AGITATOR ELEMENT FOR A VACUUM CLEANER

TECHNICAL FIELD

[0001]The present invention relates to an agitator element for a cleaner head of a vacuum cleaner, as well as to a cleaner head comprising such an agitator element, and to a vacuum cleaner comprising such a cleaner head.

BACKGROUND

[0002]A vacuum cleaner usually comprises a cleaner head having a housing defining a suction chamber. The housing is configured to be moved over a floor or other surface that needs to be cleaned while air is drawn into the suction chamber together with dust, hair, and other dirt that is thereby removed from the surface. An outlet of the housing is coupled to a motor via a wand or hose. The motor provides for the suction needed to generate the airflow through the suction chamber. In many modern vacuum cleaners, the cleaner head comprises one or more brush bars or other types of agitator elements that rotate while the housing moves over the surface to be cleaned. The agitator elements serve to detach dirt from the surface and to increase the chance that it is picked up, thereby improving the cleaning performance of the vacuum cleaner.

[0003]Typically, vacuum cleaner heads experience some degree of hair ingress during use, which means that hair can ingress into or between parts of the cleaner head. Hair can also become wound around the agitator elements which can damage the agitator elements and which can also reduce their ability to detach dirt and hair from the floor, especially if a thick layer of hair becomes wrapped around the agitator elements.

[0004]It is desirable for a vacuum cleaner to pick up as much dirt from the floor surface as possible. It is therefore desirable for the vacuum cleaner head to be able to collect dirt from the edges of a room or furniture so that no part of the floor is left uncleaned.

[0005]It is against this background that the present invention has been developed.

SUMMARY

[0006]In a first aspect, the present invention provides an agitator element for a vacuum cleaner, the agitator element comprising: a support member having opposed first and second end surfaces, and an elongate surface which extends between the first and second end surfaces, wherein the first end surface is located proximate a first end of the agitator element, and wherein the second end surface is located proximate a second end of the agitator element; and agitation material which extends away from the first end surface of the support member such that the outermost extremity of the agitation material defines the outermost extremity of the first end of the agitator element.

[0007]The agitator element of the present invention is advantageous because the agitator material extends beyond the end of the support element meaning that the width of floor that can be cleaned is larger than the elongate width of the support element.

[0008]Optionally the agitation material comprises fabric which covers at least a portion of the first end surface. Many different fabrics with many different aesthetic and functional characteristics may be selected as the agitation material. Fabric may be readily applied to the support element as a full covering, or as a partial covering. Fabric agitation material(s) may be used alone on in combination with other agitation materials such as bristles.

[0009]The first end surface optionally surrounds a recessed portion of the support member. The recessed portion may be a closed ended hole in the support member, or it may a through hole which extends along the full length of the support member.

[0010]At least part of the fabric agitation material may extend from the first end surface into the recessed portion to help secure the fabric to the support member and to avoid peeling or shedding of the fabric from the first end surface.

[0011]In one example, the agitator element comprises a stud located within the recessed portion, wherein an outer portion of the stud engages the fabric agitation material located within the recessed portion to help secure the fabric on the support member. Optionally the stud is integral with the support member for ease of manufacture and to reduce the part count.

[0012]The agitation material optionally comprises a plurality of upstanding bristles either alone, or together with other agitation material(s) such as fabric agitation material.

[0013]The support member may comprise a main body and an end cap having an external surface, wherein the external surface of the end cap defines at least a portion of the first end surface of the support member. The provision of an end cap may help to facilitate rapid assembly of the agitation element. In one example the agitation material may cover the external surface of the end cap.

[0014]Optionally the agitation material extends away from the elongate surface of the support member. At least a portion of the agitation material which extends away from the elongate surface may optionally be continuous with at least a portion of the agitation material which extends away from the first end surface so that the same fabric may be used on the first end surface and on the elongate surface thereby providing continuity of material between the two surfaces.

[0015]The composition of the agitation material which extends away from the elongate surface may be different to the composition of the agitation material which extends away from the first end surface so that agitation material(s) most suited to positioning on the first end surface may be selected independently of the agitation material(s) selected for the elongate surface.

