BACKGROUND
The present invention relates to a floor cleaner comprising a cleaning head, an agitator drive, and an agitator. The cleaning head includes an agitator chamber having an opening facing toward a surface to be cleaned. The agitator is rotatably disposed within the agitator chamber and positioned to contact the surface to be cleaned through the opening. The agitator extends longitudinally between a first end and a second end along an axis of rotation. The agitator includes a core operably connected to the agitator drive, rotatable about the axis and at least one molded agitating member integrally formed with the core. The agitating member extends from the core to contact the surface to be cleaned.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cleaning device or floor cleaner according to one embodiment of the invention.
FIG. 2 is a front view of an agitator assembly from the cleaning device shown in FIG. 1.
FIG. 3 is a perspective view of the agitator assembly of FIG. 2.
FIG. 4 is a cross-section view taken along line 4-4 of FIG. 2.
FIG. 5 is a front view of another embodiment of an agitator assembly.
FIG. 6 is a perspective view of the agitator assembly of FIG. 5.
FIG. 7 a cross-section view taken along line 7-7 of FIG. 5.
FIG. 8 is a front view of another embodiment of an agitator assembly.
FIG. 9 is a perspective view of the agitator assembly of FIG. 8.
FIG. 10 a cross-section view taken along line 10-10 of FIG. 8.
FIG. 11 is a front view of another embodiment of an agitator assembly.
FIG. 12 is a perspective view of the agitator assembly of FIG. 11.
FIG. 13 a cross-section view taken along line 13-13 of FIG. 11.
FIG. 14 is a front view of another embodiment of an agitator assembly.
FIG. 15 is a perspective view of the agitator assembly of FIG. 14.
FIG. 16 a cross-section view taken along line 16-16 of FIG. 14.
FIG. 17 is a front view of another embodiment of an agitator assembly.
FIG. 18 is a perspective view of the agitator assembly of FIG. 17.
FIG. 19 is a cross-section view taken along line 19-19 of FIG. 17.
FIG. 20 is a perspective view of a core of the agitator assembly shown in FIG. 2.
FIG. 21 is a front view of another embodiment of an agitator assembly.
FIG. 22 is a perspective view of the agitator assembly of FIG. 21.
FIG. 23 is a cross-section view taken along line 23-23 of FIG. 21.
FIG. 24 is a front view of another embodiment of an agitator assembly.
FIG. 25 is a perspective view of the agitator assembly of FIG. 24.
FIG. 26 a cross-section view taken along line 26-26 of FIG. 25.
FIG. 27 is a front view of another embodiment of an agitator assembly.
FIG. 28 is a perspective view of the agitator assembly of FIG. 27.
FIG. 29 a cross-section view taken along line 29-29 of FIG. 28.
FIG. 30 is a front view of another embodiment of an agitator assembly.
FIG. 31 is a perspective view of the agitator assembly of FIG. 30.
FIG. 31a is a detail view of the agitator assembly of FIG. 31.
FIG. 32 a cross-section view taken along line 32-32 of FIG. 31.
FIG. 33 is a front view of another embodiment of an agitator assembly.
FIG. 34 is a perspective view of the agitator assembly of FIG. 33.
FIG. 35 a cross-section view taken along line 35-35 of FIG. 34.
FIG. 36 is a front view of another embodiment of an agitator assembly.
FIG. 37 is a perspective view of the agitator assembly of FIG. 36.
FIG. 38 a cross-section view taken along line 38-38 of FIG. 37.
FIG. 39 is a front view of another embodiment of an agitator assembly.
FIG. 40 is a perspective view of the agitator assembly of FIG. 39.
FIG. 41 a cross-section view taken along line 41-41 of FIG. 40.
DETAILED DESCRIPTION
The disclosure relates to a floor cleaner such as a vacuum cleaner, an extractor, or the like, and more specifically, an agitator 20 for a floor cleaner. FIG. 1 illustrates a floor cleaner 10. The floor cleaner 10 includes a cleaning head 12 having a housing 14 including a debris inlet, an agitator chamber 16 formed in the housing 14, an agitator 20, and an agitator drive 22. The agitator chamber 16 includes an opening 18 through a bottom side of the housing 14 configured to face a surface to be cleaned during operation. The agitator 20 extends longitudinally along an axis of rotation 100 between a first end 24 and a second end 26 opposite the first end 24. The agitator 20 is operably mounted in the agitator chamber 16 rotatable by the agitator drive 22 and extends through the opening 18 to contact the surface to be cleaned during operation. The agitator 20 rotates relative to the housing 14 about the longitudinal axis 100.
