Patent Publication Number: US-8533904-B2

Title: Surface cleaning head

Description:
FIELD 
     The disclosure relates to surface cleaning heads, such as for a vacuum cleaner or other surface cleaning apparatuses. In one preferred embodiment, the disclosure relates to auxiliary surface cleaning head having a rotary brush driven by an air turbine the rotary brush and a dirt tray. In another preferred embodiment, the disclosure relates to a surface cleaning head having two air flow paths comprising a first path having an air turbine and a second path having a rotary brush driven by the air turbine and a dirt tray. 
     INTRODUCTION 
     The following is not an admission that anything discussed below is prior art or part of the common general knowledge of persons skilled in the art. 
     Auxiliary surface cleaning heads are known in the art. Such cleaning heads may be stored on a vacuum cleaner and used in an above floor-cleaning mode. For example, the auxiliary cleaning head may be connected to a wand or a flexible hose of an upright vacuum cleaner for use when the main cleaning head of the vacuum cleaner is not in use. Such auxiliary cleaning head include, for example, crevice tools. 
     Auxiliary cleaning tools are typically used for specialized tasks. For example, they may be used to clean a surface on which the main cleaning head of an upright vacuum cleaner cannot be used, such as furniture or curtains. Auxiliary cleaning heads may also be used to clean areas that are too small for the main cleaning head such a corners, under furniture or stairs. 
     SUMMARY 
     The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims. 
     According to one aspect, a surface cleaning head for a surface cleaning apparatus is provided that permits the rapid pick up of large dirt particles, such as rice or cat food, or the pick up of a large amount of debris. For example, a user may want to use the surface cleaning head to pick up a food spill. In such a case, the cleaning head may be subjected to a high loading. Due to the high loading, the airflow path in the cleaning head may become clogged reducing the airflow rate through the cleaning head and therefore reducing the amount of material that may be entrained in the airflow. Further, if the cleaning head includes a brush driven by the air turbine, then the reduced airflow through the cleaning head will reduce the power provided to the brush and decrease the effectiveness of the brush. In accordance with one aspect of this invention, a surface cleaning head is provided that comprises an air turbine and a dirt tray. The dirt tray provides an area in which dirt may be accumulated without blocking the airflow path. Accordingly, the airflow rate need not be reduced and the air turbine may provide a required amount of power to a rotary brush. Therefore, the brush will have sufficient rotation momentum to sweep dirt up into the dirt tray. The dirt in the dirt tray may be picked up at a slower rate by the air traveling by the dirt tray. Accordingly, rapid pick up of a spill may be achieved, even with an air turbine powered brush. 
     In accordance with this aspect, there is provided a surface cleaning head comprising a brush chamber comprising a dirty air inlet and a rotary brush. The surface cleaning head further comprises a dirty air outlet. A dirty airflow path extends between the dirty air inlet and the dirty air outlet. An air turbine is drivingly connected to the rotary brush. A dirt tray is positioned in the airflow path downstream of the rotary brush. The dirt tray has a collection surface. 
     The surface cleaning head may further comprise an air turbine chamber. The air turbine chamber may be is isolated from the dirty airflow path. The air turbine chamber may comprise an air turbine airflow path extending from an air turbine chamber air inlet to the dirty air outlet. The air turbine may be positioned air turbine airflow path, and the air turbine chamber air inlet may be separated from, and preferably also spaced from, the dirty air inlet. The dirty air outlet may be downstream of the dirty air inlet and the air turbine chamber air inlet. An advantage of this design is that the air turbine is driven by a separate air stream. Air may enter the air turbine chamber and flow through the turbine. If the air turbine chamber has a separate air inlet, then clogging of the airflow path at the dirt air inlet will not deprive the air turbine of airflow and reduce power to the rotary brush. 
