Patent Publication Number: US-11638507-B2

Title: Vacuum cleaner

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 62/741,440 filed on Oct. 4, 2018, the entire content of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     The present subject matter relates to vacuum cleaners and more particularly to brushrolls for vacuum cleaners. 
     SUMMARY 
     In one embodiment, a vacuum cleaner includes a base and a brushroll positioned within the base. The base has a suction opening and is configured to move along a surface to be cleaned. The brushroll is rotatable relative to the base about an axis, and the brushroll includes a first end, a second end, an inflection point located along the axis between the first end and the second end, and a first material that protrudes in a radial direction away from the brushroll. The first material, having a first width, extends between the first end and the second end and wraps around the brushroll with a pitch relative to the axis. The first material wraps in a first direction between the first end and the inflection point and wraps in a second direction between the inflection point and the second end. The pitch of the first material that wraps in the first direction is opposite to the pitch of the first material that wraps the second direction. 
     In another embodiment, a vacuum cleaner includes a base and a brushroll positioned within the base. The base has a suction opening and is configured to move along a surface to be cleaned. The brushroll is rotatable relative to the base about an axis, and the brushroll includes a body, a first end, a second end, an inflection point located along the axis between the first end and the second end, a wall that extends in a radial direction away from the body, and grooves along the wall. The wall follows a sloped path around the brushroll between the first end and the second end and wraps around the brushroll about the axis. The direction of the sloped path around the body reverses at the inflection point. The grooves along the wall extend along a length of the brushroll between the first end and the second end and are spaced around a circumference of the brushroll. 
     In yet another embodiment, a vacuum cleaner includes a base, a brushroll that is removable from and insertable into the base, and an aperture though which the brushroll is removed and inserted. The base has a suction opening and is configured to move along a surface to be cleaned. The brushroll is rotatable relative to the base about an axis, and the brushroll includes a body, a first end, and a second end. The aperture includes teeth that are spaced around a circumference of the aperture. The teeth protrude parallel with axis and away from the aperture towards the brushroll. The teeth of the aperture align with the body of the brushroll to collect debris from the brushroll as the brushroll is being removed from the base through the aperture. 
     Other aspects of the present subject matter will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of a vacuum cleaner according to an embodiment of the present disclosure. 
         FIG.  2    is a perspective view of a base of the vacuum cleaner of  FIG.  1   . 
         FIG.  3    is a bottom perspective view of the base of  FIG.  2   . 
         FIG.  4    is a bottom perspective view of the base illustrating inner components of the base. 
         FIG.  5    is a perspective view of the base illustrating a brushroll partially removed from the base. 
         FIG.  6    is a front perspective view of a portion of the base illustrating a cap removable from the base. 
         FIG.  7    is a rear perspective view of a portion of the base illustrating the cap of  FIG.  6   . 
         FIG.  8    is a top view of the brushroll of  FIG.  5   . 
         FIG.  9    is a front view of the brushroll of  FIG.  5   . 
         FIG.  10    is an exploded perspective view of the brushroll and a portion of the base. 
         FIG.  11    is a cross-sectional view of the brushroll and a portion of the base taken through the center of the brushroll. 
         FIG.  12    is a left-side view of the brushroll. 
         FIG.  13    is a right-side view of the brushroll and a portion of the base. 
         FIG.  14    is a right-side view of the brushroll. 
     
    
    
     Before any embodiments of the present subject matter are explained in detail, it is to be understood that the present subject matter is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The present subject matter is capable of other embodiments and of being practiced or of being carried out in various ways. 
     DETAILED DESCRIPTION 
       FIG.  1    illustrates a vacuum cleaner  10  according to an embodiment of the present disclosure. The vacuum cleaner  10  includes a handle  11 , a floor nozzle or base  12 , and a shaft  13  for connecting the handle  11  to the base  12 . The base  12  includes a housing  14  and a brushroll or beater bar  16  that rotates relative to the base  12  about an axis  17  ( FIG.  2   ) that extends along a length of the brushroll  16  and through a center of the brushroll  16 . In the illustrated embodiment, the base  12  includes a window  18  that allows the user to view the brushroll  16  within the base  12 . The window  18  may be transparent, or semi-transparent, in some cases. 