The agitator assembly 20 includes a core 30 operably connected to the agitator drive 22 for rotation about the axis 100 and at least one molded agitating member 32 extending from and integrally formed with the core 30. In the illustrated embodiments, the agitating members 32 are integral with the core 30. The molded agitation members 32 form a pattern along a longitudinal and circumferential direction around the agitator 20 to engage the surface to be cleaned through the opening 18, agitating the surface during operation to facilitate removal of dirt and debris.
The core 30 is rigid in one embodiment. In such embodiments, the core 30 is made from a plastic material, such as nylon or glass filled nylon, however the core may be made from other materials as desired for the application, such as polystyrene, ABS, magnesium alloy, zinc alloy, or steel. In one embodiment, the core 30 is a less rigid material, such as an elastomeric material such as polyurethane or other thermoplastic material having a durometer between about 60 and 95 Shore A. In the illustrated embodiment, the agitating members 32 are molded or cast from an elastomeric material, for example thermoplastic urethane (TPU), thermoplastic vulcanizate (TPV), or other thermoplastic elastomer, polyurethane, silicone, rubber or any other flexible, durable, resilient material as desired for the application. In one embodiment, the agitating member has a durometer between 25 and 60 Shore A. In another embodiment, the agitating member has a durometer between 55 and 80 Shore A. In one embodiment, the agitating member has a durometer between 70 and 95 Shore A. In the illustrated embodiments, the integrally formed agitating members 32 are injection molded or cast directly onto the core 30 by overmolding. In one embodiment, the integrally formed agitating members 32 are molded first, and then are affixed to the core 30 by fastening, bonding, welding, or other attachment. In the embodiment illustrated in FIG. 20, the core 30 is shown without the agitating members for illustration.
The agitating members 32 have a proximal portion 33 adjacent the core 30 and a distal portion 35 extended away from the core by a height H, the distal portion 35 configured engage a surface to be cleaned through the opening 18. In one embodiment, the height H is radial. In one embodiment, the height H is rearwardly raked relative to the direction of rotation. In one embodiment, the height H is forwardly raked relative to the direction of rotation. In the illustrated embodiments, the agitating members 32 have a longitudinal shape with a length L and thickness T. In one embodiment, the distal portion of the agitating member forms a smooth continuous edge along the length of the agitating member 32. The smooth surface of the elastomeric agitator 20 facilitates debris pickup, while allowing bending and flicking to inhibit the hair and debris from being wrapped around the agitator. By inhibiting hair and debris wrap, the longevity of the cleaner 10 is increased as well as the time required between cleaning and maintenance of the agitator 20.
In the illustrated embodiments, the agitating member 32 defines an agitating axis 100 extending outwardly from the core 30. In the embodiment illustrated in FIGS. 24-29 and 36-41, the agitating member 32 further includes a flange 65 disposed adjacent the distal portion of the agitating member 32. In the illustrated embodiments, the flange 65 is positioned along an outer circumference of the agitator 20. In one embodiment, the flange 65 is offset from the outer circumference of the agitator 20.
The flange 65 extends forwardly along a flange axis 102, away from the agitating axis 100 in the direction of rotation. In one embodiment, the flange 65 extends between 2 and 10 millimeters away from the distal portion of the agitating member 32. In one embodiment, the flange 65 extends between 10 and 20 millimeters away from the distal portion 35 of the agitating member 32. The flange axis 102 is angled forwardly relative to the agitating axis 100. In one embodiment, an angle 61 of the flange axis 102 relative to the agitating axis 100 is between 60 and 75 degrees. In one embodiment, the angle 61 of the flange axis 102 relative to the agitating axis 100 is between 75 and 90 degrees. In one embodiment, the angle 61 of the flange axis 102 relative to the agitating axis 100 is between 90 and 105 degrees. The flange axis 102 does not intersect the core 30 of the agitator 20. The flange 65 assists in debris pick up by directing the gathered debris into the debris inlet of the floor cleaner.
