Brush roll with a combined bristle and flap structure

Abstract

A vacuum cleaner includes a nozzle assembly at a distal end of the vacuum cleaner and a brush roll coupled to the nozzle assembly. The brush roll includes a cylindrical core, a compliant flap coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, and a plurality of bristles extending away from the cylindrical core in a radial direction and directly adjacent to the compliant flap. The compliant flap extends along a path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core, and the plurality of bristles also extend along the same path as the compliant flap.

Description

BRUSH ROLL WITH A COMBINED BRISTLE AND FLAP STRUCTUREBACKGROUND

[0001] Cleaning tools such as vacuum cleaners have been used for decades to aid in cleaning dirt and other debris from floors. Most vacuum cleaners have a built-in motor to facilitate air suction and a chamber to collect dirt, but the units are often heavy and bulky, thus making it difficult to deftly maneuver the unit around a given floorspace. The vacuum cleaner may also not pick up debris from every surface as effectively. Accordingly, there exist some drawbacks and other unsolved issues that limit the convenience of vacuum cleaners.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Features and advantages of embodiments of the claimed subject matter will become apparent as the following Detailed Description proceeds, and upon reference to the Drawings, in which:

[0003] FIG. 1 illustrates an isometric, three-dimensional view of a vacuum cleaner, in accordance with some embodiments of the present disclosure.

[0004] FIG. 2 illustrates a side view of an example nozzle assembly at the distal end of the vacuum cleaner, in accordance with some embodiments of the present disclosure.

[0005] FIG. 3 illustrates a more detailed cross-section view of the nozzle assembly having one or more agitators, in accordance with some embodiments of the present disclosure.

[0006] FIG. 4 illustrates a three-dimensional view of an agitator having a bristle-flap structure, in accordance with some embodiments of the present disclosure.

[0007] FIG. 5A illustrates a side view of the agitator having the bristle-flap structure, in accordance with some embodiments of the present disclosure.

[0008] FIG. 5B illustrates a cross-section view of the agitator having the bristle-flap structure, in accordance with some embodiments of the present disclosure.

[0009] FIGs. 6A - 6C illustrate various anchoring designs for the bristle-flap structure, in accordance with some embodiments of the present disclosure.

[0010] FIG. 7 illustrates a view of an agitator having the bristle flap combined structure and felt around the bristle-flap structure, in accordance with some embodiments of the present disclosure.

[0011] FIG. 8 illustrates a view of the bottom of the suction chamber with the one or more agitators removed, in accordance with some embodiments of the present disclosure.

[0012] Although the following Detailed Description will proceed with reference being made to illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent in light of this disclosure.DETAILED DESCRIPTION

[0013] As noted above, there are some non-trivial issues with the designs of most vacuum cleaners. Many of the issues pertain to matters of convenience for the user. For example, vacuum cleaners include a nozzle assembly having a brush roll or similar agitation member to facilitate the collection of debris off of a surface. Often times, the brush roll does not effectively clean all of the dirt or debris on a given surface, causing the user to run the vacuum multiple times over a given area in an effort to collect all of the dirt or debris.

[0014] Typical brush roll designs utilize various features that may protrude from the brush roll to facilitate the collection of dirt and debris. Frequently these features include some form of bristle that engages with the surface to be cleaned. In the case of carpets bristles interact with the carpet fibers to aid in the release of debris from the carpet. On hard floor soft bristles may be incorporated to release debris from the surface and entrain it into the suction path. However, such features can also pick up long strand-like objects like hair or string that wraps itself around the brush roll and can cause clogging or jamming to the rotation of the brush roll.

[0015] Thus, according to some embodiments, a brush roll design is disclosed that reduces or eliminates the wrapping of hair or other strand-like objects around the brush roll by incorporating both bristles and flaps around the brush roll. According to some embodiments, the brush roll includes one or more bristle-flap structures that traverse around the brush roll core in both a longitudinal and circumferential direction. Each bristle-flap structure includes a plurality of bristles extending radially away from the brush roll and along a path that traverses around the brush roll in a helical, chevron, or linear pattern, to name a few examples. According to some embodiments, each bristle-flap structure also includes a compliant flap extending radially away from the brush roll and directly adjacent to the bristles, such that the compliant flap follows the same path as the bristles around the brush roll. In some examples, a base portion of the compliant flap acts as a mount for the bristles to hold the bristles in place. According to some embodiments, each bristle-flap structure may include a head portion where the bristles and compliant flap extend away from the brush roll and an anchor portion that isdesigned to fit into corresponding grooves or tracks in the brush roll core. The compliant flap may wrap around a bottom portion of the bristles within the anchor portion of the structure to hold the bristles in place. In some embodiments, the remaining surface area of the brush roll around the one or more bristle-flap structures may include a felt material or other compliant material such as a foamed elastomer. As used herein, the term felt refers to any plurality of soft bristles or bristle-like material that is densely packed so as to provide some level of sealing with a floor surface while also being pliable enough to allow debris to pass through. In an example, the felt material may include nylon filaments with a filament density between about 10,000 and about 20,000 filaments / cm2and a filament length between about 3 mm and about 7 mm. In another example, the remaining area might be filled with some combination of the felt material and some other compliant material.

