Abstract:
A cleaning device for cleaning a surface is provided including a base for movement along a surface, a suction nozzle associated with the base, and a suction source for drawing liquid and dirt from the surface through the suction nozzle. The cleaning device further includes a brush assembly operatively connected to the base, wherein the brush assembly has at least one brush, which includes a first set of pliable elements extending downwardly from the brush and contacting the surface. The pliable elements slope downwardly and outwardly with the first set of pliable elements having at least a first group of pliable elements and a second group of pliable elements, wherein each of the pliable elements of the second group of the first set extend downwardly from the brush at a length less than the first group of the first set and the second group of pliable elements of the first set being positioned inwardly from the first group of the pliable elements of the first set.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a brush assembly for a cleaning device such as a carpet or hard floor cleaner. More particularly, the present application pertains to such a brush assembly that has pliable elements designed and constructed for agitating an uneven surface.  
         [0003]     2. Background Information  
         [0004]     It is known in the prior art to provide a cleaning device having a brush assembly for scrubbing of a cleaning surface being cleaned. One example of a cleaning device with a vertical axis brush assembly is illustrated by commonly owned pending U.S. patent application having Ser. No. 09/955,725 and publication number 20030051308 to Morgan et al. Other devices or machines have roller-type brush assemblies such as that disclosed in U.S. Pat. No. 6,041,472 issued to Kasen et al. or fixed brush assemblies such as that illustrated by commonly own patent application having Ser. No. 10/340,291 to Gerber et al. Typically, brush assemblies from theses and other machines have trouble cleaning grout, recessed, or other uneven areas of the cleaning surface.  
         [0005]     Hence, it is an object of the present invention to provide a brush assembly for a cleaning device with improved cleaning of grout, recessed or other uneven areas of the cleaning surface.  
       SUMMARY OF THE INVENTION  
       [0006]     The foregoing and other objects of the present invention will be readily apparent from the following description and the attached drawings. In one aspect of the present invention, a cleaning device for cleaning a surface is provided. The cleaning device includes a base for movement along a surface, a suction nozzle associated with the base, and a suction source for drawing liquid and dirt from the surface through the suction nozzle. The cleaning device further includes a brush assembly operatively connected to the base, wherein the brush assembly has at least one brush, which includes a first set of pliable elements extending downwardly from the brush and contacting the surface. The pliable elements slope downwardly and outwardly with the first set of pliable elements having at least a first group of pliable elements and a second group of pliable elements, wherein each of the pliable elements of the second group of the first set extend downwardly from the brush at a length less than the first group of the first set and the second group of pliable elements of the first set being positioned inwardly from the first group of the pliable elements of the first set.  
         [0007]     In another aspect of the invention, a cleaning device for cleaning a surface in which cleaning solution is dispensed to the surface and substantially simultaneously extracted along with the dirt on the surface in a continuous operation is provided. The cleaning device includes a base for movement along a surface and a recovery system mounted to the base. The recovery system includes a suction nozzle and a suction source for drawing liquid and dirt from the surface through the suction nozzle. The cleaning device further includes a liquid distribution system for dispensing liquid to the surface, and a brush assembly operatively connected to the base, wherein the brush assembly has at least one brush including a first set of pliable elements extending downwardly from the brush and contacting the surface with the pliable elements of the first set sloping downwardly and outwardly. The brush includes a second set of pliable elements extending downwardly from the brush and contacting the surface, wherein the second set of pliable elements is located inwardly from the first set of pliable elements. The brush has at least one opening for dispensing the liquid to the cleaning surface with the opening located between said first and second sets of pliable elements.  