     The air turbine chamber may be positioned above the dirty airflow path, and the air turbine chamber may be positioned above the dirt tray. The air turbine chamber may be positioned adjacent a lateral side of the surface cleaning head. The dirt tray may be positioned upstream from the air turbine. An advantage of such designs is that the air turbine chamber is separated from the air flow path from the dirty air inlet and reduce the likelihood of clogging of the flow path for dirty drawn in through the dirty air inlet. 
     The surface cleaning head may further comprise a dirt barrier positioned between the dirty air inlet and the dirt tray, such as a ramp. The collection surface may be positioned below an upper end of the dirt barrier. The dirt barrier may be integrally formed with the collection surface. An advantage of using a dirt barrier is that dirt will nor easily fall out of the dirty air inlet when it is stored on the collection surface. This allows large amounts of material to be swept into the dirty air inlet and slowly drawn to the filtration member of the surface cleaning apparatus. 
     The dirt tray may extend laterally across the surface cleaning head. The dirt tray may have a lateral extent that is generally the same as that of the dirty air inlet. 
     The collection surface may be formed by a lower wall of the surface cleaning head. Accordingly, the collection surface may be at the level of the dirty air inlet and this may enhance the ability of the cleaning head to pick up large amounts of material. 
     The surface cleaning head may further comprise a drive linkage that drivingly connects the air turbine to the rotary brush. The drive linkage may comprise a power output shaft. A portion of the power output shaft may be positioned exterior of the air turbine chamber. A fan belt may drivingly connect the power output shaft to the rotary brush. For example, it is preferred that the sir turbine is in an air turbine chamber that draws air into the turbine other then through the dirty air inlet. Accordingly, if the dirty air inlet is clogged by dirt, air will still be drawn into the turbine to power the rotary brush. 
     The surface cleaning head may further comprise a first air flow path extending from a turbine air chamber air inlet to the dirty air outlet wherein the air turbine is positioned in the first air flow path and a second air flow path from the dirty air inlet to the dirty air outlet. 
     The surface cleaning head may be an auxiliary surface cleaning head. The outlet may be adapted to be removably connected to an airflow conduit of the surface cleaning apparatus. 
    
    
     
       DRAWINGS 
         FIG. 1  is a top perspective view of an example of a surface cleaning head; 
         FIG. 2  is a bottom perspective view of the surface cleaning head of  FIG. 1 ; 
         FIG. 3  is a cross section taken along line  3 - 3  in  FIG. 1 ; 
         FIG. 4  is a top perspective view of the surface cleaning head of  FIG. 1 , with a top plate removed from the surface cleaning head; 
         FIG. 5  is an exploded view of the surface cleaning head of  FIG. 1 , with the top plate removed from the surface cleaning head; 
         FIG. 6  is a bottom perspective view of the top plate or upper clam shell of the surface cleaning head of  FIG. 1 ; 
         FIG. 7  is a rear perspective cutaway view of the surface cleaning head of  FIG. 1 ; 
         FIG. 8  is a cross section taken along line  8 - 8  in  FIG. 1 ; 
         FIG. 9  is a top perspective view of an alternate example of a surface cleaning head; and, 
         FIG. 10  is a cross section taken along line  10 - 10  in  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION OF VARIOUS EXAMPLES 
     Various apparatuses or methods will be described below to provide an example of each claimed invention. No example described below limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. 
     Referring to  FIG. 1 , an example of a surface cleaning head  100  is shown. The surface cleaning head  100  may be mounted, and preferably removably mounted, to any suitable surface cleaning apparatus (not shown), such as an upright vacuum cleaner, a canister type vacuum cleaner, a shop-vac type vacuum cleaner, a stick vac or a carpet extractor. The surface cleaning head  100  may be a main surface cleaning head of the surface cleaning apparatus, or may be an auxiliary surface cleaning head of the surface cleaning apparatus, i.e., useable in an alternate cleaning configuration by connection to, e.g., a wand or hose. For example, if the surface cleaning apparatus is an upright vacuum cleaner, namely a vacuum cleaner having an upper section pivotally mounted to a cleaning head, then the surface cleaning head may be the cleaning head to which the upper section is pivotally mounted. The upright vacuum cleaner may have a wand and/or hose used for above floor cleaning. In such a case, the surface cleaning head may be an auxiliary cleaning head that is attachable, and preferably removably attachable, to the wand and/or hose. 
