Patent Description:
Suction cleaning devices provide motors for establishing flow of air through the device, to transport air and entrained dirt from a suction inlet formed at the floor cleaning head of the cleaner, or from the mouth of a suction hose or cleaning tool connected to the device, to an exhaust outlet for expelling air from the device. The air with entrained dirt is drawn through a separator assembly, removing coarse dirt from the air flow, and a substantial proportion of fine dirt, for storage within a dirt bin. The filtered air is drawn through the motor and is subsequently expelled from the device via the exhaust outlet.

It is common for a floor cleaning head of a cleaner to provide an agitation device driven by a motor, to assist in dislodging dirt from the surface being cleaned, and to guide or sweep the dirt into the suction inlet of the floor cleaning head. The shape and contours of the suction inlet, and the area surrounding the suction inlet, affect the performance of the floor cleaning head in terms of the efficiency of its pick-up (i.e. the ability to gather dirt from the surface being cleaned).

<CIT> describes a dust collection floor brush.

The present invention seeks to reduce or overcome one or more of the deficiencies associated with the prior art.

According to a first aspect of the disclosure we provide a floor cleaning head for a suction cleaner, the floor cleaning head including:
a lead agitator chamber in which a rotary lead agitator is supported; and.

The sealing material may comprise a strip of bristles. The sealing material may be configured to inhibit air flow beneath the dividing wall. The sealing material may be configured to extend downwards from the dividing wall, towards the floor beneath the floor cleaning head. A lowermost part of the sealing material may lie at a height above the lowermost portions of both the lead agitator and rear agitator.

The floor cleaning head may further include a deflecting surface disposed directly in front of and in close proximity to the lead agitator, and configured to deflect forward-travelling particles of dirt leaving the lead agitator.

According to a second aspect of the disclosure, we provide a floor cleaning head for a suction cleaner, the floor cleaning head including:.

The deflecting surface of either aspect may be provided rearwardly of a front wall of a front end of the housing of the floor cleaning head. The deflecting surface may be spaced from the front wall of the front end of the housing. The deflecting surface may be upright, or substantially upright.

The deflecting surface may be spaced from the lead agitator by between <NUM> and <NUM>, or by between <NUM> and <NUM>, or by around <NUM>.

A pair of sealing pads may be provided on an underside of the floor cleaning head, and offset from the ends of the lead agitator, the cleaning pads being formed of a fibrous material.

A portion of each sealing pad may be disposed in front of a central rotational axis of the lead agitator. The whole of each sealing pad may be disposed in line with or in front of the central rotational axis of the lead agitator. Each sealing pad may be disposed adjacent a respective ground engaging wheel on the underside of the floor cleaning head.

According to a third aspect of the disclosure we provide a suction cleaner, including:.

The floor cleaning head may be formed in a base portion of the suction cleaner.

Embodiments of the technology will now be described, by way of example only, with reference to the following figures, of which:.

With reference to the drawings, we describe a suction cleaner <NUM> for cleaning a floor surface. The cleaner illustrated in this example embodiment is a floor-standing upright cleaner, although it should be understood that aspects of the invention may be applied to other types of suction cleaner, and in particular other forms of floor-standing cleaners, such as a canister type cleaner, or a cylinder cleaner, for example.

In general terms, and with reference to <FIG> and <FIG>, we describe a suction cleaner <NUM> with a floor cleaning head <NUM> providing a nozzle that defines a suction inlet (or suction inlet) for applying a suction force to a surface being cleaned. A motor (the position of which is indicated generally at <NUM>) creates a suction flow of air through the cleaner <NUM> between the suction nozzle and an exhaust outlet <NUM>. Where the term 'floor cleaning head' is used, it is with reference to the base portion of the suction cleaner <NUM>, generally providing a housing forming the suction inlet. The term floor cleaning head should be construed to cover both an integral base part of a floor-standing suction cleaner, and/or a separate floor cleaning head for use attached to a wand or the like, connected to a suction cleaner.