         [0008]     In still another aspect of the invention, a cleaning device for cleaning a surface is provided. The cleaning device includes a base for movement along a surface, a suction nozzle associated with the base and a suction source for drawing liquid and dirt from the surface through said suction nozzle. A brush assembly is operatively connected to the base, wherein the brush assembly has at least one brush including a first set of pliable elements extending downwardly from the brush and contacting the surface. The first set of pliable elements has at least a first pliable element extending a first length, at least a second pliable element extending a second length greater than the first length of the first pliable element, and at least a third pliable element extending a third length greater than the second length of the second pliable element, wherein the first pliable element is positioned inwardly from the second pliable element, and the second pliable element is positioned inwardly from the third pliable element.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     The invention will now be described, by way of example, with reference to the attached drawings, of which:  
         [0010]      FIG. 1  is a perspective view of one embodiment of a floor-cleaning device with a portion cut away to show the brush assembly according to the present invention;  
         [0011]      FIG. 2  is an exploded view of the brush assembly of the embodiment in  FIG. 1 ;  
         [0012]      FIG. 3  is a bottom view of one of the gear brushes of the brush assembly shown in the embodiment of  FIG. 2 ;  
         [0013]      FIG. 4  is a side elevation view of the gear brush of  FIG. 3 ;  
         [0014]      FIG. 5  is an enlarged view of the section of the gear brush circled in  FIG. 4 ;  
         [0015]      FIG. 6  is a perspective view of another embodiment of a floor-cleaning device with a portion cut away to show the brush assembly according to the present invention;  
         [0016]      FIG. 7  is an exploded view of the brush assembly of the embodiment of  FIG. 6 ;  
         [0017]      FIG. 8  is a bottom view of one of the gear brushes of the brush assembly shown in the embodiment of  FIG. 6 ;  
         [0018]      FIG. 9  is a side elevation view of the gear brush of  FIG. 8 ;  
         [0019]      FIG. 10  is an enlarged view of the section of the gear brush circled in  FIG. 9 ;  
         [0020]      FIG. 11  is a perspective view of a brush assembly according to still another embodiment of the present invention;  
         [0021]      FIG. 11A  is an enlarged elevation view taken along line  11 A- 11 A of  FIG. 11 ; and  
         [0022]      FIG. 12  is front perspective view of a brush assembly according to still another embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0023]     Referring to the drawings,  FIG. 1  depicts a perspective view of an upright hard floor-cleaning unit  40  having a brush assembly of one embodiment of the present invention. The hard floor-cleaning unit  40  comprises an upright handle assembly  42  pivotally connected to the rear portion of a base assembly  44  that moves and cleans along a surface. The base assembly  44  includes a nozzle assembly  62  with a squeegee  66  for recovering particles and/or fluid from the floor and a brush block assembly  216  ( FIG. 2A ) for scrubbing the floor. The handle assembly  42  includes a recovery tank  53  for collecting the particles and/or fluid picked up by the nozzle assembly  62  and a solution distribution system having a solution tank  43  containing cleaning solution for distribution on the floor. Both the nozzle assembly  62  and brush block assembly  216  are removable from the base assembly  44 . Further details of the cleaning unit  40  are disclosed in the co-pending patent application number 09/956,297; the disclosure of which is incorporated by reference.  
         [0024]     Referring to  FIG. 2 , the brush block assembly  216  comprises a brush support plate  218  having six spaced apart openings  220 A,  220 B,  220 C,  220 D,  220 E, and  220 F. Fixedly received within the openings  220  are bushings  222 A,  222 B,  222 C,  222 D,  222 E, and  222 F which in turn rotatingly receive axial shafts  224 A,  224 B,  224 C,  224 D,  224 E, and  224 F of gear brushes  226 A,  226 B,  226 C,  226 D,  226 E, and  226 F. The gear brushes  226 A-F rotate on a vertical axis. A drive shaft  225  having a square cross section is welded to the axial shaft  224 B of the gear brush  226 B adjacent the right outer brush  226 A. Each of the gear brushes  226  is basically configured as a spur gear having ten teeth  228  that intermesh such that when one gear brush  226  rotates, all other gear brushes  226  rotate accordingly. The center hub of gear brushes  226  forms a hollow downwardly projecting cup  230  having a multiplicity of openings  232  circumscribing the bottom thereof for dispensing the cleaning solution from the solution tank  43  to the cleaning surface.  
