Patent Publication Number: US-2023157509-A1

Title: Vacuum extraction head with adjustable-height brush

Description:
TECHNICAL FIELD 
     The present disclosure relates to carpeted floor cleaning devices. Particularly, the present disclosure relates to cleaning devices having vacuum extraction heads with adjustable-height brushes. 
     BACKGROUND 
     The cleaning of carpeted floors to remove stains, dirt, etc., is achieved using various methods, including dry-cleaning techniques, wet-cleaning techniques, and vacuuming. Wet-cleaning, or steam cleaning as it is commonly known, is a technique that involves spraying cleaning solution onto the floor, agitation of the floor, and extraction of the cleaning solution. The agitation step may be completed by a brush or other scrubbing device that is passed over the floor. Several passes of the scrubbing device over the floor may be used to loosen stains or dirt (collectively, debris) from the surface. 
     Many carpeted floors are variable height and contain bumps, ridges, differing piles, wear, and other irregular features. Variable-height floors prevent cleaning devices from uniformly cleaning floors because the cleaning device cannot maintain consistent contact with the floor around irregular features. Further, variable-height floors may reduce the cleaning effectiveness of the brush as the bristle stems on the brush, rather than the bristle tips, are used to agitate the floor. Variable-height floors can cause premature wear to the brush and other parts of the cleaning device. The issue of premature wear is particularly an issue for motorized cleaning devices that may move the brush repeatedly over an irregular feature. 
     BRIEF SUMMARY 
     In view of the above, there is an unmet need in the art for an extraction head for a cleaning device for traveling along a cleaning path on a variable-height floor. 
     The present disclosure affords such an extraction head. In a first aspect, the extraction head comprises an extraction head body including a floor-facing surface and an extraction aperture disposed in the floor-facing surface. The extraction head also comprises a vacuum outlet in fluid communication with the extraction aperture. Additionally, the extraction head comprises an adjustable-height brush positioned in front of the extraction head body along the cleaning path. The adjustable-height brush is configured to translocate upwardly and downwardly as the extraction head moves along the cleaning path on the variable-height floor. The adjustable-height brush may also comprise a proximal end and a distal end opposite the proximal end. The proximal and distal ends may be configured to translocate upwardly and downwardly relative to each other as the extraction head moves along the cleaning path on the variable-height floor. 
     In a second aspect, a cleaning device for cleaning a variable-height floor is provided. The cleaning device comprises a rotary vacuum head comprising a plurality of vacuum chambers disposed radially on the rotary vacuum head with each vacuum chamber including an inlet. The cleaning device also comprises a plurality of extraction heads adjustably secured to the rotary vacuum head for traveling along a cleaning path on a variable-height floor. The plurality of extraction heads are adjustably secured to the rotary vacuum head. 
     Each extraction head comprises an extraction head body including a floor-facing surface and an extraction aperture disposed in the floor-facing surface. Additionally, each extraction head also comprises a vacuum outlet in fluid communication with the extraction aperture. Each inlet is in fluid communication with the at least one vacuum outlet. Each extraction head also comprises an adjustable-height brush positioned in front of the extraction head body along the cleaning path. The adjustable-height brush is configured to translocate upwardly and downwardly as the extraction head moves along the cleaning path on the variable-height floor. The adjustable-height brush may also comprise a proximal end and a distal end opposite the proximal end. The proximal and distal ends may be configured to translocate upwardly and downwardly relative to each other as the extraction head moves along the cleaning path on the variable-height floor. 
     These features and advantages of the present disclosure will become more fully apparent from the following description and appended claims or may be learned by the practice of the disclosure as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The objects, features, and advantages of the present disclosure will become better understood regarding the following description and accompanying drawings, wherein: 
         FIG.  1    is a top perspective view illustrating one embodiment of a rotary head cleaning machine with attached extraction heads. 
         FIG.  2    is a front elevation view illustrating one embodiment of the extraction head. 
         FIG.  3    is a right side elevation view illustrating one embodiment of the extraction head. 