[0016]In one example agitation material extends away from the second end surface of the support member thereby further increasing the effective width of the agitator member. This can be especially useful when two or more agitation members are used end to end as any gap between the agitator members is at least partially spanned by agitation material.

[0017]Optionally the agitation material which extends away from the second end surface comprises fabric which covers at least a portion of the second end surface, wherein the second end surface surrounds a second recessed portion in the support member, and wherein at least part of the fabric agitation material extends from the second end surface into the second recessed portion to help secure the fabric to the support member and to avoid peeling or shedding of the fabric from the second end surface.

[0018]The agitator element optionally tapers from its first end towards its second end, or from its second end towards its first end. Tapered agitator elements are beneficial as any hair or other long fibres which are picked up by the agitator element tend to migrate along the length of the agitator element towards the tapered end where they can be removed. This helps to prevent hair and other long fibres from becoming tightly wrapped around the agitator element.

[0019]In a second aspect, the present invention provides a cleaner head for a vacuum cleaner comprising an agitator element as described above.

[0020]In a third aspect, the present invention provides a cleaner head for a vacuum cleaner, the cleaner head comprising: a housing defining a suction chamber comprising an outlet; and an agitator element as described above mounted for rotation within the housing.

[0021]Optionally the cleaner head comprises a second agitation element, wherein the housing comprises a first side and a second side, and wherein the agitator element is mounted for rotation on the first side of the housing, and the second agitator element is mounted for rotation on the second side of the housing, wherein the respective first or second ends of the agitator elements are located adjacent to one another.

[0022]In a fourth aspect, the present invention provides a vacuum cleaner comprising a cleaner head as described above.

[0023]Features described above in connection with the first aspect of the invention are equally applicable to the second, third and fourth aspects of the invention, and vice versa.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 is a perspective view of an example embodiment of a vacuum cleaner;

[0025]FIG. 2 is a perspective view of the cleaner head of the vacuum cleaner of FIG. 1;

[0026]FIG. 3 is a perspective view of an agitator element of the cleaner head shown in FIG. 1;

[0027]FIG. 4 is a cross-sectional view of the agitator element of FIG. 3;

[0028]FIG. 5 is a perspective view of an alternative agitator element;

[0029]FIG. 6 is a cross-sectional view of the agitator element of FIG. 5;

[0030]FIG. 7 is a cross-sectional view of a further alternative agitator element;

[0031]FIG. 8a is a partial cross-sectional view of an alternative agitator element similar to the agitator element of FIG. 7;

[0032]FIG. 8b is a partial perspective view of the agitator element of FIG. 8a;

[0033]FIG. 9a is a partial cross-sectional view of another alternative agitator element.

[0034]FIG. 9b is a partial perspective view of the agitator element of FIG. 9a;

[0035]FIG. 10a is a partial cross-sectional view of a still further alternative agitator element.

[0036]FIG. 10b is a partial perspective view of the agitator element of FIG. 10a; and

[0037]FIGS. 11a to 11b are partial perspective views of further alternative agitator elements.

DETAILED DESCRIPTION

[0038]FIG. 1 shows a hand-held vacuum cleaner 2 comprising a main body 4, a wand 6 and a cleaner head 20. The main body 4 comprises a separating system 10, in the form of a cyclonic separator, a motor and impeller (not visible) arranged to draw air through the separating system 10, and a power supply 12, in the form of a battery, for powering the motor. The main body 4 has a handle 14 which is gripped by a user, and a clean air outlet 16 through which air that has passed through the separating system 10 is discharged. The wand 6 is attached at one end to the main body 4 and at the other end to the cleaner head 20. The wand 6 provides fluid communication between the cleaner head 20 and the separating system 10 and supports the cleaner head 20 during use.

[0039]FIG. 2 shows the cleaner head 20 of the vacuum cleaner 2. The cleaner head 20 has a housing 32, which at least partially defines a suction chamber comprising an outlet 34 for expulsion of air and debris towards the vacuum cleaner 2. The cleaner head 20 comprises a first agitator element 22 and a second agitator element 24. In this embodiment, the agitator elements 22, 24 are implemented as frustoconical agitator elements 22, 24 as will be described in greater detail below.

[0040]The first and second agitator elements 22, 24 are each mounted for rotation about respective axes R1, R2. Each agitator element 22, 24 comprises a first, free end 26a, 26b and a second end 28a, 28b at which they are mounted to the cleaner head 20. In this embodiment, the agitator elements 22, 24 have a frustoconical shape which tapers towards the first end 26a, 26b in a direction along the axis of rotation R1, R2. Both agitator elements 22, 24 are cantilevered from opposing sides of a hub portion 30 of the cleaner head 20 at their respective second ends 28a, 28b. It should be appreciated that a portion of one or both agitator elements 22, 24 may not be tapered. For example, the shape of one or both agitator elements 22, 24 may consist of a cylindrical portion combined with a frustoconical portion. In other embodiments, the agitator elements 22, 24 may be fully cylindrical.

[0041]In the illustrated embodiment, the hub portion 30 is at a laterally central position with respect to the overall cleaner head 20, although this may not always be the case. For example, if the first and second agitator elements 22, 24 have different lengths, then the hub portion 30 could be offset laterally relative to the laterally central part of the cleaner head 20. The hub portion 30 serves to rotatably support the second ends 28a, 28b of the agitator elements 22, 24 and may comprise a drive housing holding a drive mechanism for rotating the agitator elements 22, 24. In an alternative embodiment, the agitator elements may be cantilevered from separate hubs located at the first ends 26a, 26b of the agitator elements 22, 24, or the agitator elements 22, 24 may be supported by hubs located at both the first 26a, 26b and second 28a, 28b ends of the agitator elements 22, 24.

[0042]FIGS. 3 and 4 show perspective and cross-sectional views respectively of the first agitator element 22. It will be understood that all of the features described hereinbelow with respect to the first agitator element 22 apply equally to the second agitator element 24, and that only the first agitator element 22 is described in detail below for the sake of brevity.

[0043]As best shown in FIG. 4, the agitator element 22 comprises a fabric agitation material 40 which is supported by a support member 50. The support member 50 comprises an elongate surface 53 which extends between a first end surface 51 of the support member 50 located proximate the first end 26a of the agitator element 22 and a second end surface 52 of the support member 50 located proximate the second end 28a of the agitator element 22. The support member 50 has a recessed portion 58 located proximate the first end 26a of the agitator element 22 and a second recessed portion 59 located proximate the second end 28a of the agitator element 22 such that the first and second end surfaces 51, 52 of the support member 50 are annular.

[0044]The fabric agitation material 40 comprises a woven material having a fluffy outer layer 46 and a backing layer 45. The backing layer 45 is attached to the support member 50 with an adhesive such that the whole of the elongate surface 53 and the first and second end surfaces 51, 52 are covered by the agitation material 40. The agitation material is wrapped around the ends of the support member 50 such that the agitation material 40 extends from the first and second end surfaces 51, 52 into the recessed portion 58 and the second recessed portion 59. In an alternative example (not shown), the agitation material 40 may end at the radially innermost edge of the first and/or second end surfaces 51, 52 such that it does not extend into one or both of the recessed portion 58 or second recessed portion 59.

[0045]The agitation material 40 extends away from the elongate surface 53, and away from the first and second end surfaces 51, 52 such that the outermost extremity of the agitation material 40 defines the outermost extremities of the agitator element 22. Consequently, the outermost extremity of the agitation material 40 at the first end 26a of the agitator element 22 defines the outermost extremity 60 of the first end 26a of the agitator element 22, and the outermost extremity of the agitation material 40 at the second end 28a of the agitator element 22 defines the outermost extremity 61 of the second end 28a of the agitator element 22.

[0046]FIGS. 5 and 6 show perspective and cross-sectional views respectively of an alternative arrangement for the agitator element 22. The agitator element 22 of FIGS. 5 and 6 is the same in all respects to the agitator element shown in FIGS. 3 and 4 except in that the agitation material 40 comprises a common backing layer 45 with two differing outer layers 46, 47.

[0047]The outer layers comprise a first outer layer 46 which is the same as the fluffy outer layer 46 of FIGS. 3 and 4, and a second outer layer 47. The material properties of the second outer layer 47 are different to those of the first outer layer 46 so that the agitator element 22 may fulfil two functions at the same time. For example the first outer layer 46 may be selected for its ability to detach dirt, while the second outer layer 47 is selected for its ability to polish.

[0048]The first and second outer layers 46, 47 of the agitator element 22 may comprise any suitable material. For example, both outer layers 46, 47 may be fluffy but with fibres orientated in different directions, and/or with fibres of differing stiffnesses. Alternatively, one of the outer layers may be fluffy while the other is not. It will be understood that the embodiment shown in FIGS. 5 and 6 is an example only and that it is not essential that the fluffy layer be located in the region of the agitator head indicated by reference numeral 46.

[0049]In the embodiment of FIGS. 5 and 6 the two outer layers 46, 47 of the agitation material 40 are woven together with a common backing layer 45. In an alternative example, one or both of the outer layers 46, 47 may be applied to the backing layer 45 with an adhesive. The outer layers 46, 47 may therefore be flocked, or may comprise non-woven materials such as felt or combed natural or synthetic fibres. The backing material 45 may be a woven or non-woven material. For some materials, such as felted materials, there may be no backing layer such that the material is attached directly to the support member 50.

[0050]In an alternative embodiment (not shown), the agitator element 22 may comprise separate pieces of agitation material 40 which do not have a backing layer, or which do not share a common backing layer 45. Such separate pieces may be attached to the support member 50 next to one another so that the whole of the elongate surface 53, and the first and second end surfaces 51, 52 are covered by agitation materials 40. Alternatively only parts of the elongate surface 53, and the first and second end surfaces 51, 52 may be covered by agitation materials 40. In either case, the agitation materials 40 may optionally extend into one or both of the recessed portion 58 or second recessed portion 59

[0051]In a further alternative example, the agitation material or materials 40 may comprise a plurality of upstanding bristles which are supported directly by the support member 50, or which are applied to, or formed with, a backing material 45 of one or more pieces of fabric agitation material 40. Bristles may be used together with, or instead of, fabric agitation material. The bristles may project in any suitable direction from the support member 50.

[0052]The agitator element 22 may comprise any number and/or configuration of agitation materials. The composition of the agitation material 40 on the first and/or second end surfaces 51, 52 may be different to the composition of the agitation material 40 on the elongate surface 53.

[0053]FIG. 7 is a cross-sectional view of a further alternative agitator element 22. The agitator element 22 of FIG. 7 is the same in all respects to the agitator element shown in FIGS. 3 and 4 except in that the support member 50 comprises an integral stud 54 located at the first end 26a of the agitator element 22, and in that the fabric agitation material 40 has been processed at the second end 28a after attachment to the support member 50.

[0054]As shown, the stud 54 is connected to the main body of the support member 50 by an annular wall 55 thereby defining an annular recessed portion 58 at the first end 26a of the agitator element 22 between the stud 54 and the main body of the support element 50. The agitator material 40 extends from the first end surface 51 into the annular recessed portion 58 such that an outer portion 56 of the stud engages the fabric agitation material located within the recessed portion 58. Because the radial depth of the annular recessed portion 58 is less than the thickness of the agitation material 40, the fluffy outer layer 46 of the agitation material 40 is compressed within the annular recessed portion 58. This compression may be sufficient to hold the agitation material 40 in the annular recessed portion 58. Alternatively or additionally, an adhesive and/or retaining formations may be formed in the surfaces of the recessed annular portion 58 to help hold the agitation material 40 in place.

[0055]The agitation material 40 at the second end 58a of the agitator element 22 has been processed after it has been attached to the support member 50 by removal of the outer layer 46 of the agitation material 40 from within the second recessed portion 59. The backing layer 45 remains in place within the second recessed portion 59. In an alternative example, the backing layer may also be removed during the process.

[0056]It will be understood that an annular recessed portion can be provided at the second end 28a of the agitator element 22 as well as at the first end 26a by provision of an integral stud at the second end 28a. Similarly, some or all of the agitation material 40 may be removed from within the recessed portion at the first end 26a of the agitator element 22 whether or not the recessed portion at the first end 26a is annular as shown in FIG. 7 or non-annular as shown in FIGS. 3 to 6.

[0057]FIGS. 8a and 8b show partial cross-sectional and perspective views respectively of an alternative arrangement for the first 26a and/or second 28a end of the agitator element. Although the first end 26a of the agitator element is illustrated in FIGS. 8a and 8b, it will be understood that the same arrangement could also, or alternatively, be used at the second end 28a.

[0058]The first end 26a of the agitator element 22 shown in FIGS. 8a and 8b is the same in all respects to the agitator element shown in FIG. 7 except in that a separate stud 70 is used in place of the integral stud 54. The stud 70 is positioned in the recessed portion 58 after the agitation material 40 has been applied to the support element 50 and clipped into place by engagement of a clip formation 72 at the innermost end of the stud 70 and annular wall 55. The outermost end of the stud 70 comprises a radially extending lip 71 which compresses the agitation natural 40 between the edge of the lip 71 and the main body of the support member 50. The agitation material 40 located in the recessed portion 58 may be held in place by the stud 60 alone or an adhesive may be used together with the stud 70.

[0059]FIGS. 9a and 9b show partial cross-sectional and isometric views respectively of another alternative arrangement for the first 26a and/or second 28a end of the agitator element. Although the first end 26a of the agitator element is illustrated in FIGS. 9a and 9b, it will be understood that the same arrangement could also, or alternatively, be used at the second end 28a.

[0060]In this example, the support member 50 comprises a main body 49 and an end cap 75. The main body 49 of the support member 50 is covered with agitation material and the outer end 76 of the end cap 75 is covered with agitation material 40. The end cap 75 is held in place by a clip formation 77 located at the innermost end of the end cap 75. The clip formation 77 engages with an annular wall 57 located at the outermost end of the main body 49.

[0061]In an alternative arrangement to the arrangement shown in FIGS. 9a and 9b, the end cap 75 may comprise a recessed portion such that the first end 26a of the agitator element resembles the first end 26a illustrated in FIGS. 8a and 8b.

[0062]FIGS. 10a and 10b show partial cross-sectional and isometric views respectively of a still further alternative arrangement for the first 26a and/or second 28a end of the agitator element. Although the first end 26a of the agitator element is illustrated in FIGS. 10a and 10b, it will be understood that the same arrangement could also, or alternatively, be used at the second end 28a.

[0063]In this example, the support member 50 comprises a wall 63 located at its outermost end proximate the first end 26a of the agitator element wherein the outermost surface of the wall 63 comprises the first end surface 51 of the support member 50. The elongate surface 53 of the support member is covered by a first agitation material 40 and the first end surface 51 is covered by a second agitation material 48. Alternatively, the agitation material on the first end surface 51 may be the same as the agitation material on the elongate surface 53.

[0064]An annular rim 64 surrounds the covered portion of the first end surface 51 such that a portion of the support element 50 is not covered by agitation material 40, 48. This is not essential and in another example the agitation material 40, 48 may cover all of the first end surface 51.

[0065]FIGS. 11a and 11b are partial perspective views of further alternative arrangements for the first 26a and/or second 28a end of the agitator element. Although the first end 26a of the agitator element is illustrated in FIGS. 11a and 11b, it will be understood that the same arrangement could also, or alternatively, be used at the second end 28a.

[0066]In the example of FIG. 11a only a portion of the first end surface 51 of the support member is covered by agitation material 40, and in the example of FIG. 11b a plurality of bundles of upstanding bristles 90 extend away from the first end surface of the support member which the elongate surface is covered by a fabric agitation material 40.