         [0025]     A gear guard  236  snap fits into a brush support plate  218 . Specifically, upwardly extending locking tabs  238  on the gear guard  236  catch onto steps  240  integrally molded to the lower surface of the brush support plate  218 . During assembly of the gear guard  236  to the brush support plate  218 , the locking tabs  238  deflect laterally extending cantilevered tangs  242  integrally formed in the brush support plate  218  to allow the locking tabs  238  to extend therethrough. The tangs  242  will then flex back to their initial position, closely adjacent the locking tabs  238 , to prevent the locking tabs  238  from disengaging off of the steps  240 .  
         [0026]     With continue reference to  FIG. 2 , the brush support plate  218  includes a plurality of troughs  244 A,  244 B,  244 C,  244 D for receiving the cleaning solution that flows from a distributor  246  ( FIG. 2A ) positioned thereon. Cleaning solution received in the troughs  244  flows through openings  248  in them and into the center cups  230  of the brushes  226 . Once deposited within the brush cup  230 , the cleaning solution flows outward toward the surface being cleaned through openings  232  in the bottom of the brush cups. The cups  230  contain the cleaning solution as the gear brushes  226  rotate and thus prevent solution from being sprayed outward over the top of the gear brush. The gear guard  236  is designed to withstand impact and prohibit cleaning solution from resting on its inner lip  231 . In particular, the bottom surface  241  of the inner lip  231  inclines downwardly to the edge of the inner lip  231  to direct the flow of cleaning solution off the inner lip  231 .  
         [0027]     During manufacturing of the brush assembly  216 , the gear brush axial shafts  224  are first inserted into the appropriate bushing  222  and with gear brushes  226  in their uppermost position and, with gear teeth  228  intermeshed between the gear brushes  226 . As also seen in  FIGS. 3,4  and  5 , each gear tooth  228  has a blind bore, extending to offset  233  into which pliable elements in the form of bristles  136  define bristle bundles  134  which are compressively inserted therein and extend downwardly to the cleaning surface. The bristle bundles  134  are arranged in an outer ring  137  around the gear brush  226  as seen in  FIG. 3 .  
         [0028]     Each of the bristles  136  slope or flare outwardly with respect to the brush assembly  216  at an angle of twenty degrees with respect to the vertical axis of the gear brush  226 . The bristles  136  could slope outwardly at other angles too such as, for example, those within the range of ten to thirty degrees. Such an outward sloping of bristles  136  allows the bristles to flex at various heights thereby allowing the bristles  136  to get into and scrub the grout or other recessed areas of the cleaning surface.  
         [0029]      FIGS. 6 through 10  depict another embodiment of the present invention. The same reference numbers will be used for elements that are similar in structure and function as the previous embodiment. As illustrated in  FIG. 7 , the brush block assembly  316  comprises a brush support plate  218  having six spaced apart openings  220 A,  220 B,  220 C,  220 D,  220 E, and  220 F. Fixedly received within the openings  220  are bushings  222 A,  222 B,  222 C,  222 D,  222 E, and  222 F which in turn rotatingly receive axial shafts  224 A,  224 B,  224 C,  224 D,  224 E, and  224 F of gear brushes  326 A,  326 B,  326 C,  326 D,  326 E, and  326 F. The gear brushes  326 A-F rotate on a vertical axis. A drive shaft  225  having a square cross section is welded to the axial shaft  224 B of the gear brush  326 B adjacent the right outer brush  326 A. Each of the gear brushes  326  is basically configured as a spur gear having ten teeth  228  that intermesh such that when one gear brush  326  rotates, all other gear brushes  326  rotate accordingly. The center hub of gear brushes  326  forms a hollow downwardly projecting cup  230  having a multiplicity of openings  232  circumscribing the bottom thereof for dispensing the cleaning solution from the solution tank  43  to the cleaning surface.  