         FIG.  4    is a rear elevation view illustrating one embodiment of the extraction head. 
         FIG.  5    is a left side elevation view illustrating one embodiment of the extraction head. 
         FIG.  6    is a cross-sectional view illustrating one embodiment of the extraction head. 
         FIG.  7    is a perspective view illustrating one embodiment of an extraction head showing the brush at a first height. 
         FIG.  8    is another perspective view illustrating one embodiment of an extraction head showing the brush at a second height. 
         FIG.  9 A- 9 B  are front elevation views illustrating one embodiment of an extraction head with a brush in various orientations. 
         FIG.  10    is an illustration of one embodiment of an extraction head moving over a threshold. 
         FIG.  11    is an illustration of one embodiment of an extraction head moving over an inclined surface. 
     
    
    
     DETAILED DESCRIPTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     Furthermore, the described features, structures, or characteristics of the disclosure may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the disclosure. One skilled in the relevant art will recognize, however, that the disclosure may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the disclosure. 
       FIG.  1    is a perspective view illustrating one embodiment of a vacuum rotary head  10  of a floor cleaning device, such as for cleaning soft (e.g., carpeted) floor surfaces. The vacuum rotary head  10  is coupled with one or more extraction heads  14  (shown in more detail in  FIGS.  2 - 8   ) having an adjustable-height, as described further, below. By way of example,  FIG.  1    depicts a vacuum rotary head  10  with five extraction heads  14 . However, the vacuum rotary head  10  may include more or fewer extraction heads  14  (e.g., from one to twenty or any subvalue or range thereof), depending on the floor cleaning device and/or the type of flooring to be cleaned. 
     In some embodiments, the vacuum rotary head  10  includes at least one spray nozzle  16  fluidly coupled to a cleaning solution supply for dispersing one or more cleaning solutions on the floor surface. The vacuum rotary head  10  may be configured with any suitable number of the spray nozzles  16 , each fluidly coupled with the cleaning solution supply. The vacuum rotary head  10  may have an equal number of spray nozzles  16  and extraction heads  14 , wherein each of the extraction heads  14  is disposed proximate to one of the spray nozzles  16 , as depicted in the embodiment of  FIG.  1   . The cleaning solution may be water or water and one or more cleaning agents (e.g., detergents, soaps, emulsifiers, whiteners, bleachers, surfactants, solvents, carbonators, etc.). The solution may be pressurized within the device. The cleaning solution may be supplied from the cleaning solution supply to the spray nozzles  16  via one or more supply lines  20  fluidly connecting the solution supply with the spray nozzles  16 . The supply lines  20  may be disposed (partially or fully) within, or defined by a hollow (including partially hollow) driveshaft  22 , which connects the vacuum rotary head  10  with the cleaning device and drives (e.g., is configured to selectively cause rotation of) the vacuum rotary head  10 . 
     The cleaning device may include a vacuum chamber  24  having a plurality of inlets  26 . In some embodiments, the vacuum chamber  24  may comprise one or more sub-chambers  28 . The sub-chambers  28  may be disposed radially on the rotary vacuum head  10 . The sub-chambers  28  are each in fluid communication with the inlets. The vacuum chamber  24  (and/or its sub-chambers  28 ) may comprise more than one of the inlets on the chamber  24  and each of the sub-chambers  28 . Each of the inlets are in fluid communication with a vacuum outlet  30  of each of the extraction heads  14 . 
     The plurality of inlets may be disposed around and approximately equidistant from the hollow driveshaft  22 . In some embodiments, such as the embodiment shown in  FIG.  1   , there are an equal number of extraction heads  14  and inlets. In other embodiments, there are a varying number of extraction heads  14  and inlets, such as more extraction heads  14  than inlets. Each of the inlets may be in fluid communication with more than one of the extraction heads  14 . 
