hold the guard cap 142 on the end cap 120. For example, the guard cap 142 can have a plurality of flexible cantilever arms 148 with an interlocking feature at the free ends thereof that are snapped into corresponding cavities (not shown) in the end cap 120, but these parts may instead be attached by a threaded connection, friction fit, adhesives, a bayonet fitting, or other interlocking or engaging features. The retainers if present, can be recessed into the shoulder 144 between the pulleys 136, 138.

[0095] In addition to or as an alternative to the guard cap 142, the motor pulley 108 can have a flange 152 (FIG. 6) that prevents the belt 102 from walking off the motor pulley 108, which can in turn be sufficient to prevent the belt 102 from walking off the first pulley 136 and interfering with the second belt 104.

[0096] The second pulley 138 may or may not also include a flange that prevents the belt 102 from walking off the pulley 138. Alternatively, the cover 114 may have a small clearance from the pulley 138 to help maintain alignment of the belt 102 on the pulley 138.

[0097] One end of the axle shaft 100 can be fixed on the cover 114 or another portion of the drive casing 110 and may, for example, have a knurled end 154 which is press fit into the cover 114 or other portion of the drive casing 110. In one non-limiting example, the cover 114 includes a shaft aperture 150 into which the knurled end 154 is press fit. Fixing the shaft 100 directly on the module cover 114 or another portion of the drive casing 110, rather that providing a separate mounting cap for the shaft 100, preserves lateral space within the base 12 that can be used to widen the cleaning path rather than accommodate another part within the drive module 92. Other method of affixing the axle shaft 100 with the cover 114 are possible.

[0098] The cover 114 can abut the outboard side of the end cap 120 and / or the bearing 130. On its outboard side, the cover 114 can include a mounting shoulder 156 that is captured between a portion of the base housing 14 and the sole plate 62 to mount the drive module 92 on the base 12.

[0099] FIG. 11 is a cross-sectional view of the roller 38, taken through line XI-XI of FIG. 3. The roller 38 can have any rotating agitator design, such as a generally cylindrical spindle 158 with a relatively soft material 160 extending radially therefrom. In one embodiment, the material 160 is a pile material made from microfiber. An end cap 162 closes a drive end of the spindle 158.

[0100] The drive module 92 includes drive components within the drive casing 110 to transmit the rotational force of the belt 104 to the roller 38. In one embodiment, the drive module 92 can include an agitator mount, such as a driving head 164 that engages the roller end cap 162. Upon assembly of the roller 38 onto the base 12, the driving head 164 is inserted into the roller end cap 162 to engage the roller 38 with the drive module 92. The driving head 164 and end cap 162 can have a splined connection or another type of connection that accommodates both removability of the roller 38 and secure attachment with the drive module 92.

[0101] The driving head 164 is coupled with the third pulley 140 by a driving shaft 166 that is affixed with the pulley 140 for rotation therewith. The shaft 166 is coincident with the rotational axis Y. The driving head 164 has a central aperture 168 through which the shaft 166 extends, with the pulley 140 mounted on the shaft 166 outboard of the driving head 164. A fastener 170, e.g., a screw, can be inserted through one end of the central aperture 168 and is threaded into the shaft 166 to secure the driving head 164 on the shaft 166.

[0102] The shaft 166 is supported on at least one bearing 172, 174 coupled with the drive casing 110. In one embodiment, the drive module 92 includes a first bearing 172 inside the casing 110 and a second bearing 174 outside the casing 110. The shaft 166 thereby rotatably supports the third pulley 140 on the casing 110 via the bearings 172, 174.

[0103] The casing 110 has a bearing retainer 176 into which the first bearing 172 is fitted, with the bearing 172 mounted on the shaft 166 inside of the casing 110. The cover 114 or another exterior portion of the casing 110 has a second bearing retainer 178 into which the second bearing 174 is fitted, with the bearing 174 mounted on the shaft 166 outboard of the cover 114 and / or casing 110. In one non-limiting example, the second bearing retainer 178 is open toward the outboard side of the drive module 92, and the shaft 166 extends partially through the outboard side to receive the bearing 174. Providing the bearing retainer 178 directly on the module cover 114 or another exterior portion of the drive casing 110, rather that providing a separate retainer for the bearing 174, preserves lateral space within the base 12 that can be used to widen the cleaning path rather than accommodate another part within the drive module 92. Optionally, a retaining ring 180, e-clip, or other fastener is secured to the exposed end of the shaft 166 to help hold the bearing 174 in the bearing retainer 178.