[0016] According to an embodiment, a vacuum cleaner includes a nozzle assembly at a distal end of the vacuum cleaner and a brush roll coupled to the nozzle assembly. The brush roll includes a cylindrical core, a compliant flap coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, and a plurality of bristles extending away from the cylindrical core in a radial direction and directly adjacent to the compliant flap. The compliant flap extends along a path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core, and the plurality of bristles also extend along the same path as the compliant flap.

[0017] According to an embodiment, a brush roll is configured for use within a nozzle assembly of a vacuum cleaner or within an autonomous cleaning robot. The brush roll includes a cylindrical core and an agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction. The agitation structure extends linearly along a path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core. The agitation structure includes a compliant flap and bristles directly adjacent to the compliant flap.

[0018] According to an embodiment, a brush roll includes a cylindrical core, a first agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, a second agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, and a plurality of soft bristles coupled to the cylindrical core and extending away from the cylindrical core. The first agitation structure includes a first compliant flap and first bristles directly adjacent to the first compliant flap that together extend linearly along a first path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core. The second agitation structureincludes a second compliant flap and second bristles directly adjacent to the second compliant flap that together extend linearly along a second path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core. The plurality of soft bristles substantially fill an entire surface of the cylindrical core not occupied by the first agitation structure and the second agitation structure.

[0019] These and other such embodiments will be described in more detail herein.

[0020] The description uses the phrases "in an embodiment" or "in embodiments," which may each refer to one or more of the same or different embodiments. Furthermore, the terms "comprising," "including," "having," and the like, as used with respect to embodiments of the present disclosure, are synonymous. When used to describe a range of dimensions, the phrase "between X and Y" represents a range that includes X and Y.

[0021] Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element (s) or feature (s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.

[0022] Figure 1 illustrates a perspective three-dimensional view of a vacuum cleaner 100, according to an embodiment. Vacuum cleaner 100 has the general shape of an upright vacuum, however, it should be understood that the embodiments described herein with regards to the nozzle assembly may be used on any type of vacuum cleaner, such as a stick vacuum cleaner, canister vacuum cleaner, upright vacuum cleaner, or in an autonomous cleaning robot. In some embodiments, vacuum cleaner 100 includes a nozzle assembly 102 at a distal end of vacuum cleaner 100 while a handle 104 may be coupled to a proximal end of vacuum cleaner 100. Nozzle assembly 102 can include any number of rotating brush heads for facilitating the gathering of debris from a surface. The surface is typically a floor, but may also include furniture, walls, ceiling, or vehicle interiors.

[0023] According to some embodiments, vacuum cleaner 100 also includes at least a motor 106 and a waste receptacle 108. Motor 106 may be any suitable vacuum motor, such as a universal motor or a brushless direct current (DC) motor, that draws air up through nozzle assembly 102 and into waste receptacle 108.

[0024] According to some embodiments, the waste receptacle 108 may have a substantially cylindrical shape to fit with the overall form factor of vacuum cleaner 100. Waste receptacle 108 may have any suitable elongated geometry.

[0025] Figure 2 illustrates a side view of nozzle assembly 102, according to some embodiments. Nozzle assembly 102 includes a base unit 202 and a suction chamber 204 coupled to base unit 202. According to some embodiments, a rear portion of base unit 202 is coupled to an outlet 206 to allow nozzle assembly 102 to engage with the distal end of a vacuum cleaner and connect its air suction tube to that of the vacuum cleaner. Accordingly, outlet 206 may slidably engage with a portion of any type of vacuum cleaner. As mentioned above, nozzle assembly 102 may be designed to engage with any type of vacuum, such as a stick vacuum, cannister vacuum, upright vacuum, or handheld vacuum, to name a few examples. In some examples, outlet 206 may pivot about a ball-in-socket joint and / or other structures involving tube sections that are flexible or rotate into one another to allow for pivotable movement of outlet 206 with respect to base unit 202.