     The extraction head  14  removes liquid, including dispersed water and cleaning solution, and any other pretreatment, dirty water, or other debris and other liquids or solvents from the floor. The extraction head  14  comprises an extraction head body  32 . The extraction head body  32  includes a floor-facing surface disposed on the head body  32  such that, when the cleaning device is in use, the floor-facing surface faces the floor being cleaned. One or more extraction apertures  36  may be disposed in the floor-facing surface and in fluid communication with the vacuum outlet  30 . The vacuum outlet  30  may be disposed on an upper side of the extraction head body  32  and oriented rearwardly on the extraction head body  32 , that is, opposite on the extraction head body  32  the direction of travel of the extraction head  14  moving along the cleaning path. The extraction head body  32  may also include a hollow interior. The hollow interior, whether through hoses or passageways defined by the hollow interior, may fluidly connect the vacuum outlet  30  to the one or more extraction apertures  36  such that the hollow interior and the vacuum outlet  30  are in fluid communication via the hollow interior. 
     The extraction head  14  may include a base plate  42 . The one or more extraction apertures  36  may be disposed in the base plate  42 . The base plate  42  may be secured with the floor-facing surface of the extraction head body  32 . The base plate  42  may be integrally formed with, or discrete from, the extraction head body  32 . A gasket may be disposed between the base plate  42  and the extraction head body  32  to define a seal, such as a water-tight or a vacuum-tight seal. The base plate  42  may be elongated and constructed of any suitable material (e.g., a metal, an alloy, or a polymer). The base plate  42  may sit a distance (such as about 0.125 inch, about 0.25 inch, or about 0.5 inch) above the floor surface to permit the base plate  42  to pass over the floor surface without contacting the floor surface when the floor surface cleaned, improving vacuum efficiency of the extraction head  32 . In other embodiments of the disclosure, the base plate  42  may be lower relative to, or contact, the floor surface, and the base plate  42  may be coated with an anti-friction coating to move across a floor surface more easily. Examples of coatings suitable for use in the present disclosure include, but are not limited to, polytetrafluoroethylene (PTFE). In further embodiments, various components of the extraction head  14  may be formed of PTFE, other low-friction polymers, metals, or composites. 
     Referring to  FIGS.  2 - 7   , the extraction head  14  may comprise a mount  44  for releasably securing the extraction head  14  with the vacuum rotary head  10 . In some embodiments, the mount  44  comprises a mount aperture through which a fastener  48  (such as a bolt or any suitable fastening device) engages to secure the extraction head  14  to the vacuum rotary head  10 . 
     The extraction head  14  may comprise an adjustable-height brush  50 . The brush  50  may be positioned forward of the extraction head  14 . In this context, “forward” means that the brush  50  is located ahead of the extraction head  14  relative to the direction of travel of the brush  50  and extraction head  14  on the cleaning path. 
     The brush  50  may be attached to the vacuum rotary head  10  via the extraction head  14 , or the brush  50  may be secured directly to the vacuum rotary head  10 . The brush  50  may comprise a plurality of bristles  52  and a ferrule  54  securing the plurality of bristles  52  with the brush  50 . Each of the bristles  52  comprises a stem, a base, and a tip. Each of the bases of the plurality of bristles  52  is secured within the ferrule  54 . The bristles  52  may be soft or firm. In some embodiments of the disclosure, the bristles  52  are firm and are advantageous because they extract more solution from carpeted flooring, as they pass over the floor, as compared to soft bristles  52 . 
     The brush  50  is adjustable in height and is configured to translocate upwardly and downwardly relative to the extraction head body  32  as the extraction head  14  moves along the cleaning path on the variable-height floor. The brush  50  may move partially independent of the extraction head body  32  and base plate  42 , that is, the brush  50  may move together with the head body  32  and base plate  42  to a degree and move independently of the head body  32  and the base plate  42  to a degree. The degree that the brush  50  can move upwardly and downwardly independently and relative to the base plate  42  may define a brush vertical range. At the bottom of the brush vertical range, the tips of the bristles  52  may extend lower than the base plate  42 . At the top of the brush vertical range, the tips of the bristles  52  may be equal to or higher than the floor-facing surface of the base plate  42 . 