     Referring to  FIG.  2   , the brushroll  16  includes a body  20  that has a first end  20 A, a second end  20 B, and an inflection point  20 C substantially in the middle of the first end  20 A and the second end  20 B. The details of the inflection point  20 C are described further below. The body  20  may be formed, at least partially, from a rubber or plastic material in some embodiments. The body  20  may include a plurality of grooves  22 , a wall  23 , a first recess  24  for receiving a first cleaning material  24 A, a second recess  25  for receiving a second cleaning material  25 A, and a third recess  26  for receiving a third cleaning material  26 A. As used herein, the term cleaning material refers to materials configured for cleaning, such as, for example, a textile (e.g., woven, non-woven materials) configured for cleaning, a specific fabric configured for cleaning, a bristle configured for cleaning, a foam material configured for cleaning, an electrostatic material configured for cleaning, and/or the like. The grooves  22  may extend into the wall  23  along the length of the body  20  between the first end  20 A and the second end  20 B. The brushroll  16  additionally comprises a circumference C ( FIG.  12   ) and the grooves  22  may be spaced evenly around the circumference C. Unevenly spaced grooves  22  are also contemplated. In some embodiments, the first, second and third recess  24 ,  25 ,  26  all receive a first type (i.e., a same type) of material. In the illustrated embodiment, the first recess  24  receives the first material  24 A, and the second and third recesses  25 ,  26  receive the second material  25 A. In yet another embodiment, the first, second, and third cleaning materials  24 A,  25 A, and  26 A are received and/or attached directly on the body  20  of the brushroll  16  and connected with a fastener (e.g., a glue, an adhesive, a hook and loop fastener, and/or the like). 
     With continued reference to  FIG.  2   , the first recess  24  has a first width  27  ( FIG.  8   ) and follows a V-shaped path that extends or wraps around the circumference C of the body  20 . The second and third recesses  25 ,  26  each have a second width  28  ( FIG.  8   ). The first width  27  (see, e.g.,  FIGS.  8  and  12   ) is a length of an arc extending between a top and bottom of the first recess  24  along a line normal to the axis  17 . The second width  28  (shown in  FIGS.  8  and  12   ) is a length of an arc extending between a top and bottom of the second and/or third recesses  25  and  26  along a line normal to the axis  17 . The second width  28  may be relatively narrow compared to the relatively wide first width  27 . The second and third recesses  25 ,  26  may be located on opposite sides of the first recess  24 . The first recess  24  may be disposed between the second recess  24  and third recess  26  and each of the recesses  24 ,  25 ,  26  may follow and/or be formed as a V-shaped path. 
     In the illustrated embodiment, the path of the first material  24 A may be substantially the same as the path of the first recess  24 , the path of the second material  25 A may be substantially the same as the path of the second recess  25 , and the path of the third material  26 A may be substantially the same as the path of the third recess  26 . In another embodiment, the first, second and third material  24 A,  25 A,  26 A may be received directly on the body  20  of the brushroll  16  and connected with a fastener rather than received in a first, second, or third recesses  24 ,  25 ,  26 , respectively. 
     Referring now to  FIGS.  2 - 4    of the illustrated embodiment, the first material  24 A may be formed from a plush cloth material. Other materials (e.g. non-plush materials) may also be used as the first material  24 A in some embodiments. The second material  25 A may include and/or be formed as a row of bristles. The third material  26 A may include a row of bristles. The second and third materials  25 A and  26 A may include different types of bristles (e.g., bristles having different lengths, diameters, and/or the like) and/or bristles comprised of different materials. In one embodiment, the bristles may include and/or be formed as nylon bristles. The first material  24 A may include a first length and is configured for collecting a first type of debris (e.g., dirt, dust, powder, glitter, particulates, and/or the like). The second and third material  25 A,  26 A may have a second length that is greater than the first length and are configured for collecting a second type of debris (e.g., hair, hay, thread, string, and/or the like). 