The suction cleaner <NUM> provides a separator assembly <NUM> for separating dirt from the air flow between the suction inlet and the motor <NUM>, and an exhaust assembly for separating fine contaminants from the air flow between the motor <NUM> and the exhaust outlet <NUM>.

In the embodiment illustrated, the suction cleaner <NUM> comprises an upright body <NUM> providing a handle portion <NUM> including a first user-graspable handle <NUM> to allow a user to operate and steer the device. The floor cleaning head <NUM> provides rollers <NUM> (e.g. wheels) for moving the suction cleaner <NUM> across a surface.

The floor cleaning head <NUM> provides two rotary agitators <NUM>, <NUM> for dislodging dirt from the floor surface and a floor cleaning head outlet <NUM> from which air and entrained dirt are drawn from the floor cleaning head <NUM> towards a separator assembly <NUM> via a suction passage <NUM>. Each agitator <NUM>, <NUM> is disposed across the width of the device, so that the lengthways rotary axis of each agitator is disposed widthways of the floor cleaning head <NUM>. The suction passage <NUM> fluidly connects the floor cleaning head <NUM> to an inlet of the separator assembly <NUM>. An outlet of the separator assembly <NUM> fluidly connects the separator assembly <NUM> to the motor <NUM>, via which a suction air flow is generated within the suction cleaner, so as to draw air and entrained dirt through the floor cleaning head <NUM>, to the separator assembly <NUM>, and to draw cleaned air from the separator assembly <NUM>. An exhaust outlet <NUM> vents air from the suction device <NUM>, downstream of the motor <NUM>.

In embodiments, and as shown in <FIG>, the separator assembly <NUM> comprises a separator housing <NUM> that provides a collecting volume for collecting dirt separated from the incoming air flow. The separator housing <NUM> also contains a separator, which in embodiments is formed of a first stage cyclonic separator to remove large particles of dirt, and a second stage cyclonic separator for removing smaller particles of dirt from the air flow. In embodiments, the first stage separator provides a mesh shroud for filtering relatively large particles, and the second stage separator provides a plurality of cyclonic separators, each formed as cone shape as is known in the art, for filtering fine dirt particles from the air flow.

In embodiments, the separator assembly <NUM> is mounted on a portion <NUM> of the upright body <NUM> during use, but is detachable from the body <NUM> for the purpose of emptying the dirt from the separator assembly collecting volume. The separator assembly <NUM> may further include a pre-motor filter positioned downstream of the separator stages described above. In embodiments this pre-motor filter is housed within a removable lid portion <NUM> of the separator housing <NUM>. In this way, the removable lid portion <NUM> may be detached to expose the filter for cleaning. The lid portion <NUM> may further provide a handle <NUM> to allow a user to lift away the separator housing <NUM> when detached from the upright body <NUM> of the cleaner. A motor inlet <NUM> communicates with the outlet of the separator assembly <NUM> when it is mounted on the upright body <NUM> of the suction cleaner <NUM>.

The body <NUM> further provides a power source, which in embodiments is a rechargeable battery pack <NUM>. The battery pack <NUM> may be rechargeable in situ, or when removed from the body <NUM>, as is known in the art. Alternatively, or in addition, the suction cleaner <NUM> may be provided with a power cable for connection to a mains power source.

The body <NUM> further includes a carrying handle <NUM> configured to enable a user to lift and carry the suction cleaner <NUM>.

With reference to <FIG>, we now describe aspects of the floor cleaning head <NUM> according to embodiments of the technology. In broad terms, the floor cleaning head <NUM> includes a lead agitator chamber <NUM> in which a rotary lead agitator <NUM> is supported, a suction chamber <NUM> defining a suction inlet <NUM> through which air and entrained dirt is drawn into the suction chamber <NUM>, a floor cleaning head outlet <NUM> for fluid connection to the suction flow path <NUM> of the suction cleaner <NUM>, and a rotary rear agitator <NUM> supported within the suction chamber <NUM>. The suction chamber <NUM> is disposed rearwardly of the lead agitator chamber <NUM> and separated from it by a dividing wall <NUM>.