[0026] According to some embodiments, base unit 202 includes a rigid or semi-rigid body of a lightweight material (e.g., hard plastic or molded plastic). Suction chamber 204 may be designed to house the cleaning elements of the vacuum cleaner, such as any rollers, agitators, liquid sprayers, etc. According to some embodiments, suction chamber 204 is coupled to base unit 202 by pivot structures that allow suction chamber 204 to rotate about a pivot axis passing through the suction chamber with respect to base unit 202. The range of rotational motion of suction chamber 204 may be limited to less than 15 degrees, less than 10 degrees, or less than 5 degrees in either direction (clockwise or counterclockwise) about the pivot axis.

[0027] According to some embodiments, base unit 202 includes one or more wheels 210 to balance a rear portion of base unit 202 when placed onto a surface 212. Surface 212 may represent any type of surface that nozzle assembly 102 can be placed upon to perform a cleaning operation. In some examples, surface 212 represents a hard surface such as hardwood or tile. In some examples, surface 212 represents a carpeted surface.

[0028] Figure 3 illustrates a cutaway view taken through a central portion of nozzle assembly 102, according to some embodiments. Suction chamber 204 includes a first brush roll 302 and a second brush roll 304, according to some embodiments. As used herein, a brush roll refers to any cylindrical cleaning structure that can include various parts, such as a rigid core and softer cleaning elements such as bristles, flaps, fabrics, or foams. In some examples, first brush roll 302 and / or second brush roll 304 include one or more agitation structures around the circumference of the brush roll, and thus act as agitators to help pick up dirt and debris fromcarpeted surfaces (or to dislodge debris from a hard surface). First brush roll 302 may be arranged at a front of suction chamber 204 while second brush roll 304 is arranged at a rear of suction chamber 204. According to some embodiments, suction chamber 204 includes a suction port 306 through which dirt or other debris is sucked into off of surface 212. Suction port 306 may be centrally located along a bottom surface of suction chamber 204. First brush roll 302 may have a greater diameter compared to second brush roll 304. For example, first brush roll 302 may have a diameter between about 45 mm and about 55 mm while second brush roll 304 may have a diameter between about 30 mm and about 40 mm. In some embodiments, both first brush roll 302 and second brush roll 304 have the same diameter.

[0029] According to some embodiments, base unit 202 includes an air suction tube 308 that couples to suction port 306 via a flexible duct 310. Flexible duct 310 may fit over suction port 306 when suction chamber 204 is attached to base unit 202. In a more general sense, flexible duct 310 provides a leak-proof or at least a leak-resistant seal between suction port 306 and air suction tube 308. During operation, dirt or other debris is sucked from surface 212 through suction port 306 and into air suction tube 308 where it can be passed further into the vacuum cleaner coupled to outlet 206. Note that air suction tube 308 may be made up of various segments having different diameters and / or curvatures. For example, tube segment 308a may fit over tube segment 308b to allow for backwards and forwards pivoting of outlet 206. As outlet 206 is pivoted backwards, tube segment 308a slides over tube segment 308b to maintain suction through air suction tube 308. In other examples, tube segments 308a and 308b may be replaced by a flexible, corrugated tube.

[0030] According to some embodiments, first brush roll 302 is designed to rotate in a first direction while second brush roll 304 is designed to rotate in a second direction opposite from the first direction. For example, in the illustrated view, first brush roll 302 may rotate in a counterclockwise direction to push and / or lift dirt and debris off of surface 212 and towards suction port 306 during a forward stroke of nozzle assembly 102. Similarly, in the illustrated view, second brush roll 304 may rotate in a clockwise direction to push and / or lift dirt and debris off of surface 212 and towards suction port 306 during a backstroke of nozzle assembly 102. According to some embodiments, the rotational speed of first brush roll 302 and / or second brush roll 304 can be adjusted either manually or dynamically. A velocity and / or acceleration sensor (e.g., an accelerometer) may be used to determine a movement profile of nozzle assembly 102 with the rotational speed of first brush roll 302 and / or second brush roll 304 being adjusted accordingly. For example, a motor can increase the rotational speed of first brush roll 302 in response to an output from the sensor indicating that nozzle assembly 102 isexperiencing a forward stroke. In another example, another motor can increase the rotational speed of second brush roll 304 in response to an output from the sensor indicating that nozzle assembly 102 is experiencing a backstroke. In some embodiments, the sensor may be coupled to or otherwise associated with one or more of wheels 210 to determine the speed and direction (e.g., forward stroke or backstroke) of nozzle assembly 102. In some embodiments, one or more encoders, accelerometers, gyroscopes, or LIDAR sensors may be used to determine speed, direction, and / or angle of nozzle assembly 102.