     Referring to  FIGS. 1 to 3 , the surface cleaning head  100  comprises an outer casing  102 . As exemplified, the outer casing comprises a bottom plate  104 , and a top plate  106 , which are mounted together, to define a cavity  108  therebetween. Accordingly, bottom plate  104  may be a lower clam shell and a top plate  106  may be an upper clam shell. 
     Referring to  FIG. 2 , the surface cleaning head  100  comprises at least one dirty air inlet  110 . As exemplified, a single dirty air inlet  110  is provided that preferably extends generally transversely across the front of the surface cleaning head. Dirty air inlet  110  preferably comprises an opening provided in the bottom plate  104 . As exemplified, dirty air inlet  110  is provided in a lower wall  112  of the surface cleaning head  100 , towards a front end  114  of the surface cleaning head  100 , such that in use, the dirty air inlet  110  is in facing relation to a surface to be cleaned, such as a floor. The dirty air inlet  110  has a first lateral side  111 , and a second lateral side  113 , and a lateral extent  115  extending therebetween. It will be appreciated that dirty air inlet  110  may be of any configuration known in the art. 
     Referring still to  FIG. 2 , the surface cleaning head further comprises a dirty air outlet  116 . The dirty air outlet  116  is preferably provided towards a rear end  118  of the surface cleaning head  100 . In use surface cleaning head  100  is in fluid communication with a surface cleaning apparatus via dirty air outlet  116 . For example, a wand and/or a hose may be connected, and preferably removably connected, to dirty air outlet  116 . Any mechanism known in the art to connect a cleaning head, and preferably an auxiliary cleaning head, to a surface cleaning apparatus, may be used. 
     The dirty air inlet  110  is in fluid communication with the dirty air outlet  116  via a dirty airflow path extending therebetween. As exemplified, the dirty airflow path extends through the cavity  108 , between the top plate  106  and the bottom plate  104 . The flow of air through the dirty airflow path may be driven, for example, by a motor and fan of the surface cleaning apparatus. 
     Referring to  FIGS. 2 and 3 , the surface cleaning head  100  may comprise a brush chamber  122 . As exemplified, the brush chamber  122  is formed between the top plate  106  and the bottom plate  104 , at the front end  114  of the surface cleaning head  100 . The brush chamber  122  may be positioned adjacent or above the dirty air inlet  110 . The brush chamber  122  comprises a rotary brush  124 , which is rotatably mounted therein. An air turbine  126  is drivingly connected to the rotary brush via a drive linkage  127 , as will be described further hereinbelow. The rotary brush  124  comprises a rotary shaft  128 , and a plurality of bristles  125  extending therefrom. The rotary shaft  128  is mounted such that the bristles  125  generally extend to the dirty air inlet  110 , so that in use, when the dirty air inlet  110  is in facing relation to a surface to be cleaned, the bristles  125  brush the surface to be cleaned. It will be appreciated that rotary brush  124  may be of any design known in the art. 