The lead agitator <NUM> and rear agitator <NUM> are each formed as rotational agitators, and disposed widthways of the floor cleaning head <NUM>. The floor cleaning head <NUM> provides a housing <NUM> having a front end <NUM>, which extends in front of the lead agitator <NUM>, and provides a lower edge defining a front inlet <NUM> between the lower edge and the floor surface.

In embodiments, the floor cleaning head <NUM> is supported on the floor surface by the rollers <NUM> disposed at the rear for the floor cleaning head <NUM>, and by one or more further rollers disposed at or towards the front and/or midsection of the floor cleaning head <NUM>. As shown in <FIG> and <FIG>, a pair of rollers, in this instance smaller floor-engaging wheels <NUM>, is positioned at the front of the floor cleaning head <NUM>, spaced outwardly from the ends of the lead agitator <NUM>.

A further pair of rollers <NUM> is disposed behind the suction inlet <NUM>. These rollers <NUM>, <NUM> ensure that the floor cleaning head <NUM> sits at a desired ride height above a floor surface, establishing appropriate engagement between the agitators <NUM>, <NUM> and the floor surface or carpet surface, for example.

The suction inlet <NUM> to the suction chamber <NUM> is formed as an opening in the underside of the housing <NUM>, through which air flow containing debris is drawn, under the suction applied via the floor cleaning head outlet <NUM> leading to the suction motor <NUM>. Dirt particles may be swept towards the suction inlet by the lead agitator <NUM>.

In embodiments, the central axis X of the lead agitator <NUM>, around which it rotates, lies above (i.e. higher than) the lower edge of the front end <NUM> of the floor cleaning head housing <NUM>. The leading agitator <NUM> is preferably formed with fibres of a relatively soft material compared to the bristles of the rear agitator <NUM>, such that it is suited to dislodging dirt and debris from a carpet, for example, and moving said debris rearwards towards or into the suction inlet formed behind the lead agitator <NUM>. For example, the body of the lead agitator <NUM> may be formed of uniform soft fibres which are roughly <NUM>-<NUM> in length, preferably between <NUM> and <NUM> (and most preferably around <NUM> in length). The lowermost part of lead agitator <NUM> lies roughly <NUM> from the floor surface, when the suction cleaner <NUM> is used on a hard floor.

In embodiments, each of the agitators <NUM>, <NUM> is driven via a drive belt mechanism, in which a portion of a drive belt is disposed around an end portion of each respective agitator <NUM>, <NUM>, to transfer drive from the motor, the motor being disposed rearwardly of the rear agitator <NUM>, within a rear portion of the housing <NUM> (the position of the agitator motor being indicated generally at <NUM>). In embodiments, the lead agitator <NUM> is driven by the agitator motor at a speed of between 1700rpm and 2500rpm.

In embodiments, one or both of the lead agitator <NUM> and rear agitator <NUM> are each removable axially from the housing via openings in a side of the housing which in use are sealed with removable end caps <NUM>. The agitators <NUM>, <NUM> may be inserted through the openings, and pushed by a user into contact with an engaging formation disposed within the housing on the opposing side of the floor cleaning head <NUM>. Alternatively, one or both of the lead agitator <NUM> and rear agitator <NUM> may be removable downwardly through the underside housing.

In embodiments of the technology, the lead agitator <NUM> has a diameter that is the same as or larger than the diameter of the rear agitator <NUM> (i.e. the diameter including the length of the bristles). Preferably, the lead agitator <NUM> is positioned with its central rotational axis being above the height of the central rotational axis of the rear agitator <NUM>. The axis of the lead agitator <NUM> may be <NUM> above the axis of the rear agitator <NUM>.