         [0030]     During manufacturing of the brush assembly  316 , the gear brush axial shafts  224  are first inserted into the appropriate bushing  222  and with gear brushes  326  in their uppermost position and, with gear teeth  228  intermeshed between the gear brushes  326 . As best seen in  FIGS. 8-10 , each gear brush  326  includes a gear tooth  228  having a blind bore, extending to offset  233  into which pliable elements in the form of bristles  331 ,  332  define bristle bundles  334  which are compressively inserted therein and extend downwardly to the cleaning surface. The bristle bundles  334  are arranged in an outer ring  337  around the gear brush  326 . Each of the bristle bundles  334  includes inner and outer bristle groups  335 ,  338 , respectively, that slope or flare outwardly with respect to the brush assembly  316  at an angle of thirty degrees with respect to the vertical axis of the gear brush  326 . The bristles  331  of the outer bristle group  338  are longer than the bristles  332  of the inner bristle group  335 . The inner bristle group  335  is also trimmed outwardly at an angle of forty-five degrees with respect to the cleaning surface, such that the length of each successive bristle going from the inner end  340  to the outer end  342  of the inner group  335  is longer than that of the previous bristle. For example, as illustrated in  FIG. 10 , bristle  332 C is longer than  332 B, which is longer than  332 A and so forth. Thus, when the bristles in each bristle bundle  334  are flexed outwardly the tips  344  of the bristles  332  in the inner bristle group  335  contact the cleaning surface to provide better scrubbing action.  
         [0031]     The gear brush  326  further includes a second set of bristles  346 ,  348  defining bristles bundles  350  which are received in blind bores and arranged in an inner ring  352  around the gear brush  326 . These bristle bundles  350  are shorter in length than the bristle bundles  334  of the outer ring  337 . Each of the bristle bundles  350  includes inner and outer bristle groups  354 ,  356 , respectively, that flare outwardly with respect to the brush assembly  316  at an angle of thirty degrees with respect to the vertical axis of the gear brush. The bristles  346  of the outer bristle group  356  are longer than those of the inner bristle group  354 . The inner bristle group  356  is also trimmed outwardly at an angle of forty-five degrees with respect to the cleaning surface, such that the length of each successive bristle going from the inner end  358  to the outer end  360  of the inner bristle group  356  is longer than that of the previous bristle. For example, as illustrated in  FIG. 10 , bristle  348 C is longer than  348 B, which is longer than  348 A and so forth. Thus, when the bristles in each bristle bundle  350  are flexed outwardly the tips  362  of the bristles  348  in the inner bristle group  354  contact the cleaning surface to provide better scrubbing action. Also, the difference in height of bristle bundles  334  and  350  allow the longer bristle bundles  334  to clean grout areas or other recessed areas of the floor. Bristle bundles  235  are also compressively inserted into the front corners of the brush support plate  218  for edge cleaning as shown in  FIG. 7 .  
         [0032]      FIG. 6  shows an upright hard floor-cleaning unit  41  having the brush assembly  316 . The hard floor-cleaning unit is similar to that shown in  FIG. 1  except for the brush assembly as previously described. Thus, similar reference numbers will be used. The hard floor-cleaning unit  41  comprises an upright handle assembly  42  pivotally connected to the rear portion of a base assembly  44  that moves and cleans along a surface. The base assembly  44  includes a nozzle assembly  62  with a squeegee  66  for recovering particles and/or fluid from the floor and the brush block assembly  316  for scrubbing the floor. The handle assembly  42  includes a recovery tank  53  for collecting the particles and/or fluid picked up by the nozzle assembly  62  and a solution tank  43  containing cleaning solution for distribution on the floor. Both the nozzle assembly  62  and brush block assembly  316  are removable from the base assembly  44 . Further details of the cleaning unit  41  are disclosed in the co-pending patent application number 09/956,297; the disclosure of which is incorporated by reference. The bristle arrangement of the brush assemblies  216  and  316  of the above-mentioned embodiments can also be incorporate into the brush assembly shown in co-owned U.S. Pat. No. 6,009,593; the disclosure of which is incorporated by reference.  