     Advantageously, the height-adjustable brush  50  can move up and down (i.e., upwardly and downwardly translocate) in response to variance in the height of the floor being cleaned.  FIG.  7    depicts an embodiment of the extraction head with the brush at the lowest position permitted by the depicted embodiment.  FIG.  8    depicts an embodiment of the extraction head with the brush at the highest position permitted by the depicted embodiment. The degree of the brush movement within the vertical range is directly related to the degree of height variation of the floor being cleaned. By way of example, if the extraction head  14  moves over a rise or obstruction in the floor that is less than the brush vertical range, the extraction head body  32  and base plate  42  may rise a short distance while the brush  50  stays on a generally level path. Some of the plurality bristles  52  of the brush  50  may deflect to allow the rise or obstruction to pass through the brush  50  while the remainder of the plurality of the bristles  52  remain generally orthogonal to the floor surface to agitate the floor surface around the rise or obstruction. The brush  50  may rise a distance due to the upward force exerted on the brush by the rise or obstruction rather than the extraction head body  32  exerting force on the brush  50 . In another example, if the extraction head  14  moves over a rise or obstruction taller than the brush vertical range, the extraction head body  32  and base plate  42  may rise and lift the brush  50  off of the floor, although the brush  50  may rise less than the base plate  42  due to the brush vertical range. In a further example, if the extraction head  14  moves off of a rise or an obstruction in the floor surface, the brush  50  may lower and contact the surface at a base of the rise or obstruction before the base plate  42  lowers onto the surface at the base of the rise or obstruction. 
     The brush  50  may also comprise a proximal end  62  that is closer to the center of the rotary vacuum head  10  and a distal end  64  that is opposite the proximal end  62  and farther from the center of the rotary vacuum head  10 . In some embodiments, the height-adjustable connection between the extraction head body  32  and the brush  50  may allow the brush proximal and distal ends  62 ,  64  to translocate upwardly and downwardly relative to each other and the extraction head body  32 . In other words, the brush  50  may tilt or rotate in a vertical plane that is perpendicular to the cleaning path of the extraction head  14 .  FIGS.  9 A- 9 B  depict an embodiment of the extraction head with the brush rotated in opposite directions, that is, with one spring  80  in a more compressed position than the other spring  80  such that the proximal and distal ends  62 ,  64  are at uneven heights, and the brush is shown as tilting within the vertical plane. The movements of the brush proximal and distal ends  62 ,  64  are also at least partially independent from each other and from the extraction head body  32 . That is, the brush proximal and distal ends  62 ,  64  may move together with each other and the extraction head body  32  to a degree, and the proximal and distal brush ends  62 ,  64  may move independently of each other or of the extraction head body  32  to a degree. The rotational or tilting movement may allow one of the brush proximal end  62  or distal end  64  to be lower than the floor-facing surface of the base plate  42  while the higher of the brush proximal end  62  or distal end  64  is equal to or higher than the floor-facing surface of the base plate  42 . The net difference of the height difference a fully rotated or tilted proximal end  62  and distal end  64 , in absolute numbers, is referred to as the brush tilt range. The brush tilt range may be 0.01 inch to 5 inches, or any subrange or subvalue thereof. 
     The degree of independence of the movements of the brush ends  62 ,  64  are from each other depends on the level of the brush tilt range and the variance of the height of the floor. For example, the brush  50  may pass over a variable-height floor where the surface under the proximal end  62  is higher than the surface under the distal end  64 . If the height difference between the surfaces under each brush end  62 ,  64  is less than the brush tilt range, the brush  50  may tilt such that the brush proximal end  62  is higher than the brush distal end  64  without lifting the brush distal end  64  off the floor. Thus, the brush  50  may contact both the higher and lower areas of the variable-height floor if the height difference between the surfaces under each brush end  62 ,  64  is less than the brush tilt range. If the height difference between the surfaces under each brush end  62 ,  64  is greater than the brush tilt range, the brush  50  may still tilt such that the proximal end  62  is higher than the distal end  64 . However, the brush distal end  64  may lift off the floor due to the upward force exerted on the proximal end  62 . 