In embodiments, and as shown in <FIG> and <FIG> of the drawings, the rear agitator <NUM> is a bristled roller, having a row of relatively firm bristles <NUM> (i.e. firm compared to the lead agitator <NUM>) extending outwardly from its cylindrical core. Preferably, the bristles are formed in clumps or tufts. Preferably, the rear agitator <NUM> provides multiple rows of bristles which wind around its perimeter in a chevron-style formation, for example.

The one or more rows of bristles <NUM> may be interspersed between one or more ridges <NUM> or flaps formed of a plastic or rubberised material, extending outwardly from the core of the agitator <NUM>. The ridges <NUM> are preferably provided so as to impact the uppermost parts of a carpet surface, for example, to assist in dislodging dirt attached to or lodged in the carpet, so that the dirt particles can readily be swept into the suction inlet <NUM> by the bristles <NUM> as the agitator rotates. The ridges <NUM> also serve to prevent fine threads, hair, and the like from becoming wound tight around the core of the rear agitator <NUM>, during use. It is well established that hairs and threads may be picked up by a bristled agitator such as the rear agitator <NUM>, and commonly become wound tightly around the core of the agitator as it rotates. This tight binding of the threads around the core makes the threads difficult to remove, since it is hard to cut or unbind the threads without risking damaging the agitator itself. Having a flexible strip or ridge <NUM> running along the length of the rear agitator <NUM>, means that threads or the like become wrapped around the ridge <NUM> (rather than tightly around the core), thus ensuring that there is at least a small gap between the threads and the core of the agitator, so that a user may use a scissor blade, or similar, to cut through the threads or hairs to cut them free from the agitator.

The rear agitator <NUM> is substantially housed within the suction chamber <NUM> formed within the housing, to which suction is applied via the suction passage <NUM>, such that only a lowermost part of the rear agitator <NUM> or its bristles (and/or ridge <NUM>) protrudes from the suction inlet <NUM>. In this way, the rear agitator <NUM> is disposed in the suction flow path formed between the suction inlet <NUM> and the floor cleaning head outlet <NUM>.

In embodiments, a rear sealing strip <NUM> formed of a plastic, rubberised, or a fibrous material, is formed adjacent a rear portion of the suction inlet <NUM>. The rear sealing strip <NUM> extends substantially across the width of the suction inlet <NUM>, lying close to a rear edge of the suction inlet <NUM>. The rear sealing strip <NUM> has the effect of creating a partial seal at the rear edge of the suction inlet, against a floor surface below, so as to concentrate the suction effect in the area in front of the strip, improving the pick-up efficiency of the floor cleaning head <NUM> in lifting dirt from the surface below.

The floor cleaning head <NUM> provides the housing <NUM> having a suction inlet <NUM>, and the housing <NUM> provides a lead agitator chamber <NUM> having ends forming a pair of side walls disposed on opposing sides of the floor cleaning head <NUM>. A dividing wall <NUM> lies to the rear of the agitator <NUM>, between the lead agitator <NUM> and rear agitator <NUM>, forming a back part of the lead agitator chamber <NUM>. The lead agitator <NUM> is supported between the side walls and configured to rotate about a lengthways central rotational axis X.

In embodiments of the technology, a ramp may extend around a portion of a periphery of the lead agitator and inwardly from a side wall of the chamber, the ramp providing a deflecting surface configured to deflect dirt particles inwardly from the side wall of the chamber towards a central portion of the floor cleaning head <NUM>. Preferably, such a ramp is provided at each end of the agitator chamber.

The lead agitator <NUM>, as described above, effectively lies at the very front of (or slightly in advance of) the suction inlet <NUM>, and acts to dislodge particles from a carpet surface, for example, in order to transfer those dirt particles back towards and into the suction inlet <NUM> lying behind it. The dividing wall <NUM> lies to the rear of the lead agitator <NUM>, under which dislodged particles of dirt are flung by the rotational movement of the lead agitator <NUM>. At either side of the housing, surrounding the lead agitator <NUM>, the separating wall seals to the side wall of the housing, on which the agitator is supported and from which it extends inwardly towards the centre of the floor cleaning head <NUM>. In this way, the floor cleaning head <NUM> is effectively divided into a lead agitator chamber <NUM> and a suction chamber <NUM> spaced behind it, the two chambers being separated by the dividing wall <NUM>.