[0104] The pulley 140 has a central aperture 182 through which the shaft 166 extends. The central aperture 182 can include a shoulder 184 formed by a reduced-diameter section of the aperture 182 which abuts a radially-extending flange 186 on the shaft 166 to help hold the pulley 140 at a proper distance from the non-rotating casing 110 and / or cover 114. The pulley 140 can also include a flange 188 that prevents the belt 104 from walking off the pulley 140.

[0105] The drive casing 110 can have an annular recess 190 which partially receives the driving head 164. For example, the driving head 164 can include a skirt 192 outboard of the portion that is inserted into the roller end cap 162, and the skirt 192 is inserted into the annular recess 190. In one embodiment, the annular recess 190 can be disposed radially of the bearing retainer 176, such that the skirt 192 overlaps the bearing 172 and bearing retainer 176. Accordingly, the skirt 192 of the driving head 164 is radially outward of the bearing 172 along an axis that is perpendicular to the rotational axis X. The skirt 192 can help prevent debris from entering the drive module 92. In the embodiment shown, the skirt 192 is flared and has an increasing diameter in the outboard direction, which can discourage hair from climbing outwardly past the skirt 192. Other shapes for the skirt 192 are possible, including the skirt 192 being flat or otherwise shaped without an increasing diameter.

[0106] The drive casing 110 is preferably substantially air-tight since it is inside the active or working air path of the vacuum cleaner; however, entrances for the drive components associated with the brushroll 36 and roller 38 are necessary. According to one aspect of the disclosure, the drive casing 110 can include features for preventing debris, including hair, from contaminating the bearing, gears, second belt, and other components within the casing. For example, a gasket 194 maybe located between the end cap 120 and the drive casing 110 to inhibit foreign objects from entering the drive module 92. The gasket 194 may be inserted into a groove 196 in the peripheral wall 122 of the end cap 120 and be compressed against an inner surface of an annular wall 198 on the inboard side of the drive casing 110 that is sized to receive the end cap 120. Further, for a drive casing with a cooperating cover 114, the drive casing 110 can have a tongue-and-groove connection 200 between the drive casing 110 and the cover 114 to prevent debris from getting inside the drive module 92. Other ways of sealing the drive module 92 include, but are not limited to using one or more gaskets between the drive casing 110 and cover 114 and / or employing a labyrinth construction comprising interposed annular walls formed between parts on each of the driven and drive end assemblies for inhibiting hair and other contaminants from reaching the bearings.

[0107] Referring to FIG. 10, the assembly 40 can also include a driven-end mounting assembly 202 at the end of the brushroll 36 opposite the drive module 92. The driven-end mounting assembly 202 for the brushroll 36 can include, in one embodiment, an agitator mount, such as an end cap 204 having a radially extending peripheral wall 206 that fits into a corresponding opening 208 in the driven end of the spindle 94. The end cap 204 also has a bearing retainer 210 into which a bearing 212 is fitted and an annular recess 214 around the bearing retainer 210. The end cap 204 has a central aperture 216 in the bearing retainer 210 through which the axle shaft 100 extends, with the bearing 212 mounted on the axle shaft 100 outboard of the aperture 216. The central aperture 216 has a clearance from the axle shaft 100, so that the end cap 204 can rotate relative to the axle shaft 100 without creating friction. A washer spring 218 is disposed between the bearing 212 and the bearing retainer 210 to reduce wear on the bearing 212 and is adapted to deform slightly as the bearing 212 is pressed into the bearing retainer 210. The drive module 92 can have a similar washer spring for the bearing 130, or may not include a washer spring, as shown, to simplify tolerance stacking and reduce cost.