In the embodiments illustrated in FIGS. 2-10, each agitating member 32 defines a plurality of chevron or V-shaped portions extending lengthwise along the agitator 20 between the first end 24 and the second end 26. The agitating member 32 has a leading side 36 facing in a direction of rotation 44 and a trailing side 38 opposite the leading side 36. During rotation, the distal portion of the leading side 36 contacts the surface to be cleaned before the trailing side 38. Each chevron-shaped portion of the agitating member 32 is formed by two diverging agitating vanes 42, each agitating vane 42 having a forward end and a rearward end, the forward end of each agitating vane 42 forming the chevron-shaped portion converging at a leading peak 40 in the direction of rotation 44. The rearward ends of agitating vanes 42 of adjacent chevron-shaped portions converge at a trailing peak 41 opposite the direction of rotation 44. The agitating member 32 is configured such that the leading peaks 40 contact the surface to be cleaned prior to the leading sides 36 of the agitating vanes 42 and the trailing peaks 41 during rotational operation.
In the embodiments illustrated in FIGS. 2-10, the plurality of chevron or V-shaped portions forming the agitating member 32 are conterminous, such that adjacent agitating vane 42 are connected together at the leading peaks 40 and trailing peaks 41. In one embodiment, the agitating member 32 defines a plurality of chevron or V-shaped portions extending along the agitator 20 between the first end 24 and the second end 26, wherein the rearward ends of agitating vanes 42 of adjacent chevron-shaped portions are discontinuous at one or more trailing peaks 41. In one embodiment, the agitating member 32 defines a plurality of chevron or V-shaped portions extending along the agitator 20 between the first end 24 and the second end 26, wherein the forward ends of agitating vanes 42 forming the chevron-shaped portions are discontinuous at one or more leading peaks 41. In one embodiment, the agitating member 32 defines a plurality of chevron or V-shaped portions extending along the agitator 20 between the first end 24 and the second end 26, wherein the rearward ends of agitating vanes 42 of adjacent chevron-shaped portions are discontinuous at one or more trailing peaks 41 and wherein the forward ends of agitating vanes 42 forming the chevron-shaped portions are discontinuous at one or more leading peaks 41.
In various embodiments, the arrangement of chevrons may be closer to one end of the agitator or another, or may be centered longitudinally. In the embodiment illustrated in FIGS. 2 and 3, the agitating vane 42 adjacent the first end 24 of the agitator 20 is positioned such that the forward end of the agitating vane 42 is adjacent the first end 24, and the agitating vane 42 adjacent the second end 26 of the agitator 20 is positioned such that the rearward end of the agitating vane 42 is adjacent the second end, e.g. ½ of a chevron adjacent the first end 24. In one embodiment, illustrated in FIGS. 5 and 6, the agitating vanes 42 adjacent the first end 24 and the second end 26 of the agitator 20 are both positioned such that rearward ends of the agitating vanes 42 are adjacent the agitator ends, with the peaks 40, 41 spaced from the first end 24 and the second end 26 by the agitating vanes 42. In one embodiment, illustrated in FIGS. 8 and 9, the agitating vanes adjacent the first end 24 and the second end 26 of the agitator 20 are both positioned such that the forward ends of the agitating vanes 42 are adjacent the agitator ends.
In one embodiment, adjacent vanes converge at the peaks 40, 41 at an angle 48 between 10 degrees and 75 degrees. Decreasing the angle 48 of the peaks 40, 41 results in more chevrons, more peaks 40, 41 across the agitator 20, and a more compressed zig-zag pattern of chevrons. Increasing the angle 48 of the peaks 40, 41, reduces the number of chevrons, with fewer peaks 40, 41 across the agitator 20. The angle 48 may be varied based on desired cleaning outcome. The length L of the agitating vanes 42 from the leading peak 40 to the trailing peak 41 varies based on the length of the agitator and the number of chevrons desired, and could be any value based on the desired geometry. In some embodiments the length may be between 10 millimeters and 75 millimeters, or between 15 millimeters and 50 millimeters. In one example, the length of the agitator 20 is 30 centimeters, the peak 40, 41 angles are 70 degrees, and the length of the agitating vanes 42 is 47 millimeters, resulting in 10 total peaks 40, 41 spanning the agitator 20.