In embodiments, the lead agitator <NUM> in the lead agitator chamber <NUM> lies largely outside of the suction flow path, separated from the suction chamber <NUM> by the dividing wall <NUM> between the two agitators <NUM>, <NUM>. The surface of the lead agitator <NUM> may contact the dividing wall <NUM>, or may lie very close to the dividing wall <NUM>. A portion of the dividing wall <NUM>, shown at <NUM>, may have a concave side cross-sectional profile to conform to the shape of the surface of the lead agitator <NUM>. Alternatively, the portion <NUM> of the dividing wall <NUM> may be flat, angled from the vertical, to align tangentially with the surface of the lead agitator <NUM> at its closest point. Preferably, the separation between the lead agitator <NUM> and the dividing wall <NUM> is very small or non-existent, to prevent or inhibit ingress of dirt particles into an upper part of the lead agitator chamber <NUM>.

The lead agitator <NUM> preferably sits at a height such that the lowermost surface of the lead agitator <NUM> is raised slightly above the surface being cleaned, where that surface is a flat floor surface. When used on a carpet surface, the lower most portion of the lead agitator <NUM> impacts the carpet surface as the device moves across the carpet. A lower edge of the dividing wall <NUM> sits at a position raised above the surface being cleaned, so as not to interfere with the carpet surface since doing so would create unwanted friction and drag on the surface, and potentially cause snagging.

A sealing material <NUM> is provided on a lower part of the dividing wall <NUM>. In embodiments, the sealing material is formed as a row or strip of bristles which descend from the lower edge of the dividing wall <NUM> (preferably extending downwards toward s the floor), to inhibit the flow of air beneath the dividing wall <NUM>; i.e. between the lowest portion of the lead agitator <NUM> and the suction chamber located behind it. The bristles are typically fine bristles. In this way, the sealing material <NUM> has the effect of defining a front portion of the suction inlet <NUM>. It should be noted that the fine bristles do not directly contact the floor surface; a lowermost part of the sealing material <NUM> lies at a height above the lowermost portions of both the lead agitator <NUM> and rear agitator <NUM>. Even so, the sealing material <NUM> provides an effective screen with the aim of concentrating the suction applied to the floor surface, to the area directly behind the row of bristles.

As shown in <FIG>, the front end <NUM> of the housing <NUM> extends in front of the lead agitator <NUM>. The lower edge of the front end <NUM> defines a front inlet <NUM> between the lower edge and the floor surface below. In embodiments of the technology, and as shown, the lower edge lies below a rotational central axis of the lead agitator <NUM>. This configuration means that if a dirt particle is drawn into the lead agitator chamber <NUM> and rotated with the lead agitator <NUM>, it is not then flung forwardly out of the housing <NUM>, in front of the suction cleaner <NUM>, as the agitator rotates. Instead, the front end <NUM> of the housing <NUM> provides a surface against which dirt particles, released from the agitator surface with a forward moment, collide and either drop to the floor surface in front of the lead agitator <NUM> or rebound back towards the suction inlet <NUM>.