     The details regarding the inflection point  20 C will now be described with reference to the V-shaped path. In some embodiments, the inflection point  20 C lies along the axis  17  and is about equidistant between the first end  20 A and the second end  20 B. The first material  24 A protrudes in a radial direction away from the brushroll  16  and extends between the first end  20 A and the second end  20 B. The path of the first material  24 A wraps around the brushroll  16  with a pitch P ( FIG.  9   ) relative to the axis  17 . Between the first end  20 A and the inflection point  20 C, the path of the first material  24 A wraps in a first direction (i.e., clockwise). Between the inflection point  20 C and the second end  20 B, the path of the first material  24 A wraps in a second direction (i.e., counter-clockwise). At the inflection point  20 C, the pitch P of the path of first material  24 A wrapping in the clockwise direction flips such that the pitch P of the path of first material  24 A wrapping in the counter-clockwise direction is equal and opposite, or substantially equal and opposite. 
     In the illustrated embodiment, the V-shaped path extends between the first end  20 A and the second end  20 B, and the inflection point  20 C represents the tip of the letter “V” where the V-shaped path changes direction. The first, second, and third recesses  24 ,  25 ,  26  and the first, second, and/or third materials  24 A,  25 A,  26 A disposed in the recesses may each follow the V-shaped path as described in the illustrated embodiment. In the illustrated embodiment, each of the first, second, and third recesses  24 ,  25 ,  26  are duplicated at least once around the brushroll  16 . In another embodiment, the first, second, and third recess  24 ,  25 ,  26  are duplicated multiple times around the brushroll  16 . 
     The illustrated brushroll  16  further includes the wall  23  which extends in a radial direction away from the body  20  and follows a sloped path around the brushroll  16 . The wall  23  extends between the first end  20 A and the second end  20 B and wraps around the brushroll  16  about the axis  17 . The direction of the sloped path about the axis  17  reverses at the inflection point  20 C. The sloped path of the wall  23  substantially follows the path of the first material  24 A around the brushroll  16 . The sloped path has the pitch P angle that remains constant as the wall  23  wraps clockwise around the brushroll  16  between the first end  20 A and the inflection point  20 C. At the inflection point  20 C, the pitch P angle changes by about 90 degrees relative to the axis  17 . As the wall  23  wraps counter clockwise around the brushroll  16  between the inflection point  20 C and the second end  20 B, the pitch P angle remains constant. The wall  23  between the first end  20 A and the inflection point  20 C is substantially the same as the wall  23  between the inflection point  20 C and the second end  20 B when mirrored across the inflection point  20 C along the axis  17 . In the illustrated embodiment, an entire outer surface of the body  20  is covered by the first material  24 A, second material  25 A, third material  26 A and the wall  23 . Meaning that when the materials  24 A,  25 A,  26 A are received on the brushroll  16 , none of the outer surface of the body is exposed. In another embodiment, some of the body  20  (e.g., a portion of the body  20 ) is exposed or uncovered. In yet another embodiment, the entire outer surface of the body  20  is covered by only the first material  24 A and the wall  23 . 
       FIGS.  8  and  9    illustrate the brushroll  16  with the first, second, and third material  24 A,  25 A,  26 A removed from the brushroll  16  to reveal the body  20 , grooves  22 , wall  23  and the first, second, and third recess  24 ,  25 ,  26 .  FIGS.  8  and  9    illustrate the wall  23  and the first, second, and third recesses  24 ,  25 ,  26  each following substantially the same V-shaped path. The wall  23  starts at one point of, on, or around the circumference C of the brushroll  16  and the first recess  24  starts at a different point of, on, or around the circumference C of the brushroll  16 . A third width  72  (shown in  FIGS.  8  and  12   ) is a width of the wall  23 . The third width  72  is an arc having a length between a top and bottom of the wall  23  along a line normal to the axis  17 . The first width  27 , second width  28  and third width  72  may each remain substantially consistent regardless of where the width is being measured along the axis  17 , in some embodiments. 
     Referring now to  FIGS.  3  and  4   , the base  12  may additionally include wheels  30 , support rollers  34 , a motor  38 , a driving mechanism  42 , a suction opening  44 , a suction inlet  46  and roller support assembly  48 . The wheels  30  and the support rollers  34  enable the base  12  to be moved along a surface to be cleaned. The handle  11  of  FIG.  1    includes a power source  50  operable to generate a suction airflow through the vacuum cleaner  10 . The suction airflow is brought in to the base  12  through the suction opening  44  and enters the vacuum cleaner  10  through the suction inlet  46 . In another embodiment the power source  50  is located in the base  12 . With specific reference to  FIG.  4    of the illustrated embodiment, the motor  38  rotates the drive mechanism  42  for rotating the brushroll  16 . 