[0031] Figure 4 illustrates an isometric view of a brush roll 400, according to some embodiments. Brush roll 400 may represent either first brush roll 302 or second brush roll 304 described above. Brush roll 400 includes a core 402 and one or more bristle-flap structures 404 around core 402. According to some embodiments, core 402 is a substantially rigid material, such as metal or hard plastic, and may be solid or have a hollow interior. Core 402 may have a cylindrical shape.

[0032] According to some embodiments, bristle-flap structures 404 extend both longitudinally and circumferentially along the outside surface of core 402, according to some embodiments. In other embodiments, bristle-flap structures 404 extend longitudinally but not circumferentially along the outside surface of core 402. A given bristle-flap structure 404 may start at one end of core 402 and extend towards the opposite end. In some examples, each bristle-flap structure 404 extends along more than 50% of the entire length of core 402, such as at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% the entire length of core 402. In the illustrated example of Figure 4, two bristle-flap structures 404 extend along the entire length of core 402 in a helical pattern.

[0033] According to some embodiments, bristle-flap structure 404 includes bristles 406 directly adjacent to a compliant flap 408. Bristles 406 may be relatively stiff bristles having a length between about 3 mm and about 6 mm extending away from the outer surface of core 402. Compliant flap 408 may extend the same distance away from the outer surface of core 402 directly adjacent to bristles 406. Compliant flap 408 may be an elastomeric material, such as a suitable polymer material. In some examples, an outer surface of compliant flap 408 (e.g., opposite from the surface directly adjacent to bristles 406) may include a fabric material or felt-like material.

[0034] According to some embodiments, one or both ends of core 402 may include a recess 410 that is shaped to engage with a motorized rotating structure in order to rotate brush roll 400. Core 402 may be hollow along the entire length of core 402 (from end to end), or hollow for only a portion of the length.

[0035] Figure 5 A illustrates a side view of brush roll 400 and Figure 5B illustrates a crosssection view through brush roll 400 taken across the line B-B in Figure 5 A, according to some embodiments. Bristle-flap structure 404 may include a head portion 502 that extends away from core 402 and an anchor portion 504 beneath the outer surface of core 402. According to some embodiments, anchor portion 504 slides into or is otherwise engaged with a matching groove 506 that extends around core 402 in order to attach bristle-flap structure 404 to core 402.

[0036] A bottom portion of compliant flap 408 may wrap fully or at least partially around the bottom portion of bristles 406 in anchor portion 504. In this way, compliant flap 408 may help to hold bristles 406 in place. Anchor portion 504 may have a ‘T’ shape that engages into groove 506 having the matching ‘T’ shape. Other matching shapes may be possible as well to hold bristle-flap structure 404 in place.

[0037] In some embodiments, core 402 includes a flange 508 that extends from core 402 and adjacent to bristles 406. Flange 508 may be provided to help protect bristles 406 and to keep them aligned in place. In some embodiments, flange 508 extends up only a portion of the total length of bristles 406, such as up to 20%, up to 30%, up to 40%, or up to 50% the total length of bristles 406. Flange 508 may follow bristles 406 along the entire path taken by bristle-flap structure 404 around core 402.

[0038] Figures 6A - 6C illustrate cross-section views of various designs of bristle-flap structure 404, according to some embodiments. As shown in Figure 6A, compliant flap 408 wraps around a portion of the bottom of bristles 406 within anchor portion 504. In some examples, the bottom of bristles 406 has a ‘T’ shape with compliant flap 408 wrapping around at least one end of the head of the ‘T’ shape.

[0039] Figure 6B illustrates another bristle-flap structure 404 where compliant flap 408 is angled away from bristles 406 by an angle 0, according to some embodiments. A base portion of compliant flap 408 may remain directly adjacent to bristles 406 while an extension of compliant flap 408 above the surface of core 402 is bent at the angle 0 away from bristles 406. The bent angle of compliant flap 408 can give bristles 406 more room to bend through certain floor surfaces. In some examples, compliant flap 408 is bent at an angle 0 of up to 20°, up to 30°, or up to 45° from bristles 406.