     The rotary brush  124  may be rotatably mounted in the brush chamber  122  in any manner known in the art. As exemplified in  FIGS. 4 to 6 , the rotary shaft  128  comprises a first end portion  132  and an opposed second end portion  134 . First and second brackets  142 ,  144  provide a rotatable mount for rotary shaft  128 . As exemplified, the first bracket  142  may be received in a first lateral mount provided adjacent the first lateral side  111  of the dirty air inlet  110 . The first lateral mount may comprise a first portion  146  that is integrally formed with the bottom plate  104 , and a second portion  148  that is integrally formed with the top plate  106 . When the bottom plate  104  is mounted to the top plate  106 , the first  146  and second  148  portions align and cooperate to form the first lateral mount. Similarly, the second bracket  144  may be received in a second lateral mount provided adjacent the second lateral side  113  of the dirty air inlet  110 , and which may comprise a first portion  158  that is integrally formed with the bottom plate  104 , and a second portion  160  that is integrally formed with the top plate  106 . When the bottom plate  104  is mounted to the top plate  106 , the first  158  and second  160  portions align and cooperate to form the second lateral mount. Accordingly, the rotary brush  124  is mounted to and rotates with respect to the first  142  and second  144  brackets, which are mounted to the top  106  and bottom  104  plates. 
     As mentioned hereinabove, the rotary brush  124  is driven by an air turbine  126  via a drive linkage  127 . Any such drive linkage known in the art may be used. Preferably, a fan belt is used. In a particularly preferred embodiment, air turbine  126  is located in an airflow path that is exterior or separate from the air flow path extending downstream from dirty air inlet  110 . 
     Referring still to  FIGS. 4 to 6 , in the example shown, the drive linkage  127  comprises a fan belt (not shown) that extends between pulleys  170 ,  172 , and the surface cleaning head  100  further comprises an optional fan belt housing, which may be positioned within the cavity  108  and may extend rearwardly from the front end  114  of the surface cleaning head  100 . As exemplified, the belt housing comprises a first portion  166 , which is integrally formed with or removably secured to the top plate  106 , and a second portion  168  that may be integrally formed with or removably secured to the bottom plate or which may be removably secured to the first portion  166 . When the surface cleaning head  100  is assembled, the first  166  and second  168  halves align and cooperate to form the fan belt housing. If a fan belt housing is provided, it is preferably constructed so as to isolate, or essentially isolate, the fan belt for the air stream passing through chamber  108  and to thereby prevent or reduce contacting the fan belt. In an optional embodiment, top and/or bottom plate  104 ,  106  may be constructed so as to define the fan belt housing. 
     Referring to  FIGS. 4 and 5 , the belt housing comprises a rear portion  167 , which is adjacent the air turbine  126 , and a front portion  169 , through which the rotary shaft  128  extends. A first pulley  170  is mounted in the rear portion. The first pulley  170  is driven by the air turbine  126 , as will be described further hereinbelow. A second pulley  172  is mounted in the front portion  169 . The second pulley  172  is drivingly connected to rotary shaft  128 . For example, the second pulley  172  may be received on and fixedly secured to the rotary shaft  128 , such as by a set screw (not shown). The belt is mounted around and between the first pulley  170  and second pulley  172 , to transfer rotational motion from the first pulley to the second pulley, as is known to those of skill in the art. 
     Preferably, as exemplified in  FIGS. 7 and 8 , the air turbine  126  is provided in an air turbine chamber  174 . Air turbine chamber  174  may be at any location and of any design provided that air turbine chamber  174  such that the air that travels past or through the air turbine does not contain dirty air that has been drawn in by the cleaning head  100 . 
     As exemplified, air turbine  126  and the air turbine chamber  174  are positioned in the cavity  108 , and isolated from the dirty airflow path. The air turbine chamber  174  is formed by an air turbine casing  176 , as well as by a portion  178  of the top plate  106 . That is, the air turbine casing  176  and a portion  178  of the top plate  106  cooperate to form the air turbine chamber  174 . The air turbine casing  176  may be secured to the portion  178  of the top plate  106  in any suitable manner, such as by a fastener or an adhesive or welding. Any construction technique may be used. 