     With reference to  FIGS.  5 - 7   , the base  12  of the illustrated embodiment further includes a cap or cover  54 . The cover  54  may be removably attached to the housing  14 . The cover  54  includes a cover handle  58  that can be grabbed by a user using their thumb and index finger in one method of operation. In one embodiment, the cover  54  may be rotated (e.g. about one-quarter turn) relative to the housing  14  by the user to release or unlock the cover  54 . This allows the user to pull the cover  54  away from the base  14  to access and remove the brushroll  16 .  FIGS.  6  and  7    illustrate the housing  14  further including an aperture  60  and a radial groove  62  and the cap  54  including a tab  66 . The tab  66  corresponds to the radial groove  62  for interlocking the cap  54  to the housing  14  and thereby securing the brushroll  12  in the housing  14 . 
     With continued reference to  FIGS.  6  and  7   , the aperture  60  may be substantially circular and include teeth  70  that are spaced circumferentially around the aperture  70 . The teeth  70  may protrude away from the aperture in a direction toward the second end  20 B of the brushroll  16  and parallel to the axis  17 . The teeth  70  are configured to align with the spacing of the grooves  22  along the brushroll  16  to collect debris (e.g., hair, dirt, dust, and/or the like) as the brushroll  16  is being removed from the base  12  through the aperture  60 . In another embodiment, the teeth  70  need not align with the grooves  22  to collect debris. In yet another embodiment, the body  20  may not include the grooves  22  and the teeth  70  still collect debris. The teeth  70  each have a similar size and shape that correspond with a similar size and shape of the grooves  22 . In the illustrated embodiment, the teeth  70  also collect debris as the brushroll  16  is being used. The teeth  70  are also configured to collect elongated debris that would otherwise be missed by the brushroll  16 . In this way, the brushroll  16  may be more easily cleaned and/or maintained. The grooves  22  also provide a guide or path for a knife, scissors or other cutting instrument to glide over and remove hair or other debris. The user can move the cutting instrument along the grooves  22  while the grooves  22  guide the movement to cut or otherwise loosen any debris, including hair, which is wrapped around or on the brushroll  16 . 
     In some embodiments, the cover  54  is attached to the brushroll  16  so that the cover  54  may be pulled to pull the brushroll  16  through the aperture  60 . That is, the brushroll  16  may be removed along with the cover  54 . In such an embodiment, the cover  54  may be rotatable within the aperture  60  relative to the brushroll  16  to align with the radial groove  62  to lock and unlock the cover  54  from the housing  14 . 
     Referring now to  FIGS.  10 - 14    of the illustrated embodiment, the base  12  further includes an end cap  74  located at the second end  20 B of the brushroll  16 . The end cap  74  may be chamfered or angled toward the brushroll  16  and covers bearing  78  that facilitates rotation of the brushroll  16 . The angled or chamfered end cap  74  has been found to minimize the amount of hair and other debris that interferes with rotation of the brushroll  16  and the bearing  78 . 
     The housing  14  may additionally include a plug  82 , and a gear  86 . The plug  82  includes slots  90  that engage with internal blades  94  of the brushroll  16  such that the plug  82  rotates with the brushroll  16 . In the illustrated embodiment, the plug  82  further includes a circular opening  98  for receiving a shaft  102  connected to the cover  54  and the circular opening  98  includes a stopper  106  for preventing the cap  54  from being removed from the plug  82 . In another embodiment, the cover  54  may be separated from the plug  82 . In still another embodiment, the plug  82  is fixed to the brushroll  16  and the cover  54  is fixed to the plug. 
     The gear  86  includes gear teeth  110  that engage with roller teeth  114  on the inside of the brushroll  16 . The gear  86  is driven by the driving mechanism  42  which rotates the gear teeth  110  to engage the roller teeth  114  to rotate the brushroll  16  relative to the base  12 . 
     Although the present subject matter has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope of one or more independent aspects of the subject matter as described.