[0040] Figure 6C illustrates another bristle-flap structure 404 that includes a shim 602 between the bottom of bristles 406 and compliant flap 408 within anchor portion 504, accordingto some embodiments. Shim 602 may be any suitable rigid or semi-rigid material to provide additional support beneath bristles 406.

[0041] Figure 7 illustrates another brush roll 700 that includes core 402 and one or more bristle-flap structures 404 around the outside surface of core 402. Brush roll 700 may represent either first brush roll 302 or second brush roll 304 described above. According to some embodiments, regions on the outside surface of core 402 not occupied by one or more bristleflap structures 404 include felt 702. In some examples, felt 702 represents densely packed soft filament material. In the illustrated example, felt 702 substantially fills the entire outer surface of core 402 adjacent to one or more bristle-flap structures 404. In other examples, felt 702 is present in specific regions on the outer surface of core 402. For two-roller or multi-roller nozzle designs (e.g., having more than two brush rolls), the presence of felt 702 can aid in forming a vacuum seal beneath the nozzle between the brush rolls. In some examples, the presence of felt 702 can also provide vacuum chamber sealing in a single roller configuration.

[0042] Figure 8 illustrates the underside of suction chamber 204 with the one or more brush rolls removed. A rotating structure 802 may be coupled to suction chamber 204 and designed to fit within or otherwise engage with recess 410 at one or both ends of brush roll 400 or 700. Rotating structure 802 may be motorized using, for example, one or more motors within the nozzle assembly to rotate thus causing a respective rotation of brush roll 400 or 700.

[0043] It should be understood that the nozzle assembly 102 illustrated, for example, in Figures 2, 3, or 8, and the roller design illustrated, for example, in any of Figures 4-7 can be utilized within any type of vacuum cleaner. For example, the illustrated nozzle assembly 102 can be used within any standard upright vacuum cleaner, any stick vacuum cleaner, or any canister vacuum cleaner. Furthermore, brush roll 400 or 700 may be used in any suction chamber design for any type of vacuum cleaner. In some embodiments, brush roll 400 or 700 are utilized on the underside of an autonomous cleaning robot.

[0044] Numerous specific details have been set forth herein to provide a thorough understanding of the embodiments. It will be understood in light of this disclosure, however, that the embodiments may be practiced without these specific details. In other instances, well known operations and components have not been described in detail so as not to obscure the embodiments. It can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments. In addition, although the subject matter has been described in language specific to structural features and / or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described herein.Rather, the specific features and acts described herein are disclosed as example forms of implementing the claims.

Claims

CLAIMSWhat is claimed is:

1. A vacuum cleaner, comprising: a nozzle assembly at a distal end of the vacuum cleaner; a brush roll coupled to the nozzle assembly, wherein the brush roll comprises a cylindrical core; a compliant flap coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, wherein the compliant flap extends along a path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core; and a plurality of bristles extending away from the cylindrical core in a radial direction and directly adjacent to the compliant flap such that the plurality of bristles also extend along the same path as the compliant flap.

2. The vacuum cleaner of claim 1, wherein an outer surface of the compliant flap comprises a fabric material.

3. The vacuum cleaner of claim 1, wherein the compliant flap extends along at least 50% of a total length of the cylindrical core.

4. The vacuum cleaner of claim 1, wherein the compliant flap extends along an entire length of the cylindrical core.

5. The vacuum cleaner of claim 4, wherein the path is a helical path around the cylindrical core.

6. The vacuum cleaner of claim 1, wherein the compliant flap is a first compliant flap, the plurality of bristles is a first plurality of bristles, and the path is a first path, the brush roll further comprising: a second compliant flap coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, wherein the second compliant flap extends along a second path around at least a portion of the circumference of the cylindrical core and along the length of the cylindrical core; anda second plurality of bristles extending away from the cylindrical core in a radial direction and directly adjacent to the second compliant flap such that the second plurality of bristles also extend along the same second path as the second compliant flap.

7. The vacuum cleaner of claim 6, wherein the first path and the second path have the same helical design.

8. The vacuum cleaner of claim 1, wherein the compliant flap and plurality of bristles together comprise an anchor portion that extends beneath an outer surface of the cylindrical core.

9. The vacuum cleaner of claim 8, wherein the anchor portion slots into a groove that extends around at least a portion of the circumference of the cylindrical core while extending along the length of the cylindrical core.