The agitator 20 includes between 1 and 6 agitating members 32, or more than 6 agitating members 32 as desired. In the embodiments illustrated in FIGS. 2-10, the agitator 20 includes 5 agitating members 32. The circumferentially adjacent agitating members 32 may be reinforced by connecting ribs. In the embodiment illustrated in FIGS. 2, 3, 8, and 9, circumferentially adjacent agitating member 32 are reinforced by annular ribs 34. The ribs 34 may be positioned to connect one or more leading peaks 40 to circumferentially adjacent leading peaks 40. Alternatively or additionally, the ribs 34 may be positioned to connect one or more trailing peaks 41 to circumferentially adjacent trailing peaks 41. In one embodiment, the annular ribs 34 reinforce the agitating member 32 by intersecting the agitating vanes 42, between the peaks 40, 41. The annular ribs 34 reinforce the agitating members 32 during contact with surface to be cleaned, which may increase the longevity of the agitating member 32 and the agitator 20.
In one embodiment, the height of the agitating member 32 from the proximal portion 33 to the distal portion 35 is constant along the length of the agitating vane 42 and is equivalent to the height of the peaks 40, 41 from the core 30. In another embodiment, the height of the agitating member 32 decreases from the leading peak 40 to the trailing peak 41. In one embodiment, the height of the agitating member 32 increases from the leading peak 40 to the trailing peak 41. In another embodiment, the height of a portion of the agitating member 32 is greater than the height of both the leading peak 40 and the trailing peak 41, such that the height of the agitating member 32 increases in a slope or arc away from the leading peak 40, and then decreases in a slope or arc toward the trailing peak 41. In illustrated embodiments, the height of the annular rib 34 from the core 30 is less than the height of the agitating members 32. In one embodiment, the height of the annular rib 34 is the same or greater than the height of the agitating members 32.
In the embodiment illustrated in FIGS. 5 and 6, the peaks 40, 41 have a thickness T1 greater than a thickness T2 of the adjacent vanes 42 reinforcing the connection between adjacent agitating vanes 42. The increased thickness of the peaks 40, 41 extends the life of the agitator 20. In one embodiment, the peak 40, 41 is between 1.25 and 4 times the thickness of the adjacent vanes 42. In one embodiment, the thickness T1 is between 20% and 30% of the height H of the agitating member 32, measured from the proximal portion 33 to the distal portion 35. In one embodiment, the thickness T1 is between 30% and 40% of the height H of the agitating member 32, measured from the proximal portion 33 to the distal portion 35. In one embodiment, the thickness T1 is between 40% and 50% of the height H of the agitating member 32, measured from the proximal portion 33 to the distal portion 35.
In the embodiments illustrated in FIGS. 2-7, the agitator members 32 are arranged along a straight line along the longitudinal axis between the first end 24 and the second end 26. In the embodiment illustrated in FIGS. 8 and 9, the agitator members 32 are arranged along a curve such that the agitator members 32 follow a curve or parabola 46 between the first end 24 and the second end 26. In one embodiment, the agitator members 32 follow a non-linear path, such as a helix or other path.
In the embodiments illustrated in FIGS. 11-16, the agitator 120 includes a plurality of annular agitating members 132, each agitating member 132 defines a plurality of chevron or V-shaped portions extending circumferentially along the agitator 120, where the peak 140 of the V-shaped portion is in the direction of one of the first end 124 or the second end 126, and the connection between adjacent V-shape portions is in the direction of the other of the first end 124 or the second end 12. Stated another way, the agitating members 132 form an annular zig-zag pattern around the circumference of the agitator 120. Each V-shaped portion of the agitating member 132 is formed by two diverging agitating vanes 142, each agitating vane 142 having a forward end and a rearward end, the forward end of one agitating vane 142 converging with a rearward end of an adjacent agitating vane 142 at a peak 140 to form the V-shaped portion. This arrangement creates left-to-right agitation of carpet fibers on the surface to be cleaned as the agitator 120 rotates.
The agitating vanes 142 converge at a peak 140 forming an angle between the vanes. The angle of the chevron or V-shape varies based on the number of chevron shaped portions and the diameter of the agitator, which may be modified based on the desired cleaning outcome, as seen by the different angle illustrated in FIGS. 11-12 and FIGS. 14-15. In the embodiment illustrated in FIGS. 11-16, three V-shapes are arranged about the circumference in each annular agitating member 132.
The agitator 120 includes a plurality of annular agitating members 132 arranged along the agitator between the first end 124 and the second end 126. In one embodiment, the agitator 20 includes more than 6 agitating members 132. In the embodiment illustrated in FIGS. 11-13, the agitator 20 includes 17 agitating members 132. In the embodiment illustrated in FIGS. 14-16, the agitator 20 includes 15 agitating members 132.
In the embodiments illustrated in FIGS. 11-16, the plurality of chevron or V-shaped portions forming the annular agitating member 132 are conterminous, such that adjacent agitating vanes 142 are connected together at the peaks 140. In one embodiment, the agitating member 32 defines a plurality of chevron or V-shaped portions extending along the circumference of the agitator 20, wherein adjacent agitating vanes 142 are discontinuous at one or more peaks 140.
A connecting rib 134 may be provided between adjacent agitating members 132 to reinforce the annular agitating members. In the embodiment illustrated in FIGS. 11-16, adjacent annular agitating member 132 are reinforced by the ribs 134 extending longitudinally along the agitator between the first end 124 and the second end 126. The ribs 134 may be positioned to connect one or more peaks 140 to adjacent peaks 140. In the embodiment illustrated in FIGS. 11-16, six longitudinal ribs 134 are provided spaced circumferentially about the core intersecting the peaks 140 of adjacent agitating members. In other embodiments, fewer than six ribs may be provided, or more than six ribs may be provided as desired for the geometry of the agitator and the application. In one embodiment, the ribs 134 reinforce the agitating member 132 by intersecting the agitating vanes 142, between the peaks 140.
In the embodiment illustrated in FIGS. 17 and 18, the agitator 220 includes a plurality of annular agitating members 232, each arranged in a helical direction. In one embodiment, the agitating members 232 form a continual helix from a first end 224 to a second end 226. In the illustrated embodiment, the agitating members 232 are discontinuous, including gaps 260 in the helical pattern. In the illustrated embodiment, the agitating members 232 extend ⅓ of the circumference of the agitator 220 between gaps 260. In other embodiments the agitating members 232 extend ½ of the circumference between gaps 260, or ¼ of the circumference between gaps 260. Adjacent agitating members 232 may be separated by between 3 millimeters and 15 millimeters. The agitating members 232 are divided into a first group or segment 232a each having a left hand flight, and a second group or segment 232b each having a right hand flight. The end of the first segment 232a is axially adjacent to the end of the second segment 232b at a convergence area 250 such that rotation 244 of the agitator 220 tends to move dirt, debris, and hair along the first and second segments 232a, 232b in opposed axial directions toward the convergence area 250.
A connecting rib 234 may be provided between adjacent agitating members 232 to reinforce the agitating members. In the embodiment illustrated in FIGS. 17-19, adjacent annular agitating member 232 are reinforced by the ribs 234 extending longitudinally along the agitator between the first end 224 and the second end 226. In the illustrated embodiment, six longitudinal ribs 234 are provided spaced circumferentially about the core. In other embodiments, fewer than six ribs may be provided, or more than six ribs may be provided as desired for the geometry of the agitator and the application.
The shape and direction of the agitating members 232 move the dirt and debris on the surface in an axial direction as the agitator 220 rotates. The surface cleaning head 12 will move in the forward or reverse direction as the agitator 220 is rotating and therefore the movement of the debris will not be purely axial but will likely also have some forward or rearward component of movement as well. In one embodiment, the convergence area 250 is aligned with a suction inlet such that the rotating agitator 220 moves the debris toward the convergence area 250 and the suction inlet. Directing debris to the convergence area 250 aligned with the suction inlet enables improved collection of debris drawn by the suction source 22 into the suction inlet.
In the embodiment illustrated in FIGS. 21-23, the agitator 320 includes a plurality of annular agitating members 332, each agitating member 332 defines a plurality of chevron or V-shaped portions extending around the circumference of the agitator 320, where the peak 340 of the V-shape portion is in the direction of one of the first end 324 or the second end 326, and the connection between adjacent V-shape portions is in the direction of the other of the first end 124 or the second end 12. Additionally, adjacent agitating members 332 are arranged such that the direction of the peak 340 of the V-shape portions alternate so that the agitating members 332 are arranged in an X-shape 370 pattern along the circumference of the agitator 320. The arrangement of the agitating members 332 may be modified to increase or decrease the number of X-shaped areas 370 based on desired cleaning performance. In the embodiment illustrated in FIGS. 21-23, adjacent annular agitating member 332 are reinforced by the ribs 334 extending longitudinally along the agitator between the first end 324 and the second end 326. Additionally, the height of the rib between peaks forming the center of the X-shapes may be the same height as that of the agitating member 332.
The flexibility of the agitating members 32, 132, 232, 332 allows for bending and flexing during operation, which may reduce debris wrap around the agitator 20, 120, 220, 320. The agitating members 32, 132, 232, 332 promote surface debris pick-up and inhibit hair and debris wrap around the agitator body 22.
The floor cleaning device 10 is illustrated as an upright floor cleaner including an upper body 28 coupled to the surface cleaning head 12. With further reference to FIG. 1, the surface cleaning head 12 includes the agitator chamber 16, the opening 18 facing the surface to be cleaned, the agitator 20 rotatably mounted within the agitator chamber 16, and the agitator drive 22 for selectively rotating the agitator 20 about the axis 100. In one embodiment, the agitator 20 is removable from the cleaning head 14, for example, to allow an operator to clean, maintain, or replace the agitator 20. The agitator 20 may be removable through a lateral side of the housing 14 or through the bottom opening 18 or through another access location. The floor cleaning device may further include a suction inlet in the surface cleaning head, a suction motor in communication with the suction inlet, a debris separator such as a filter bag, filter, a cyclonic separator, or other debris separator in communication with the suction inlet, and an air outlet downstream of the debris separator. The suction inlet may be integrated with the agitator chamber, or may be separate from the agitator chamber. Although the invention is described for use in an upright floor cleaner, the invention is not limited to only this use. Rather, the invention could be used with other floor cleaning devices such as upright carpet extractors, robot floor cleaners, canister-type cleaners, wet/dry utility vacuum cleaners, hard floor cleaner, and the like.
In one embodiment, the agitating member 32 includes one or more support ribs 67 integral with the agitating member 32. The support ribs 67 extend between the leading side 36 and/or the trailing side 38 and the core 30. In the illustrated embodiments, the support ribs 67 extend along the height H of the agitating members 32 from the core 30 to the outer circumference of the agitator. The support ribs 67 help support, strengthen, and reinforce the agitating member 32. The support of the ribs 67 limits the flexing of the agitating member 32, which improves surface pick up and cleaning performance. In the embodiments illustrated in FIGS. 30-41, the support ribs 67 extend on the leading side 36 of the agitating member 32, in the direction of rotation. In one embodiment, the support ribs 67 extend on the trailing side 38 of the agitating member 32, in the direction opposite of rotation. In one embodiment, the support ribs 67 are spaced from adjacent support ribs by between 2 and 40 millimeters. In another embodiment, the support ribs 67 are spaced from adjacent support ribs by between 5 and 20 millimeters.
In the embodiment illustrated in FIG. 31a, the support ribs 67 extend from the leading side 36 in a forward direction F. In another embodiment (not shown), the support ribs 67 extend at an angle to the forward direction F, and may extend generally perpendicular to the agitating member 32. In one embodiment, the front edges of the support ribs 67 extend at the same angle as the agitating axis 100. Said another way, when looking at a cross-sectional view, the front edges of the support ribs 67 extend roughly parallel to the agitating axis 100 In the embodiment illustrated in FIGS. 30-41, the support ribs 67 extend at an angle 70 to the agitating axis 100. This is illustrated in the cross-sectional views of FIGS. 32, 35, 38, and 41, where the forward edge of the support ribs 67 extend at a rake angle different from the rake angle of the agitating axis 100. In the embodiments illustrated in FIGS. 36-41, the agitating member 32 includes both the plurality of support ribs 67, as well as the flange 65 extending from the agitating member 32.
It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
Patent Application
20210330151