     The air turbine chamber  174  comprises an air turbine chamber air inlet  180  upstream of the air turbine  126 . As exemplified, the air turbine air inlet  180  is spaced from and separate from the dirty air inlet  110  of the surface cleaning head, and may comprise a grill formed in the portion  178  of the top plate  106 . The air turbine chamber  174  further comprises an air turbine chamber air outlet  182  downstream of the air turbine  126 . As exemplified, the air turbine chamber air outlet  182  comprises an opening in the air turbine casing  176 . The air turbine chamber air outlet  182  is within the cavity  108 , and is upstream of the dirty air outlet  116  of the surface cleaning head  100 . Accordingly, an air turbine airflow path is a second airflow path in cleaning head  100  and extends from the air turbine chamber air inlet  180 , out of the air turbine chamber air outlet  182 . The air turbine  126  is positioned in the air turbine airflow path. 
     As a suction force is created by the surface cleaning apparatus, air is drawn from air outlet  116 . Accordingly, air will be drawn into the air turbine chamber  174  via the air turbine chamber air inlet  180 , past the air turbine  126  causing the air turbine to rotate, out of the air turbine chamber air outlet  182 , into the cavity  108 , and out of the dirty air outlet  116 . At the same time, air will be drawn in from dirty air inlet  110  and flow through chamber  108  to air outlet  116 . 
     As mentioned hereinabove, the air turbine  126  is drivingly connected to the first pulley  170 . As shown, the air turbine  126  is mounted to a power output shaft  184 , a first portion  185  of which is received in the air turbine casing  176 , and a second portion  187  of which is positioned exterior to the air turbine casing  176 , e.g., within the fan belt housing. The second portion is mounted to the first pulley  170 . The power output shaft  184  is drivingly connected to the rotary brush  124  by the fan belt. 
     Preferably, as exemplified, the air turbine chamber  174 , as well as the air turbine  126 , is positioned adjacent a lateral side of the surface cleaning head  100 , and is above the dirty airflow path. Accordingly, the air turbine chamber is positioned so as to impart a minimal restriction to airflow through chamber  108 . In alternate examples, the air turbine chamber  174  and the air turbine  126  may be positioned in another position. For example, the air turbine chamber  174  and air turbine  126  may be centrally positioned between opposed lateral sides of the surface cleaning head  100 . Further, the air turbine chamber  174  and air turbine  126  may be positioned below the dirty airflow path, or centrally within the airflow path. In some examples, the air turbine may be in chamber  108 , i.e. a separate air turbine chamber need not be provided (see the embodiment of  FIGS. 9 and 10 ). 
     Referring back to  FIGS. 3 to 5 , the surface cleaning head  100  further comprises a dirt tray  186  in the airflow path, downstream of the rotary brush  124 . Dirt tray may be of any construction that will provide a surface on which dirt, particularly larger and/or heavier dirt particles may accumulate if the dirt particles are not able to be drawn directly to air outlet  116 . Accordingly, dirt tray  186  is positioned such that the dirt that is accumulated thereon may be brushed thereon by the rotary brush and is preferably immediately downstream of dirty air inlet  110 . Further, a barrier  190  may be provided to prevent such dirt particles from fall out of dirt air inlet  110 . 
     Preferably, as exemplified, the dirt tray  186  extends laterally across the surface cleaning head  100 . The dirt tray  186  comprises a collection surface  188 . When the surface cleaning head  100  is in use, dirt or other materials are brushed or directed by the brush  124  into the surface cleaning head  100  via the dirty air inlet  110 , and are brushed onto the collection surface  188 . From the collection surface  188 , the dirt or other materials are entrained in the airflow passing thereabove and drawn out of the surface cleaning head  100  via the dirty air outlet  116 . 
     In the example shown, the collection surface  188  is formed by the lower wall  112  of the bottom plate  106 . In alternate examples, the collection surface  188  may be formed by any other suitable surface. 