10. The vacuum cleaner of claim 9, wherein the groove and the anchor portion share a matching shape.

11. The vacuum cleaner of claim 10, wherein the matching shape is a ‘T’ shape.

12. The vacuum cleaner of claim 8, wherein the compliant flap in the anchor portion wraps at least partially around a bottom portion of the plurality of bristles.

13. The vacuum cleaner of claim 8, wherein the anchor portion comprises a shim between a bottom surface of the plurality of bristles and at least a portion of the compliant flap.

14. The vacuum cleaner of claim 1, wherein the brush roll further comprises felt coupled to the cylindrical core and extending away from the cylindrical core, the felt substantially filling an entire surface of the cylindrical core not occupied by the compliant flap or the plurality of bristles.

15. The vacuum cleaner of claim 14, wherein the felt comprises a plurality of filaments, and the plurality of bristles have a higher stiffness compared to the plurality of filaments.

16. The vacuum cleaner of claim 1, wherein the vacuum cleaner is a canister vacuum.

17. The vacuum cleaner of claim 1, wherein the vacuum cleaner is an upright vacuum.

18. The vacuum cleaner of claim 1, wherein the vacuum cleaner is a stick vacuum.

19. A brush roll configured for use within a nozzle assembly of a vacuum cleaner or within an autonomous cleaning robot, the brush roll comprising: a cylindrical core; and an agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, wherein the agitation structure extends linearly along a path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core, and wherein the agitation structure comprises a compliant flap and bristles directly adjacent to the compliant flap.

20. The brush roll of claim 19, wherein an outer surface of the compliant flap comprises a fabric material.

21. The brush roll of claim 19, wherein the agitation structure extends along at least 50% of a total length of the cylindrical core.

22. The brush roll of claim 19, wherein the agitation structure extends along an entire length of the cylindrical core.

23. The brush roll of claim 22, wherein the path is a helical path around the cylindrical core.

24. The brush roll of claim 19, wherein the agitation structure is a first agitation structure, the compliant flap is a first compliant flap, the bristles are first bristles, and the path is a first path, the brush roll further comprising: a second agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, wherein the second agitation structure extends linearly along a second path around at least a portion of the circumference of the cylindrical core and along the length of the cylindrical core, and wherein the second agitation structure comprises a second compliant flap and second bristles directly adjacent to the second compliant flap.

25. The brush roll of claim 24, wherein the first path and the second path have the same helical design.

26. The brush roll of claim 19, wherein the agitation structure comprises an anchor portion that extends beneath an outer surface of the cylindrical core.

27. The brush roll of claim 26, wherein the anchor portion slots into a groove that extends around at least a portion of the circumference of the cylindrical core while extending along the length of the cylindrical core.

28. The brush roll of claim 27, wherein the groove and the anchor portion share a matching shape.

29. The brush roll of claim 28, wherein the matching shape is a ‘T’ shape.

30. The brush roll of claim 26, wherein the anchor portion includes a portion of the compliant flap that wraps at least partially around a bottom portion of the bristles.

31. The brush roll of claim 30, wherein the anchor portion comprises a shim between the portion of the compliant flap and a bottom surface of the bristles.

32. The brush roll of claim 19, further comprising a felt coupled to the cylindrical core and extending away from the cylindrical core, the felt substantially filling an entire surface of the cylindrical core not occupied by the agitation structure.

33. The brush roll of claim 32, wherein the felt includes a plurality of filaments, and the bristles have a higher stiffness compared to the plurality of filaments.

34. The brush roll of claim 19, wherein the agitation structure is one agitation structure of a plurality of similar agitation structures coupled to the cylindrical core.

35. A brush roll, comprising: a cylindrical core; a first agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, wherein the first agitation structure extends linearly along a first path around at least a portion of a circumference of the cylindrical core and along a length of the cylindrical core, and wherein the first agitation structure comprises a first compliant flap and first bristles directly adjacent to the first compliant flap. a second agitation structure coupled to the cylindrical core and extending away from the cylindrical core in a radial direction, wherein the second agitation structure extends linearly along a second path around at least a portion of the circumference of the cylindrical core and along the length of the cylindrical core, and wherein the secondagitation structure comprises a second compliant flap and second bristles directly adjacent to the second compliant flap; and a plurality of soft bristles coupled to the cylindrical core and extending away from the cylindrical core, the plurality of soft bristles substantially filling an entire surface of the cylindrical core not occupied by the first agitation structure and the second agitation structure.

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