Abstract:
A vacuum sweeper roller brush having tuft segments arranged in straight lines is employed to slap the carpet and dislodge particulate dirt and dust lodged therein. The tuft segments are made up of groups of tufts and each tuft segment has a corresponding tuft segment spaced apart from the first tuft segment. The tuft segments are arranged in a double helix or partially in a first double helix and partially in a second double helix. Alternatively, a single helix may be used. Other embodiments employ tufts which link one tuft segment to another in a stepped pattern or employ tuft segments which link tuft segments together in a helical pattern.

Description:
FIELD OF THE INVENTION 
     This invention relates primarily to vacuum sweeper roller brushes. However, it will be appreciated by those skilled in the art that the invention has broader applications and may also be adapted for use in many other environments where a brushroll is utilized. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 5,452,490 to Brundula, et al. discloses a dual roll of bristles, one supporting the other, for improved sweeping performance. U.S. Pat. No. 5,495,634 to Brundula et al. discloses a plurality of brush tufts and stiffener bars used to support the tufts for improved sweeping performance. Sweeping performance is determined by the amount of dirt, dust and debris removed from a surface to be cleaned. 
     Stiffeners and beater bars add cost and complexity to the brushroll as described in the &#39;490 patent to Brundula, et al. 
     SUMMARY OF THE INVENTION 
     A roller brush for use in a vacuum cleaner which has first tuft segments arranged in straight lines is disclosed. The roller brush may be made of wood, plastic, metal or any combination thereof Each tuft segment comprises groups of tufts. Tufts are sometimes referred to as bristles. The bristles/tufts can be of any suitable material either man-made or natural. One such material is nylon. The tufts/bristles are secured in holes in the roller brush and the holes in the roller brush are filled with as many bristles as will fit in them. The bristles may be angled in one or the other longitudinal directions. 
     Tuft segments which correspond to the first tuft segments are arranged in straight lines and are located in the roller brush at a point 180 degrees from the first tuft segments. The tuft segments may be arranged in a single or dual helix or in another arrangement. It should be noted that the helical arrangement of the tuft segments is done step-wise with spaces or gaps in between the tuft segments. For instance, a portion of the roller brush may employ a dual helix comprised of straight line segments and the remainder of the roller brush may include two partial dual helixes. 
     Alternatively, the tuft segments may be oriented in the direction of the helix with gaps or spaces such that the helix is not continuous. Further, the tuft segments may be oriented off-center, for example, not radially oriented. 
     Alternatively, the tufts segments may be linked by one or more tufts or tuft segments. A stepped pattern or a helical pattern may be formed by the linking tufts and/or the linking tufts segments. 
     The tuft segments comprise groups of tufts or bristles. Four, three, or two group tuft segments or any combination thereof may be employed. Longitudinal and angular gaps between the tuft segments exist in some embodiments. In other embodiments, the tuft segments are linked by one or more tufts and/or tuft segments. Tufts from the tuft segments form, in part, a linking tuft segment. 
     It is an object of the present invention to provide a brush roll which slaps the surface to be cleaned. Slapping is accomplished by the orientation of groups of tufts spaced longitudinally and angularly from each other. Longitudinal and angular spacing provides room for the agitated dirt, dust and debris to be removed by the suction of the vacuum pump. In those embodiments employing linking tufts or tuft segments, the continuity of the tuft pattern facilitates the removal of dirt, dust and debris by directing it to the suction of a vacuum pump. 
     It is an object of the present invention to provide a brush roll which does not employ a stiffener or a beater bar. 
     It is an object of the present invention to provide a brush roll which can be driven by a belt in its middle or at its ends. 
     It is an object of the present invention to provide a brush roll which can be supported by conventional bearings. 
     Still other advantages, benefits and objects of the present invention will become more readily apparent to those skilled in the art upon a reading and understanding of the following drawings and description which follows hereinbelow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front plan view of the roller brush illustrating tuft segments helically oriented. There are two double helixes, one double helix beginning from the left side and one beginning from the right side. 
     FIG. 1A is a front plan view of another roller brush illustrating tuft segments helically oriented with each tuft segment having four tufts. 
     FIG. 1B is a front plan view of another roller brush illustrating tuft segments helically oriented with each segment having three tufts. 
     FIG. 1C is a front plan view of another roller brush illustrating tuft segments helically oriented with each tuft segment having two tufts. 
     FIG. 1D is a front plan view of a roller brush similar to FIG. 1 illustrating a gap located in the middle portion of the brush which may be adapted for driving the roller brush. 
     FIG. 1E is a front plan view of a roller brush similar to FIG. 1 wherein tufts are placed intermediate tuft segments so as to link the segments together. 
     FIG. 2 is a cross-sectional view of the roller brush illustrated in FIG. 1 taken along the lines  2 — 2  illustrating tuft segments 180 degrees apart. 
     FIG. 3 is a cross-sectional view of the roller brush illustrated in FIG. 1 taken along the lines  3 — 3  illustrating tuft segments 180 degrees apart. 
     FIG. 4 is an enlarged portion of FIG. 1 illustrating some of the tuft segments of FIG.  1 . 
     FIG. 5 is a perspective view of FIG.  1 . 
     FIG. 5A is a perspective view of FIG.  1 A. 
     FIG. 5B is a perspective view of FIG.  1 B. 
     FIG. 5C is a perspective view of FIG.  1 C. 
     FIG. 6 is a perspective view of a roller brush illustrating tuft segments helically oriented in a single helix. 
     FIG. 6A is a perspective view of a roller brush illustrating tuft segments helically oriented in a single helix with each segment having four tufts. 
     FIG. 6B is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment having three tufts. 
     FIG. 6C is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment having two tufts. 
     FIG. 7 is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment aligned in a double helix. 
     FIG. 7A is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment of tufts aligned on a double helix similar to FIG. 7 except each segment includes four tufts. 
     FIG. 7B is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment of tufts aligned in a double helix similar to FIGS. 7 and 7A except each segment includes three tufts. 
     FIG. 7C is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment of tufts aligned in a double helix similar to FIGS. 7,  7 A and  7 B except each segment includes two tufts. 
     FIG. 7D is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment of tufts aligned in a double helix similar to FIGS. 7 and 7A except each segment includes three tufts and each segment is linked to the next segment by intermediate tufts. 
     FIGS. 8,  8 A,  8 B, and  8 C are cross-sectional views of other embodiments of the roller brush illustrating tufts which are not radially oriented. 
     FIG. 9 illustrates the attachment of one tuft to the roller brush. 
     A better understanding of the drawings will be had when the following Description Of The Invention is read and understood. 
    
    
     DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, wherein the showings are for purposes of illustrating several embodiments of the invention only and not for purposes of limiting same, FIG. 1 is a front plan view of the roller brush  100  illustrating tuft segments (i.e., tuft segments  200 ,  300 ) helically oriented. 
     Roller brush  100  is illustrated in FIG. 1 with segmented tufts. Each segment of tufts is oriented perpendicularly to a tangent on the surface of the roller brush  100 . Put another way, the tuft segments are radially oriented. Tuft segment  200  is illustrated and comprises four tufts. Tuft segment  200 A is located 180 degrees away from tuft segment  200 . Tuft segment  300  is comprised of three tufts. There is a corresponding tuft segment to tuft segment  300  located 180 degrees from tuft segment  300  but it is not illustrated in FIG. 1 as FIG. 1 is a front plan view. The instant invention contemplates corresponding tuft segments placed at other angles such as 120 degrees from each other. 
     FIG. 2 is a cross-sectional view of the roller brush illustrated in FIG. 1 taken along the lines  2 — 2  and indicates the 180 degree relationship between tuft segment  200  and tuft segment  200 A. 
     FIG. 3 is a cross-sectional view of the roller brush illustrated in FIG. 1 taken along the lines  3 — 3 . In this view tuft segment  300  is shown along with corresponding tuft segment  300 A. The 180 degree spacing between tuft segments is obvious when viewing FIG.  3 . It will be noted that tufts segments  200  and  200 A comprise four tufts while tuft segments  300  and  300 A comprise three tufts. It will be further noted that there is an angular space of 180 degrees between tuft segments  200  and  200 A and  300  and  300 A. This angular space does not include any tufts. Further, there is a longitudinal space between tufts  200  and  300 . In this embodiment, dirt, dust and debris agitated by the tuft segments are suspended in the air space between the tuft segments until they are removed by the vacuum pump. 
     FIG. 1 illustrates a left portion  100 L of the roller brush  100  and a right portion  100 R of the roller brush  100 . The right portion  100 R of the roller brush comprises a dual helix. Tuft segment  403  and tuft segment  403 A represent the beginning of the dual helix of the right portions  100 R. The dual helix continues throughout the right portion  100 R of the roller brush and into  100 L, the left portion of the roller brush  100 . Tuft segments  150  and  150 A represent the end of the dual helix which began with tuft segments  403  and  403 A. Another dual helix starts with tuft segments  200  and  200 A and they extend up to and including tuft segments  150  and  150 A. Tuft segments  150  and  150 A are the ends of all four helixes. 
     FIG. 1 also illustrates tuft segments  400 ,  401  and  402  as well as corresponding tuft segments  400 A,  401 A and  402 A which are, as stated previously, 180 degrees apart. 
     FIG. 1A is a front plan view of another roller brush  100 A illustrating tuft segments  110  helically oriented with each tuft segment  110  having four tufts. FIG. 1B is a front plan view of another roller brush  100 B illustrating tuft segments  120  helically oriented with each segment  120  having three tufts. FIG. 1C is a front plan view of another roller brush illustrating another roller brush  100 C with tuft segments  130  helically oriented with each tuft segment having two tufts. 
     FIG. 1D is a front plan view of the roller brush  100 D similar to FIG. 1 illustrating a gap  140  located in the middle portion of the brush  100 D. This gap may be used or adapted to receive a driving mechanism or means to rotate the roller brush. All of the roller brushes illustrated are adapted for rotation in a vacuum cleaner or other cleaning device . 
     FIG. 1E is a front plan view of a roller brush similar to FIG. 1 wherein tufts  155  are placed intermediate tuft segments so as to link the segments together. The tufts  155  create a stepped pattern of tuft segments. Tufts  155  link the other tuft segments and form tuft segments which are oriented helically in a stepped pattern. For instance, tuft  155 , sometimes referred to herein as a linking tuft, connects or links tufts  154  and  156  together in a stepped pattern of tuft segments. Tufts  154 ,  155  and  156  form another tuft segment which is located at an angle with respect to the tuft segments thereby joined. 
     FIG. 4 is an enlarged portion of FIG. 1 illustrating the tuft segments  400 ,  401  and  402  of FIG.  1 . Each tuft segment, for example tuft segment  402 , includes three tufts  410 ,  411  and  412 . 
     FIG. 5 is a perspective view of FIG.  1 . FIG. 5 illustrates the double helix  195 ,  196  starting with tuft segments  403  and  403 A and terminating with tuft segments  150  and  150 A. The second double helix  197 ,  198  beginning with tuft segments  200  and  200 A are also illustrated in FIG.  5 . FIG. 5 does a particularly good job at illustrating the longitudinal axis of the roller brush  100 . Longitudinal gaps represented by reference numerals  180  and  190 , for instance, are well illustrated in FIG.  5 . 
     FIG. 5A is a perspective view of roller brush  100 A. FIG. 5A illustrates a roller brush having a double helix with tuft segments  110  each having four tufts. 
     FIG. 5B is a perspective view of FIG.  1 B. FIG. 5B illustrates a double helix with tuft segments  120  each having three tufts. FIG. 5C is a perspective view of FIG. 1C illustrating roller brush  100 C and tuft segments  130 . Each tuft segment  130  has two tufts. In FIGS. 5A,  5 B, and  5 C each tuft segment shown includes a tuft segment 180 degrees apart therefrom. Additionally each tuft segment is spaced longitudinally from its adjacent tuft segment so as to provide space for the agitated dirt, dust and debris to become airborne for evacuation by the vacuum pump of the vacuum cleaner (not shown). 
     FIG. 6 is a perspective view of a roller brush  600  illustrating tuft segments  601  helically oriented in a single helix  601 . The tuft segments of roller brush  600  are aligned in straight rows and may comprise either four, three, or two tufts. Longitudinal spaces between the tuft segments can be seen by reference numerals  610  and  620 . 
     FIG. 6A is a perspective view of a roller brush  600 A illustrating tuft segments helically oriented in a single helix with each segment having four tufts. Reference numeral  602  generally indicates the single helix. The embodiments illustrated in FIGS. 6,  6 A,  6 B and  6 C are single helixes meaning there is not a corresponding tuft segment 180 degrees apart from the tuft segments illustrated. 
     FIG. 6B is a perspective view of a roller brush  600 B illustrating tuft segments helically oriented with each segment having three tufts. Reference numeral  603  indicates the single helix. FIG. 6C is a perspective view of a roller brush  600 C illustrating tuft segments helically oriented as indicated by reference numeral  604  with each segment having two tufts. 
     FIG. 7 is a perspective view of a roller brush  700  illustrating tuft segments helically oriented with each segment aligned in a double helix  701 ,  702 . Longitudinal gaps or spaces  710  and  720  are illustrated. In this embodiment the tuft segments have either four, three, or two tufts in each segment and they are spaced rotationally or angularly 180 degrees apart. Spacing of the tufts in this embodiment provide good sweeping performance. 
     FIG. 7A is a perspective view of a roller brush  700 A illustrating tuft segments helically oriented with each segment of tufts aligned on a double helix similar to FIG. 7 except each segment includes four tufts. The helixes are indicated by reference numerals  703  and  704 . 
     FIG. 7B is a perspective view of a roller brush  700 B illustrating tuft segments helically oriented with each segment of tufts aligned in a double helix similar to FIGS. 7 and 7A, except each segment includes three tufts. Here, in FIG. 7B, reference numeral  705  and  706  indicate the helixes. Unnumbered longitudinal spaces are evident from FIGS. 7,  7 A,  7 B and  7 C. 
     FIG. 7C is a perspective view of a roller brush  700 C illustrating tuft segments helically oriented with each segment of tufts aligned in a double helix similar to FIGS. 7,  7 A and  7 B except each segment includes two tufts. Reference numeral  707  and  708  illustrate the helixes. 
     FIG. 7D is a perspective view of a roller brush illustrating tuft segments helically oriented with each segment of tufts aligned in a double helix similar to FIGS. 7 and 7A except each segment includes three tufts and each segment is linked to the next segment by an intermediate tuft. For instance, tuft segment  730  is linked to tuft segment  732  by tuft segment  731 . Tuft segment  731  is sometimes referred to herein as a linking tuft segment and it comprises two tufts. Tufts of segments  730  and  732  in effect form part of a tuft segment. 
     FIGS. 8,  8 A,  8 B and  8 C are cross-sectional views of other embodiments of the roller brush illustrating tuft segments which are not radially oriented. It is expressly contemplated within this invention that the tufts be oriented off-center. The orientation of the tufts off center will create a slapping action of the surface to be cleaned. Roller brush  800  is shown with tufts  801 ,  802 ,  803 ,  804 ,  805 ,  806 ,  807 , and  808  illustrated in various embodiments of off-center tufts. 
     Referring again to FIG. 5, the roller brush  100  is supported by bearings which may be inserted into the ends of the roller brush. The brush may be driven by either of its ends or it may be driven in its center. If it is driven in its center, the embodiment illustrated in FIG. 1D must be used. The tufts are sometimes referred to in the art as bristles and they can be made of any suitable material either man-made or natural. One such material is nylon. The tufts/bristles are secured in holes in the roller brush and the holes are filled with as many bristles as will fit in them. 
     FIG. 9 illustrates the attachment of bristles or tufts to a wooden roller brush. The wooden roller brush may alternately be made of plastic or metal. 
     The foregoing invention has been described by way of example only. Other embodiments and changes can and will be made without departing from the spirit and scope of the claims which follow hereinbelow.