     A dirt barrier  190  is positioned between the dirty air inlet  110  and the dirt tray  186 . The dirt barrier  190  is preferably constructed so as to require dirt to travel upwardly to fallout of dirty air inlet  110 . Accordingly, barrier  190  may be a ramp and dirt may be swept by the rotary brush up the ramp. Alternately, collection surface  188  may be below dirty air inlet  110  such that a wall, e.g., a vertical wall extends downwardly from dirty air inlet  110  to collection surface  188  (see the embodiment of  FIGS. 9 and 10 ). 
     As exemplified, dirt barrier is a ramp that is generally upwardly extending, and has an upper end  192  and a lower end  194 . The collection surface  188  is positioned below the upper end  192 . The dirt barrier  190  generally prevents or inhibits dirt from exiting the surface cleaning head  100  via the dirty air inlet  110 . 
     As exemplified, the dirt barrier  190  is integrally formed with the collection surface  188 , and comprises a first wall  196  extending upwardly and forwardly from the collection surface  188 , and a second wall  198  extending downwardly and forwardly from the first wall  196 . Accordingly, the dirt barrier  190  may be generally triangular in transverse cross-section. As can be seen in  FIG. 2 , the dirt barrier  190  may therefore form a recess  197  in the bottom plate  104 , in which one or more wheels  195  may be received. In alternate examples, the dirt barrier may be another suitable shape. For example, the dirt barrier may comprise a single wall extending vertically upwardly from the collection surface  188 . 
     Preferably, as exemplified, the dirt tray  186  has a lateral extent  199  that is slightly longer than the lateral extent  115  of the dirty air inlet  110 . In alternate embodiments, the lateral extent  199  of the dirt tray  186  may be less than or is generally the same as the lateral extent  115  of the dirty air inlet  110 . 
     As exemplified in  FIG. 8 , the air turbine  126  and air turbine chamber  174  are above the dirt tray  186 , and the airflow path extends between the dirt tray  186  and the air turbine chamber  174 . In alternate examples, the air turbine chamber  174  may be seated on or adjacent to the dirt tray  186 . Further, as exemplified, the dirty airflow path along the dirt tray  186  is parallel to the air turbine airflow path. In alternate examples, the airflow path along the dirt tray  186  may be in sequence with the air turbine airflow path. For example, the air turbine air inlet  180  may be in communication with and downstream of the dirty air inlet  110 , and the dirt tray  186  may be either upstream or downstream of the air turbine  126 . 
     Referring to  FIGS. 9 and 10 , wherein like numerals are used to indicate like features as in  FIGS. 1 to 8 , with the first digit incremented to 9 to refer to the figure number, an alternate example of a surface cleaning head is shown. Similarly to the example of  FIG. 1 , the surface cleaning head  900  comprises a casing  902 , which is formed by a bottom plate  904  and a top plate  906 . A cavity  908  is formed between the bottom plate  904  and the top plate  906 , and the cavity defines an airflow path between a dirty air inlet  910  and a dirty air outlet  916 . The surface cleaning head  900  comprises a brush chamber  922 , which houses a rotary brush  924 , and which includes the dirty air inlet  910 . 
     Similarly to the example of  FIGS. 1 to 8 , an air turbine  926  is drivingly connected to the rotary brush  924 . However, in the example of  FIGS. 9 and 10 , the air turbine  926  is provided in the airflow path upstream of dirty air inlet  910 . That is, the air turbine  926  is not provided in a separate casing, and does not include an air turbine inlet that is separate from the dirty air inlet. Air entering the dirty air inlet  910  passes through the air tribune  926 . 
     Similarly to the example of  FIGS. 1 to 8 , a dirt tray  986  is provided in the airflow path, downstream of the rotary brush  924 . The dirt tray  986  comprises a collection surface  988 , onto which materials are brushed by the rotary brush  924 . The collection surface is below the upper end of the vertical wall defining the dirty air inlet. In this embodiment, the dirt tray  986  is positioned upstream of the air turbine  926 . 
     What has been described above has been intended to be illustrative of the invention and non-limiting and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto.