Helical Dual-Material Agitator for Low-Energy Vacuum Pickup

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Solution Overview

Problem

Cordless vacuum cleaners face a design challenge in maintaining effective pickup performance while reducing energy consumption, as high power settings compromise battery run time.

Innovation Solution

A cleaner head design featuring a rotatable cylindrical agitator with alternating rows of different materials (e.g., nylon and carbon fibre) arranged in helical directions to ensure a single point of contact with the floor, guiding airflow and maintaining consistent friction, thereby improving dirt and dust pickup across various surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high power settings are used to improve pickup performance, then dirt removal effectiveness is improved, but battery run time is severely compromised

Engineering Contradiction:

Improvepickup performanceVSAvoidbattery run time

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The agitator is segmented into alternating rows of stiff and compliant materials, creating distinct functional zones that work together to achieve effective dirt removal while reducing overall energy consumption

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the agitator have different material properties - stiff sections for aggressive dirt dislodgement and compliant sections for gentle surface contact, optimizing performance across various floor types without requiring high power throughout

Inventive Principle:

Principle #3Local quality

2Productivity

If stiff bristles are used to aggressively engage the floor surface, then dirt scraping and striking capability is improved, but energy consumption increases

Engineering Contradiction:

Improvedirt removal capabilityVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The agitator circumference is divided into alternating segments of stiff and compliant materials, allowing aggressive dirt removal only where necessary while reducing energy consumption in compliant sections

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The agitator combines dissimilar materials (stiff bristles and compliant rubber or thermoplastic elastomer) in a single composite structure, leveraging the advantages of both material types to achieve effective cleaning with reduced power requirements

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If a single material is used for the agitator, then manufacturing simplicity is maintained, but versatility across different floor surfaces is limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfloor surface adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The agitator is segmented into alternating rows of different materials, allowing each segment to be optimized for specific floor types while maintaining a relatively simple overall manufacturing process

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The use of composite material construction with alternating stiff and compliant sections enables the agitator to adapt to various floor surfaces (hard floors, carpets, rugs) while remaining manufacturable through established processes

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enhances the versatility and effectiveness of the cleaner head by maintaining pickup performance across different surfaces while balancing the loading on the motor, reducing energy consumption and extending battery life.

Implementation Method 1

a first helical agitator row that extends around the cylindrical body in a first direction from a first edge of the cylindrical body towards a centre of the cylindrical body, and a second helical agitator row that extends around the cylindrical body in a second direction from the first edge of the cylindrical body towards the centre of the cylindrical body

Methodology Applied

Scientific EffectAirflow generation:

Implementation Method 2

maintaining consistent friction, thereby improving dirt and dust pickup across various surfaces

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP4041040B1Cleaner head for a vacuum cleaning appliance

Publication Date: 2023.10.25 DYSON TECH LTD

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AI summary

This invention concerns a cleaner head (10) for a vacuum cleaning appliance, the cleaner head (10) comprising a main body (12) supporting an agitator (36). The agitator (36) comprises a rotatable cylindrical body (42) that bears an elongate agitator formation (44) for engaging a floor surface as the cylindrical body (42) rotates. The elongate agitator formation (44) includes a first agitator row (46) extending around the cylindrical body (42) from a respective first edge L of the cylindrical body (42) towards its centre C in a first helical direction and a second agitator row (47) extending around the cylindrical body (42) from a respective second edge R of the cylindrical body (42) towards its centre C in a second helical direction that is counter to the first helical direction, wherein the first agitator row (46) comprises agitators of a first material and wherein the second agitator row (47) comprises agitators of a second material that is different to the first material.