     The feature of independent vertical movement and rotational or tilting movement of the brushes  50  relative to the extraction head  14  provides several benefits as compared to brushes  50  that are stationary relative to the extraction head  14 . The independent movement of the brush  50  on multiple axes helps to reduce premature wear on the brush  50  as the brush can move upwardly over rises or obstructions rather than forcing the rise or obstruction through the brush  50 . Additionally, such movement helps to increase the cleaning consistency across the floor by helping to keep the bristles  52  in consistent contact with the floor, particularly around variable-height floor features (e.g., thresholds, HVAC registers, etc.). Further, such movements increase the cleaning efficacy as the brush tips rather than the brush stems contact the floor. Such movement also allows the base plate  42  of the extraction head  14  to remain near the floor and remove more debris and solution from the floor. These advantages are particularly true for brushes  50  on the cleaning devices that are rotary, moving the brushes  50  along an elliptical or circular path. The brushes  50  on the rotary cleaning device may contact irregular- or variable-height features on a floor at different angles depending on where the brush is along the elliptical or circular path. The brush movement allows the brush  50  to more effectively agitate the floor regardless of the angle at which the brush  50  is encountering the irregular- or variable-height feature as compared to brushes without this movement. Such movement of the extraction head over an irregular or variable-height feature is depicted in  FIGS.  10 - 11   . More particularly,  FIG.  10    shows the movement of the extraction head over a threshold, with the brush adjusting in height.  FIG.  11    shows the movement of the extraction head over an uneven or slanted floor, with the brush adjusting in height. 
     As shown in  FIG.  6   , the brush  50  may be attached to the extraction head body  32  by a bracket  66 . The bracket  66  may be integrally formed with the extraction head body  32  or be distinct components from one another. In some embodiments, the bracket  66  comprises a rear plate  68  adjacent to the extraction head body  32 , a forward plate  70  opposite the rear plate  68 , at least one side plate  72  connecting the rear and forward plates  68 ,  70 , or at least one top plate  74  connecting the rear and forward plates  68 ,  70 . In some embodiments, the rear plate  68 , the forward plate  70 , the side plate(s)  72 , and the top plate(s)  74  define a partially enclosed brush socket  76 . The bracket  66  may have an open bottom  78  for accessing the brush socket  76 . The brush  50  may be securely received in the brush socket  76  via the open bottom  78 . 
     At least one spring  80  is disposed between the brush bracket  66  and the brush  50 . The at least one spring  80  biases the brush  50  away from the brush bracket  66 . A spring guide  82  may be positioned in a central opening of the spring  80  and disposed on the brush ferrule  54  or the brush bracket  66 . The spring guide  82  prevents the spring  80  from bending laterally as the brush  50  compresses the spring  80  against the brush bracket  66 . In some embodiments, the spring guide  82  is a rod. The brush ferrule  54  and brush bracket  66  may each comprise indentations for receiving a top or a bottom of the spring  80 , respectively. In further embodiments, the at least one spring  80  comprises a first spring  92  and a second spring  94 , the springs  92 ,  94  positioned between the brush bracket  66  and the brush  50  and bias the brush  50  away from the brush bracket  66 . Each of the springs  92 ,  94  may have the spring guide  82 . Any suitable biasing element may be used in place of the at least one spring  80 , such as a shock, a strut, or a similar biasing device. 
     The at least one spring  80  exerts both a downward force on the brush  50  and an upward force on the brush bracket  66 . The downward force of the at least one spring  80  on the brush  50  increases the contact between the bristles  52  and the floor as the extraction head  14  moves over the cleaning path of the floor. The increased contact between the brush  50  and the floor agitates the floor to remove solution and debris. The upward force of the spring  80  may bias the brush bracket  66  and extraction head  14  away from the floor. An operator may select different springs  80  that exert varying amounts of force on the brush  50  and brush bracket  66  depending on the design of the cleaning device and the floor to be cleaned. For example, the upward force of the springs  80  on the bracket  66  may be less than or equal to the downward force, or weight, of the extraction head  14  to promote the cleaning efficiency of the extraction head  14 . 