Further, in embodiments of the technology and as shown in <FIG>, a front deflecting surface <NUM> may be provided. The front deflecting surface <NUM> lies directly in front of and in close proximity to the lead agitator <NUM>, and is configured to deflect forward-travelling particles of dirt leaving the lead agitator <NUM>. In embodiments, and as shown, the front deflecting surface <NUM> is disposed between the front end <NUM> of the housing <NUM> and a leading surface of the lead agitator <NUM> (i.e. a frontmost part of the agitator); in other words, it is provided rearwardly of a front wall forming the front end <NUM> of the housing <NUM>, and is spaced from that front wall. The front deflecting surface <NUM> may be provided as a flat surface or as a curved surface (e.g. concave facing the lead agitator <NUM>). In embodiments, the front deflecting surface <NUM> is substantially flat, and extends vertically (or close to vertical) close to the leading surface of the lead agitator <NUM>. The frontmost part of the lead agitator <NUM> may be separated from the front deflecting surface <NUM> by a distance of between <NUM> and <NUM>, and preferably between <NUM> and <NUM>, or around <NUM>. The front deflecting surface <NUM> may extend downwards from an upper part of the lead agitator chamber <NUM>. Alternatively, the front deflecting surface <NUM> may be provided by a portion of the front end <NUM> of the housing <NUM>, having an increased thickness, so that the surface on the inside of the front end <NUM> of the housing, i.e. facing the lead agitator <NUM>, provides the front deflecting surface <NUM>. The deflecting surface <NUM> is preferably spaced from the lead agitator <NUM> by between <NUM> and <NUM>, and more preferably between <NUM> and <NUM>, and yet more preferably by around <NUM>.

In embodiments, on either side of the floor cleaning head <NUM>, air channels <NUM> are provided in the side walls of the floor cleaning head. The air channels <NUM> provide an opening through the side wall of the housing <NUM>, to allow air to flow inwardly from the sides of the floor cleaning head <NUM>, into the suction inlet <NUM>. This has the effect of drawing fine dirt from the sides of the floor cleaning head <NUM> into the suction inlet <NUM>, and also assists in allowing air flow into the suction flow path when the device is used on a very deep carpet, to ensure the carpet does not entirely block access to the suction inlet <NUM>.

In embodiments of the technology, at either side of an underside of the floor cleaning head <NUM>, a sealing pad <NUM> is provided, positioned behind the floor-engaging wheels <NUM> at the front of the floor cleaning head <NUM>. The sealing pads <NUM> are aligned with the lead agitator <NUM> and offset from the ends of the lead agitator <NUM>. The sealing pads <NUM> are preferably formed of a material (such as felt, or another suitable fibrous fabric) that will form at least a light seal with the floor surface below the cleaner (such as a carpet, for example), to inhibit the flow of air between the sealing pad <NUM> and the floor below. In this way, positioning the sealing pads <NUM> at the front of the floor cleaning head <NUM> and in front of a central rotational axis of the lead agitator <NUM>, means that the suction effect provided at the suction inlet <NUM> behind the lead agitator <NUM>, is concentrated more to the front of the floor cleaning head <NUM> and less to the position of the floor-engaging wheels <NUM>, for example. The sealing pads <NUM> are preferably disposed in front of the rotational axis of the lead agitator <NUM>, so that at least a portion of each pad lies in front of that axis. In embodiments, the whole of each pad lies level with or in front of the axis. Preferably, no part of the cleaning pads lies rearwardly of the axis.

By providing a light sealing effect directly rearwardly of the floor-engaging wheels <NUM> at the front of the floor cleaning head, dirt is less likely to be drawn towards or into the wheels or into the housing <NUM> at the position of the wheels <NUM>. Furthermore, by positioning the sealing pads <NUM> towards the front of the lead agitator <NUM>, the suction effect applied at the lowest point of the lead agitator <NUM> and the floor below is focused more underneath the agitator than towards its ends, at either side of the width of the floor cleaning head <NUM>.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claim 1:
A floor cleaning head (<NUM>) for a suction cleaner (<NUM>), the floor cleaning head including:
a lead agitator chamber (<NUM>) in which a rotary lead agitator (<NUM>) is supported; and
a suction chamber (<NUM>) defining a suction inlet (<NUM>) through which air and entrained dirt is drawn into the suction chamber, a suction outlet (<NUM>) for fluid connection to a suction flow path (<NUM>) of the suction cleaner, and a rotary rear agitator (<NUM>) supported within the suction chamber;
the suction chamber being disposed rearwardly of the lead agitator chamber and separated from it by a dividing wall (<NUM>);
wherein a sealing material (<NUM>) is provided on a lower part of the dividing wall; characterized in that the sealing material comprises a strip of bristles.