[0108] A mounting cap 220 mounts the driven-end of the assembly 40 to the housing 14, and may be fixed on the end of the axle shaft 100, which may, example have a knurled end 222 which is press fit into the mounting cap 220. Other method of affixing the axle shaft 100 with the mounting cap 220 are possible. The mounting cap 220 partially inserts into the annular recess 214 of the end cap 204. Outboard of the annular recess 214, the mounting cap 220 includes a mounting shoulder 224 that is captured between a portion of the base housing 14 and the sole plate 62 to mount the driven-end mounting assembly 202 on the base 12.

[0109] The mounting cap 220 also encloses the bearing 212 within the recess 214 of the end cap 204. The mounting cap 220 may have a stepped diameter that abuts the bearing 212 and / or the end cap 204 to hold the bearing 212 and / or end cap 204 at a proper distance from one another.

[0110] The axle shaft 100, cover 114, and mounting cap 220, are stationary or non-rotatable components of the assembly 40, while the brushroll 36, end cap 120, and end cap 204 are rotatable components of the assembly 40. The bearings 130, 212 support the end caps 120, 204 on the axle shaft 100 and constrain the relative motion to only rotating motion of the brushroll 36 and end caps 120, 204.

[0111] The end caps 120, 204 can have anti-rotation features where they connect with spindle 94. For example, the drive-end end cap 120 can have a keyed connection with the spindle 94 so that torque is transmitted from the end cap 120 to the spindle 94 without slipping. A similar keyed connection can also be provided at the driven-end end cap 204. The end cap connections may alternatively include a threaded connection, or attachment of these parts by friction fit, adhesives, bayonet fittings, or other interlocking or engaging features.

[0112] Referring to FIG. 11, the roller 38 can also include a driven-end mounting assembly 226 at the end of the roller 38 opposite the drive module 92. The driven-end mounting assembly 226 for the roller 38 can include, in one embodiment, an agitator mount, such as an end cap 228 fitted into or otherwise coupled with the driven end of the spindle 158 and a mounting cap 230 fitted over the end cap 228. The mounting cap 230 has a bearing retainer 232 into which a bearing 234 is fitted.

[0113] A stub shaft 236 is coupled with the spindle 158, and may, for example, be pressed into a corresponding stub shaft sleeve 238 the driven end of the spindle 158. A portion of the stub shaft 236 extends out of the sleeve 238, and the bearing 234 is mounted on the shaft 236 outboard of the sleeve 238. The bearing retainer 232 of the mounting cap 230 partially inserts into a space between the end cap 228 and the sleeve 238.

[0114] Outboard of the bearing 234, the mounting cap 230 includes a mounting shoulder 240 that is captured between a portion of the base housing 14 and the sole plate 62 to mount the driven-end mounting assembly 226 on the base 12. The mounting cap 230 mounts the driven-end of the roller 38 to the housing 14. The mounting cap 230 is a stationary or non-rotatable component of the roller 38, while the spindle 158, end cap 228, and stub shaft 236 are rotatable components of the roller 38. The bearing 234 supports the spindle 158, end cap 228, and stub shaft 236 on the mounting cap 230, and constrains the relative motion to only rotating motion of the spindle 158 and stub shaft 236.

[0115] Referring to FIGS. 10 and 11, the various bearings 130, 172, 174, 212, 234 may comprise any suitable rotary mounting device, such as roller bearings, ball bearings, or simple bushings. In one non-limiting example, one or more of the bearings 130, 172, 174, 212, 234 may each have an inner race that fits over their associated shaft 100, 166, 236 and an outer race that fits within the corresponding bearing retainer 128, 176, 178, 210, 232 which may include a hollow cylindrical portion into which the outer race of its respective bearing 130, 172, 174, 212, 234 fits. If desired, the one or more of the bearings may be firmly locked in place by adhesives, staking, friction fitment, and so on.

[0116] The sole plate 62 can secure the agitator assembly 40 in a working position on the housing 14. For a removable agitator assembly 40 as shown, the sole plate 62 can secure the brushroll 36 and drive module 92 against the housing 14 in the working position. Removal of the sole plate 62 from the housing 14 exposes the drive module 92, and the user can remove the assembly 40 from the housing 14. As discussed above, the leading roller 38 may be removed prior to removing the assembly 40.

[0117] Referring to FIG. 5, in one embodiment, a plurality of non-rotating portions of the agitator assembly 40 are clamped between the housing 14 and the sole plate 62 to hold the assembly 40 in the working position. The clamping action can be affected by the action of the sole plate 62 and the fasteners 64 for the sole plate 62 in pulling the sole plate 62 toward the housing 14 to clamp the assembly 40 between the sole plate 62 and the housing 14. The base housing 14 and sole plate 62 can have structures that engage non-rotating portions of the drive module 92 and the brushroll 36 and that prevent movement of the assembly 40 in multiple directions (e.g., front or back, side to side, up or down, or any combination thereof).

[0118] In one non-limiting example, on the inboard side of the drive casing 110, the drive module 92 can include an annular wall 242 disposed in front of annular wall 198, with the rear annular wall 198 generally surrounding the brushroll end cap 120 and the front annular wall 242 generally surrounding the drive head 164 and defining the recess 190. The right rear cradle 82 presses against the rear annular wall 198 and the right front cradle 84 presses against the front annular wall 242 to support the drive module 92. The left cradle 80 presses against the mounting shoulder 224 of the mounting cap 220 affixed on the driven end of the brushroll 36. The cradles 80, 82, 84 may extend at least partially around front-facing and rear-facing sides of the non-rotating portions of the agitator assembly 40 they receive in order to prevent movement of the agitator assembly 40 in at least a front-to-back direction relative to the housing 14.

[0119] Referring to FIGS. 13-14, alternatively or additionally to the above-described cradles of the sole plate 62, the base housing 14 can include a slot 244 at one end of the brush chamber 24 that receives mounting shoulder 156 on the outboard side of the drive module 92. A block 246 (FIG. 10) on sole plate 62 can engage bottom of mounting shoulder 156 to sandwich the shoulder 156 between the slot 244 and sole plate 62. The base housing 14 can also include a base cradle 248 at one end of the roller chamber 48 that engages the front annular wall 242 of the drive module 92 on a side thereof opposite the sole plate cradle 82. Yet other slots, cradles, or the like may be provided on the housing 14 to support the drive module 92 and provide rigidity to the assembly 40 in the working position.

[0120] On the driven end of the agitators, the housing 14 can have slots, cradles, or the like for receiving non-rotating portions of the brushroll 36 and roller 38. For example, the base housing 14 can also include a brushroll cradle 250 at the end of the brush chamber 24 that engages the mounting shoulder 224 on the driven end of the brushroll 36 on an upper side thereof opposite the sole plate cradle 80 and a roller cradle 252 at the end of the roller chamber 48 that engages the mounting cap 230 (FIG. 5) of the roller 38. It is noted that, in some embodiments, the underside of the driven end of the roller 38 may not be supported by the sole plate 62 so that the roller 38 may be removed from the base 12 without having to remove the sole plate 62.

[0121] The mounting shoulders 156, 224, 240 and mounting walls 198, 242 can have various outer profiles, with the base housing 14 and / or sole plate 62 having corresponding profiles on the receiving parts thereof. According to one aspect of the disclosure, and with additional reference to FIG. 7, the mounting shoulder 156 of the drive module 92 has a non-circular profile shaped to guide proper alignment and installation of the drive module 92 of the assembly 40. For example, the mounting shoulder 156 can have a square-shaped profile that is received by square-shaped slot 244. This limits front-to-back rotation of the drive module 92 and adds rigidity to the assembly 40 in the working position. The driven-end mounting shoulders 224, 240 and drive-end walls 198, 242 illustrated herein have circular profiles, but other profiles are possible.

[0122] In one aspect of the disclosure, the user must separate only one drive connection to disassemble the assembly 40 from the housing 14. For example, to disassemble the assembly 40 from the base 12, the first belt 102 is uncoupled from the motor pulley 108. The motor 60, motor shaft 106, and motor pulley 108 remain in place while the assembly 40, including the first belt 102, is removed. The second belt 104 and other drive connections are within the drive module 92, and are removed as one with the assembly 40.

[0123] Referring to FIGS. 5 and 12, the base 12 may include a belt compartment 254 in which the motor pulley 108 is housed. The first belt 102 can extend from the drive module 92 and through the belt compartment 254 to couple with the motor pulley 108. The belt compartment 254 may be closed by the belt guard 86 of the sole plate 62, and removable of the sole plate 62 can open the belt compartment 254. The drive belt 102 is exposed to the user's view upon removal of the sole plate 62 from the housing 14. Additionally to being exposed to a user's view, the belt 102 and belt compartment 254 are exposed for access from an exterior of the housing 14, e.g., from the underside 22, when the sole plate 62 is removed. The belt compartment 254 may be sized with a clearance gap 256 next to the belt 102 and pulley 108 so that a user has space to pull the belt 102 off the pulley 108. For example, the belt compartment 254 can provide enough space to accommodate different finger sizes, but can leave clearance gap 256 between the belt 102 and / or pulley 108 and the housing 14, allowing space for the tip of a user's finger to move easily to install and remove the belt 102.

[0124] Other drive modules 92 for the assembly 40 are possible and within the scope of the present disclosure. For example, instead of a separate drive motor 60, the drive module 92 can operably connect the agitators 36, 38 with the suction motor 32 (FIG. 3). This may add complexity to the design, and is not preferred where the vacuum cleaner 10 has a lift-off design where the suction motor 32 and collection container 44 are incorporated into a detachable pod for portable use. In another example, instead of second belt 104, the drive module 92 may contain a gear train coupling the driving head 164 with the brushroll 36. In yet another example, the assembly 40 can have more than one drive module 92. In this example, a brushroll drive module, which may include the belt 102 and first pulley 136, is provided at one end of the brushroll 36, and a roller drive module, which may include the driving head 164 and other drive components coupling the driving head 164 with the brushroll 36, is provided at the other end of the brushroll 36. This may also add complexity to the design, and may negatively affect edge cleaning since having one drive module 92 on just one side of the brushroll 36 allows the opposite end of the brushroll 36 and roller 38 to be closer to the lateral edge of the base 12 for better edge cleaning on the side of the base opposite the drive module 92.

[0125] In one aspect of the disclosure, the leading roller 38 can be removed from housing 14 without removing the sole plate 62 and without removing the agitator assembly 40. Referring to FIGS. 5 and 13, the driven end of the roller 38 may be secured to the housing by a latch that is accessible from an exterior of the housing 14. To remove the leading roller 38, the driven end of the roller 38 may be unsecured / uncoupled from the rest of the housing 14 via operation of the latch, thereby allowing the drive end of the leading roller 38 to disengage from the drive head 164, and allowing the leading roller 38 to be removed from a leading roller chamber 48. One embodiment of a roller release latch includes a user accessible push button 258, which may be located on the side 18L of the housing 14 opposite the drive module 92. To remove the leading roller 38, the user may apply a force to the push button 258 to disengage an internal spring-biased block 260 from mechanical engagement with an aperture 262 in the non-rotating end of the roller 38, for example in the mounting cap 230 of the roller 38, thereby allowing the leading roller 38 to be removed from the chamber 48. Other ways of removably coupling the leading roller 38 within the housing 14 are also possible and within the scope of the present disclosure, including, but not limited to, requiring removal of the sole plate 62 prior to removal of the leading roller 38 and / or non-spring-biased roller latches.

[0126] Optionally, the roller 38 can comprise a handle, grip, or tab 264 on the driven end that the user can grip to pull the roller 38 out of the housing 14. In one example, the mounting cap 230 can comprise the tab 264. The driven end of the roller 38 can be biased by a spring 266 (FIG. 11) to pop out of the roller chamber 48 when the button 258 is pressed to release the roller 38. With reference to FIG. 2, the tab 264 can be exposed on the underside 22 of the housing 14 (i.e., is not covered by the sole plate 62) and can pop out from the underside 22 when the button 258 is pressed so that the user has a convenient place to grip the roller 38.

[0127] FIGS. 5 and 12-14 show one example of a user disassembly process for the cleaning base 12. First, referring to FIG. 5, the roller 38 may be uncoupled from the housing 14 and removed from the chamber 48. Next, the sole plate 62 is detached from the housing 14 (e.g., by unscrewing fasteners 64). This exposes the drive module 92 and unclamps the assembly 40 from the housing 14. Referring to FIG. 12, the cord guard 34, if present and separate from the sole plate 62, is then moved to the open position. In one example, the user grips the cord guard 34 and lifts the cord guard 34 away from the underside 22 of the base 12 in a pivoting movement to the open position. In embodiment where the cord guard 34 is coupled with the sole plate 62, removal of the sole plate 62 may also remove the cord guard 34.

[0128] Once the cord guard 34 is in the open position or is otherwise moved out of the way, the assembly 40 can be removed from the housing 14, e.g., through the underside 22, as a complete unit. For example and referring to FIG. 13, to remove the assembly 40, the assembly 40 is lifted and rotated around a pivot point defined by the connection of the first belt 102 with the motor pulley 108, i.e., about motor axis M. This movement can slacken the belt 102. Finally, the user manually pulls the belt 102 off the motor pulley 108 to complete the disassembly of the agitator assembly 40, as shown in FIG. 14. Other ways of removably coupling the assembly 40 within the housing 14 are also possible and within the scope of the present disclosure. For example, the belt 102 may be disconnected from the motor pulley 108 before moving the assembly 40 out of the housing 14.

[0129] According to another aspect of the disclose, a method of user disassembly may comprise providing any of the devices according to optional aspect described above, removing the sole plate 62, and thereafter removing the agitator assembly 40 from the housing 14. Optionally, the method further comprises removing the assembly 40 through the underside 22 of the housing 14. Optionally, the method further comprises removing the leading roller 38 before removing the sole plate 62 and / or before removing the assembly 40. Alternatively, the method further comprises removing the leading roller 38 after removing the sole plate 62 and / or after removing the assembly 40. Removing the sole plate 62 may optionally comprise unscrewing the sole plate 62 from the underside 22 of the housing 14. Removing the assembly 40 may comprise lifting the assembly 40 out of the housing 14 and rotating the assembly 40 around a pivot point defined by the connection of the first belt 102 with the motor pulley 108, and then uncoupling the belt 102 from the pulley 108. Lifting and rotating the assembly 40 may optionally comprise slackening the belt 102 so that the user can more easily pull the belt 102 off the pulley 108.

[0130] User assembly of the agitator assembly 40 may be accomplished with generally the same steps in reverse order. During assembly, the user need only connect the belt 102 with the motor pulley 108 before setting the agitator assembly 40 in place. The drive connection between the rear and front agitators is already set in place within the drive module 92. This reduces the number of assembly steps for the end user, as most of the drive connections are already set within the drive module 92.

[0131] Although specific embodiments of the cleaning base with dual agitators and a removable module including at least one of the agitators are shown, other embodiments of the cleaning base with dual agitators and a removable module are within the scope of the present disclosure. The cleaning base with dual agitators and a removable module including at least one of the agitators may be used in different types of vacuum cleaners including, without limitation, an “all in the head” type vacuum, upright vacuum cleaners having a cleaning base and an upright body for directing the base across the surface to be cleaned, canister vacuum cleaners having a cleaning implement connected to a wheeled base by a vacuum hose, stick vacuum cleaners, portable vacuum cleaners adapted to be hand carried by a user for cleaning relatively small areas, robotic vacuum cleaners, and central vacuum systems. The cleaning base with dual agitators and a removable module including at least one of the agitators may also be used in vacuum cleaners having liquid and / or steam delivery. may be similarly removable. Aspects of the removable agitator assembly may also be applicable to a vacuum cleaner with only one agitator or more than two agitators.

[0132] The terms “comprising” or “comprise” are used herein in their broadest sense to mean and encompass the notions of “including,”“include,”“consist(ing) essentially of,” and “consist(ing) of. The use of “for example,”“e.g.,”“such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples.

[0133] The above description relates to general and specific embodiments of the disclosure. However, various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. As such, this disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. Any reference to elements in the singular, for example, using the articles “a,”“an,”“the,” or “said,” is not to be construed as limiting the element to the singular.

[0134] Likewise, it is also to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments that fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and / or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

Claims

1. A vacuum cleaner comprising:a housing defining an agitator chamber and a suction conduit with a suction conduit opening on an underside of the housing facing a surface to be cleaned, wherein the suction conduit passes through at least a portion of the agitator chamber;an agitator drive motor;a first agitator rotatably mounted to the housing within the agitator chamber with at least a portion of the first agitator extending through the suction conduit opening, the first agitator rotatable about a first agitator axis;a second agitator mounted to the housing and rotatable about a second agitator axis;a sole plate removably attached on the underside of the housing, the sole plate defining at least a portion of the suction conduit opening; andan agitator assembly removably mounted to the housing as a complete unit, the agitator assembly comprising:the first agitator; anda drive module comprising:a first belt coupling the first agitator with the drive motor; anda second belt coupling the second agitator with the first agitator;wherein the drive module is disposed on a lateral side of housing and is outboard of a cleaning path of the vacuum cleaner; andwherein the agitator assembly is clamped to the housing by the sole plate to hold the agitator assembly in a working position, whereby the agitator assembly is removable as a complete unit through the underside of the housing after removal of the sole plate from the housing.

2. The vacuum cleaner of claim 1, wherein at least a portion of the drive module is clamped between the housing and the sole plate to hold the agitator assembly in the working position.

3. The vacuum cleaner of claim 1, wherein the drive module comprises a drive casing having an interior chamber, wherein the second belt is contained entirely within the interior chamber of the drive casing, and wherein the first belt extends from the interior chamber of the drive casing to outside of the drive casing to couple with the drive motor.

4. The vacuum cleaner of claim 3, wherein the drive casing comprises a cooperating cover that encloses the interior chamber.

5. The vacuum cleaner of claim 4, comprising an axle shaft coincident with the first agitator axis, wherein the axle shaft is fixed on the cover.

6. The vacuum cleaner of claim 4, comprising a driving shaft coincident with the second agitator axis, wherein the cover comprises a bearing retainer into which a bearing is fitted, wherein the bearing is mounted on the driving shaft.

7. The vacuum cleaner of claim 1, wherein the drive module comprises a first pulley associated with the first agitator and that engages the first belt, a second pulley coupled with the first pulley, and a third pulley associated with the second agitator, wherein the second belt is wrapped around the second and third pulleys.

8. The vacuum cleaner of claim 7, wherein the drive module comprises an end cap affixed to an end of the first agitator for rotation therewith about the first agitator axis, wherein the end cap carries the first pulley and the second pulley.

9. The vacuum cleaner of claim 8, comprising an axle shaft coincident with the first agitator axis, wherein the second pulley comprises a bearing retainer into which a bearing is fitted, wherein the bearing is mounted on the axle shaft.

10. The vacuum cleaner of claim 7, wherein the agitator drive motor comprises a motor shaft carrying a motor pulley, wherein the first belt is wrapped around the first pulley and the motor pulley.

11. The vacuum cleaner of claim 1, wherein:the agitator drive motor comprises a motor shaft carrying a motor pulley;the housing comprises a belt compartment in which the motor pulley is housed, and the first belt extends from the drive module and through the belt compartment to couple with the motor pulley; andthe belt compartment is sized with a clearance gap next to the first belt and motor pulley whereby a user can insert a finger into the clearance gap to pull the first belt off the motor pulley using a finger.

12. The vacuum cleaner of claim 1, wherein:the sole plate comprises a cradle configured to receive a non-rotating portion of the drive module;the non-rotating portion of the drive module is clamped between the housing and the cradle to hold the agitator assembly in the working position; andthe cradle is configured to prevent movement of the drive module in at least a front-to-back direction relative to the housing.