     As shown in  FIGS.  2  and  7 - 8   , the extraction head  14  may comprise a guide track  96 . The guide track  96  may be disposed on the brush bracket  66 . For example, the guide track  96  may comprise a slot  98  in the rear or forward plates  68 ,  70  of the brush bracket  66 . The guide track  96  may have a top end, a bottom end, and a track height defined by the distance from the top end to the bottom end. The guide track  96  may include a proximal edge closer to the center of the rotary vacuum head  10  and a distal edge opposite the proximal edge and farther from the center of the rotary vacuum head  10 . A guide track width is defined by a distance between the proximal and distal edges. The guide track width and the guide track height may be in planes that are generally perpendicular to one another. 
     The brush  50  may have a first brush guide  110  disposed on or secured with the brush  50  and slidably engaged with the guide track  96 . The first brush guide  110  may be positioned on the brush ferrule  54 . A second brush guide  112  may be secured to the brush ferrule  54  and slidably engaged with the guide track  96 . The brush guides  110 ,  112  may be vertically aligned such that they define an upper brush guide and a lower brush guide. The guide track  96  may restrict the brush  50  from moving toward or away from the center of the rotary vacuum head  14  when the brush guide(s) contact the proximal and distal edges, of the guide track  96 . The guide track  96  may also restrict vertical movement of the brush  50  when the brush guide(s) contact a top or a bottom of the guide track  96 . The upper brush guide may have a top edge, and the lower brush guide may have a bottom edge. A brush guide span6 may extend from the top edge of the upper brush guide to the bottom edge of the bottom brush guide. Together, both brush guides may restrict rotational movement, or the tilt, of the brush  50 . 
     The brush vertical range and the brush tilt range may be varied depending on the type of floor to be cleaned and the variance in the height of the floor. The brush vertical range and brush tilt range may be modified by changing any combination of the guide track height, guide track width, and the brush guide span. For example, increasing the guide track height increases the brush vertical range while decreasing the guide track height decreases the brush vertical range. Increasing the brush guide span decreases the brush vertical range and the brush tilt range while decreasing the brush guide span increases the brush vertical range and brush tilt range. The brush vertical range is approximately equal to the difference between the guide track height and the brush guide span. Increasing the guide track width increases the brush tilt range while decreasing the guide track width decreases the brush tilt range. In some embodiments, the guide track width is shorter than the brush guide span to restrict the rotational movement of the brush. 
     As shown in  FIGS.  1 - 2  and  7 - 8   , the extraction head  14  may include a guide bar  128 . The guide bar  128  extends away or forward from the base plate  42  relative to the direction of travel of the extraction head  14  to guide the extraction head  14  over raises or obstructions on the floor. For example, because the guide bar  128  extends forward in front of the base plate  42 , the guide bar  128  will contact raised areas or features before the base plate  42  as the extraction head  14  moves over the variable-height floor. As depicted, the guide bar  128  may be configured with a leading bar  130  positioned above a plane defined by the base plate  42 . As such, as the leading bar  130  encounters a raised feature or obstruction, the guide bar  128  will follow the raised feature or obstruction and consequently lift the base plate  42  over that raised feature or obstruction. In other words, the guide bar  128  protects the base plate  42  from impacts with the raised feature or obstruction and prevents the extraction head  14  from catching on raised features or obstructions on the variable-height floor. The brush  50  may be located in between the leading bar  130  and the extraction head body  32 . In some embodiments, the brush  50  may contact the guide bar  128  when the brush  50  adjusts downward. Thus, the guide bar  128  may also restrict vertical movement of the brush  50  in addition to the brush guide(s) and the guide track  96 . 
     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present disclosure should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed herein. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages, and characteristics of the disclosure may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the subject matter of the present application may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the disclosure. 
     The present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The above description of preferred embodiments should not be interpreted in a limiting manner since other variations, modifications and refinements are possible within the spirit and scope of the present disclosure. The scope of the invention(s) is defined in the appended claims and their equivalents.