         [0033]      FIGS. 11 and 11 A show still another embodiment of the brush block assembly  416 . In particular, the brush assembly  416  comprises a rectilinear brush support member  418  having blind bores into which pliable elements in the form of bristles  476 ,  478 ,  480 ,  482 ,  494 ,  496 ,  498 ,  500  defining bristle bundles  460 ,  462 ,  464 ,  466  are compressively inserted therein. The brush assembly  416  includes an outer front row  419  of bristle bundles  460 , an inner front row  421  of bristle bundles  462 , an inner rear row  423  of bristle bundles  464 , and an outer rear row  425  of bristle bundles  466 . The rows are parallel to the longitudinal axis of the brush support member  418  and also oriented transversely to the cleaning path. The bristle bundles  420  project downwardly from the support member  418  for engagement with the cleaning surface. The bristles in the outer rows  419  and  492  are longer than the bristles in the inner rows  421  and  423 .  
         [0034]     Each of the bristle bundles  460 ,  462  include respective inner or rear bristle groups  468 ,  470  and respective outer or front bristle groups  472 ,  474  that slope or flare outwardly or forwardly with respect to the brush assembly  416  at an angle of thirty degrees with respect to the vertical axis of the brush assembly  416 . The bristles  476 ,  478  of the respective outer bristle groups  472 ,  474  are longer than the bristles  480 ,  482  of the respective inner bristle groups  468 ,  470 . Each of the inner bristle groups  468 ,  470  is also trimmed outwardly at an angle of forty-five degrees with respect to the cleaning surface, such that the length of each successive bristle going from the inner end to the outer end of the inner group is longer than that of the previous bristle.  
         [0035]     For example, as illustrated in  FIG. 11A  bristles  480 C and  482 C are longer than  480 B and  482 B, which is longer than  3480 A and  482 A and so forth. Thus, when the bristles in each of the bristle bundles  460 ,  462  are flexed outwardly the tips  484  of the bristles  480 ,  482  in the respective inner bristle groups  468 ,  470  contact the cleaning surface to provide better scrubbing action.  
         [0036]     Each of the bristle bundles  464  and  466  include respective inner or front bristle groups  485 ,  486  and respective outer or rear bristle groups  490 ,  492  that slope or flare outwardly or rearwardly with respect to the brush assembly  416  at an angle of thirty degrees with respect to the vertical axis of the brush assembly  416 . The bristles  494 ,  496  of the respective outer bristle groups  490 ,  492  are longer than the bristles  498 ,  500  of the respective inner bristle groups  485 ,  486 . Each of the inner bristle groups  485 ,  486  is also trimmed outwardly at an angle of forty-five degrees with respect to the cleaning surface, such that the length of each successive bristle going from the inner end to the outer end of the inner group is longer than that of the previous bristle. For example, as illustrated in  FIG. 11A  bristles  498 C and  500 C are longer than  498 B and  500 B, which is longer than  498 A and  500 A and so forth. Thus, when the bristles in each of the bristle bundles  464 ,  466  are flexed outwardly the tips  484  of the bristles  498 ,  500  in the respective inner bristle groups  485 ,  486  contact the cleaning surface to provide better scrubbing action.  
         [0037]     The bristle bundles  460 ,  466  in the outer rows  419  and  425  are longer than the bristle bundles  462 ,  464  in the inner rows  421  and  423 . This difference in height allows the longer bristle bundles  460 ,  466  to clean grout areas or other recessed areas of the floor.  
         [0038]     As best shown in  FIG. 11 , the support member  418  further includes a line of elongated slots  422  spaced longitudinally and disposed between the front and rear edges of the support member  418 . A dispensing bar  424  ( FIG. 11A ) is integrally formed with the bottom of the support member  418 , underlying the bottom of slots  422 . An additional scrub strip  430  ( FIG. 11A ) is adhesively mounted on the bottom of the support member rearwardly adjacent the dispensing bar  424 .  
         [0039]     Together, the dispensing bar  424  and slots  422  define relatively deep compartments or troughs  432  in the support member  418 , which break up bubbles of cleaning solution that collects therein. The relatively wide troughs  432  also allow easy rinsing and cleaning of dirt in collected therein. Recessed channels  440  are disposed in the upper surface  438  of the support member  418  to direct the cleaning solution to flow into the troughs  432 . Integrally formed on the top surface  446  of the support member  418  are splashguards  436  that surround the channels  440  to prevent the cleaning solution from splashing out of the channels. Since the troughs  432  are spaced apart, the collecting of cleaning solution in one area is minimized in case of an error occurring in molding an uneven dispensing bar  424 . A pair of outwardly curved ribs  454 ,  456 , which define a handgrip, is attached on the top surface  446  of the support member near the front end. A nub  458  is formed at the forward end of each of the ribs  454 ,  456  for added grip support.  
         [0040]     A pair of locating hooks  442  is attached to the top surface of the support member and extends rearwardly. The hooks  442  are slidably received in a base assembly of floor cleaning unit. Further details of the floor cleaning and brush assembly are described in commonly owned co pending patent application having Ser. No. 10/340,291; the disclosure which is incorporated by reference. Optionally, the bristle bundles as a whole for each row may vary in length or height with respect to cleaning surface. For example, one bristle bundle may be longer than its adjacent bristle bundles to the right and left of it in the row.  
         [0041]      FIG. 12  illustrates another embodiment of the present invention. In this embodiment, the brush assembly  516  is a horizontal brush roll including a cylindrical drum  514  and a plurality of pliable elements in the form bristles  520  and  521  defining bristle bundles  522  secured to the drum  514  extending radially therefrom. The bristle bundles  522  are secured to the drum  514  in a generally helical pattern originating at each end of the drum  514  and terminating at the center of the drum  514 .  
         [0042]     Each of the bristle bundles  522  include inner and outer bristle groups  524 ,  526  as viewed when the bristle extends down and is located in front of the drum  514 . Alternatively, each of the bristles  520  and  521  can slope or flare outwardly with respect to the brush assembly  516  (when the bristle extends down and is located in front of the drum  514 ) at an angle of thirty degrees with respect to a plane extending radially from the secured end of the bristle and oriented perpendicular to the horizontal axis of the brush roll  516 . The bristles  521  of the outer bristle group  526  are longer than the bristles  520  of the inner bristle group  524 . The inner bristle group  524  is also trimmed outwardly at an angle of forty-five degrees with respect to a plane across the free ends of the bristles  521  of the outer bristle group  526 , such that the length of each successive bristle going from the inner end to the outer end of the inner bristle group  524  is longer than that of the previous bristle. For example, bristle  520 C is longer than  520 B, which is longer than  520 A and so forth. Thus, when the bristles in each bristle bundle are flexed outwardly the tips  528  of the bristles  520  in the inner bristle group  524  contact the cleaning surface to provide better scrubbing action. The bristle bundles  520  as a whole for each row vary in length or height with respect to the cleaning surface. For example, bristle bundle  520 B is longer than its adjacent bristle bundles  520 A and  520 C to the right and left of it in the helical row. The brush assembly  516  is rotatably mounted to several floor cleaning machines such as the floor-cleaning machine  40  of  FIG. 1  and the carpet extractors in co-owned U.S. Pat. No. 5,406,673 and U.S. Pat. No. 5,983,442; the disclosures of which are incorporated by reference. The brush assembly  516  is also rotatably mounted to floor cleaning machines such as U.S. Pat. No. 6,041,472 issued to Kasen, U.S. Pat. No. 6,467,122 issued to Lenkiewicz, and U.S. Pat. Nos. 6,533,871 and 6,073,300 issued to Zahuranec; the disclosures of which are incorporated by reference. Brush assemblies  216 , 316 , and  416  from the previous embodiments can also be mounted to these floor-cleaning machines.  
         [0043]     For all of the embodiments, each bristle is crimped instead of straight so that when the bundles are formed, more scrubbing coverage is provided. Such crimping on the bristles in the bundles also reduces deflection of the bristles as they scrub, thereby minimizing the spraying or splattering of cleaning solution from the bristles.  
         [0044]     The present invention has been described by way of example using the illustrated embodiment. Upon reviewing the detailed description and the appended drawings, various modifications and variations of the preferred embodiment will become apparent to one of ordinary skill in the art. All such obvious modifications and variations are intended to be included in the scope of the present invention and of the claims appended hereto.  
         [0045]     In view of the above, it is intended that the present invention not be limited by the preceding disclosure of a preferred embodiment, but rather be limited only by the appended claims.