13. The vacuum cleaner of claim 1, wherein:the drive module comprises a mounting shoulder clamped between the housing and the sole plate to hold the agitator assembly in the working position;the housing comprises a slot at an end of the agitator chamber configured to receive the mounting shoulder; andthe mounting shoulder and the slot have non-circular profiles.

14. The vacuum cleaner of claim 1, wherein:the drive module comprises a driving head that engages a drive end of the second agitator; anda driven end of the second agitator is disposed opposite the drive end and the driven end is releasably secured to the housing by a latch accessible from an exterior of the housing,wherein the second agitator is removable from the housing without necessitating removal of the sole plate or removal the agitator assembly.

15. A vacuum cleaner comprising:a housing defining an agitator chamber and a suction conduit with a suction conduit opening on an underside of the housing facing a surface to be cleaned, wherein the suction conduit passes through at least a portion of the agitator chamber;an agitator drive motor;a first agitator rotatably mounted to the housing within the agitator chamber with at least a portion of the first agitator extending through the suction conduit opening, the first agitator rotatable about a first agitator axis;a second agitator mounted to the housing and rotatable about a second agitator axis;a sole plate removably attached on the underside of the housing, the sole plate defining at least a portion of the suction conduit opening; andan agitator assembly removably mounted to the housing as a complete unit, the agitator assembly comprising:the first agitator; anda drive module coupling the first agitator directly with the drive motor and coupling the second agitator indirectly with the drive motor via a coupling with the first agitator;wherein the drive module is disposed on a lateral side of housing and is outboard of a cleaning path of the vacuum cleaner; andwherein the agitator assembly is clamped to the housing by the sole plate to hold the agitator assembly in a working position, whereby the agitator assembly is removable as a complete unit through the underside of the housing after removal of the sole plate from the housing.

16. The vacuum cleaner of claim 15, wherein at least a portion of the drive module is clamped between the housing and the sole plate to hold the agitator assembly in the working position.

17. The vacuum cleaner of claim 15, wherein:the agitator drive motor comprises a motor shaft carrying a motor pulley;the drive module comprises a first belt coupling the first agitator with the motor pulley;the housing comprises a belt compartment in which the motor pulley is housed, and the first belt extends from the drive module and through the belt compartment to couple with the motor pulley;the belt compartment is sized with a clearance gap next to the first belt and motor pulley whereby a user can insert a finger into the clearance gap to pull the first belt off the motor pulley using a finger; andthe sole plate comprises a belt guard configured to close the belt compartment when the sole plate is attached on the underside of the housing, whereby removal of the sole plate from the housing exposes the first belt and belt compartment for access from an exterior of the housing.

18. A removable agitator assembly for a vacuum cleaner comprising:a first agitator; anda drive module connected to the first agitator and comprising:a drive casing having an interior chamber;a cover enclosing the interior chamber;a first belt coupled with the first agitator and extending from the interior chamber to outside of the drive casing to couple the first agitator with a drive motor of the vacuum cleaner; anda second belt coupled with the first agitator and contained entirely within the interior chamber;wherein the first agitator is freely rotatable relative to at least the drive casing and the cover;wherein the drive module is configured to couple a second agitator indirectly with the drive motor via the second belt; andwherein the agitator assembly is removable as a complete unit from an underside of the vacuum cleaner.

19. The removable agitator assembly of claim 18, wherein the drive module comprises a first pulley associated with the first agitator and that engages the first belt, a second pulley coupled with the first pulley, and a third pulley, wherein the second belt is wrapped around the second and third pulleys, wherein the drive module comprises an end cap affixed to an end of the first agitator for rotation therewith, wherein the end cap carries the first pulley and the second pulley.

20. The removable agitator assembly of claim 18, wherein the drive module comprises:an inboard side;an outboard side;a bearing retained by the cover;a driving shaft, wherein the bearing is mounted on the driving shaft; anda driving head coupled with the second belt via the driving shaft, wherein the driving head is on the inboard side of the drive module and is configured to couple with the second agitator to couple the second agitator indirectly with the drive motor.

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