VACUUM CLEANER WITH DUAL ROTATING AGITATORS AND DUAL COMBS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]The present application claims the benefit of U.S. Provisional Application No. 63/717,327, filed Nov. 7, 2024, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002]Vacuum cleaners generally include a suction conduit with an opening on the underside of a surface cleaning base for drawing air and debris into and through the cleaning base. A goal with vacuum cleaner design is to effectively loosen debris and capture the debris in the flow of air into the suction conduit. Vacuum cleaners generally use an agitator to aid in this goal. An agitator is often used in the suction conduit of a cleaning base proximate a suction inlet to cause agitated debris to flow into the suction conduit. If the agitator is unable to loosen the debris or if the debris is too small, the suction conduit may pass over the debris without removing the debris from the surface. In other cases, the surface cleaning head may push or plow larger debris forward without ever allowing the debris to be captured in the flow into the suction conduit. To combat these issues, some vacuum cleaners have dual agitators, with a front or leading agitator configured to prevent plowing of larger debris without scattering smaller debris and a rear or trailing agitator located in the suction conduit.

[0003]One challenge with a rotating agitator is that debris (e.g., hair, threads, other elongated debris) may become entangled around the agitator. Some solutions have been proposed for single agitator vacuum cleaners, but it remains challenging to implement a solution on a dual agitator vacuum cleaner. As such, there exists a need for a vacuum cleaner that can generally reduce and/or prevent debris from becoming entangled around dual agitators.

BRIEF SUMMARY

[0004]A vacuum cleaner with dual agitators and combs is provided herein.

[0005]According to one aspect of the disclosure, a vacuum cleaner includes a housing defining a main agitator chamber and a suction conduit with a suction conduit opening on an underside of the housing, a main agitator rotatably mounted to the housing within the main agitator chamber with at least a portion of the main agitator extending through the suction conduit opening, a leading agitator mounted to the housing in front of the main agitator, and an agitator cover on the housing. The agitator cover at least partially covers the main agitator and includes a first wall defining a portion of the main agitator chamber and spaced outwardly from the main agitator, the first wall having an inner surface confronting an outer surface of the main agitator, a first comb contacting the main agitator above a main agitator axis, and a second comb contacting the leading agitator above a leading agitator axis.

[0006]In this and other aspects of the disclosure, the second comb is in front of the first comb.

[0007]In this and other aspects of the disclosure, one or both of the combs include a plurality of teeth extending toward the associated agitator.

[0008]In this and other aspects of the disclosure, the main agitator axis is spaced farther from the surface to be cleaned than the axis of leading agitator.

[0009]In this and other aspects of the disclosure, the point of contact between the first comb and the main agitator is above the main agitator axis and the point of contact between the second comb and the leading agitator is above the leading agitator axis.

[0010]In this and other aspects of the disclosure, the first comb is spaced farther from the surface to be cleaned than the second comb.

[0011]In this and other aspects of the disclosure, the agitator cover is interior to the housing and/or is not configured for disassembly from the housing by the user.

[0012]In this and other aspects of the disclosure, the first and second combs are joined by the first wall.

[0013]In this and other aspects of the disclosure, the agitator cover at least partially covers the leading agitator and defines at portion of a leading agitator chamber in which the leading agitator is at least partially mounted.

[0014]In this and other aspects of the disclosure, the agitator cover is a unitary, monolithic part including at least the first wall, the first comb, and the second comb.

[0015]In this and other aspects of the disclosure, a sole plate is removably attached on an underside of the housing, and is removable from the housing to permit access to at least the main agitator.

[0016]According to still another aspect of the disclosure, a method for user disassembly of a vacuum cleaner with dual agitators and dual combs is provided herein.

[0017]According to still another aspect of the disclosure, a method for servicing a vacuum cleaner with dual agitators and dual combs is provided herein.

[0018]These and other features and advantages of the present disclosure will become apparent from the following description of particular embodiments, when viewed in accordance with the accompanying drawings and appended claims.

[0019]Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. In addition, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

DESCRIPTION OF THE DRAWINGS

[0020]FIG. 1 is a side sectional view of a cleaning base for a vacuum cleaner with dual agitators and dual combs according to one aspect of the disclosure;

[0021]FIG. 2 is a front perspective view of the vacuum cleaner of FIG. 1;

[0022]FIG. 3 is a bottom perspective, partially exploded view of the cleaning base of FIG. 1 showing a sole plate and the agitators disassembled from the cleaning base;

[0023]FIG. 4 is an enlarged perspective sectional view of a portion of the cleaning base FIG. 1;

[0024]FIG. 5 is an enlarged view of a portion of FIG. 1 showing the clearances and orientations of the agitators and combs relative to each other and relative to the surface to be cleaned, according to one aspect of the disclosure;

[0025]FIG. 6 is an enlarged view of a portion of FIG. 1 showing details of the main agitator and main agitator comb according to one aspect of the disclosure; and

[0026]FIG. 7 is an enlarged view of a portion of FIG. 1 showing details of the leading agitator and leading agitator comb according to one aspect of the disclosure.

BRIEF DESCRIPTION

[0027]The invention generally relates to a vacuum cleaner with dual agitators and dual combs. The combs are configured to remove debris (such as, but not limited to, hair, string, and the like) that may be wrapped around and/or entrained in/on the agitators, and prevent damage to the agitators as a result. Aspects of the disclosure described herein further relate to a cleaning base with dual agitators and dual combs. Aspects of the disclosure described herein also relate to a vacuum cleaner or a cleaning base with a single internal plastic component is capable of extending comb features to dual agitators simultaneously.

[0028]As used herein, a “cleaning base” refers to a device configured to contact a surface for cleaning the surface by use of suction air flow, agitation, or a combination thereof. A cleaning base may be coupled with an upright body, wand, or handle for directing the base across the surface to be cleaned, and may be pivotably or steeringly coupled by a swivel connection to an upright body, wand, or handle. A cleaning base may also be operable without an upright body, wand, or handle.

[0029]As used herein, “seal” or “sealing” refers to preventing a substantial amount of air from passing through to the suction conduit but does not require an airtight seal.

[0030]As used herein, “agitator” refers to any element, member, or structure capable of agitating a surface to facilitate movement of debris into a suction air flow in a surface cleaning base.

[0031]As used herein, “soft” and “softer” refer to the characteristics of a cleaning element being more compliant or pliable than another cleaning element.

[0032]As used herein, the term “flow path” refers to the path taken by air as it flows into a suction conduit when drawn in by suction.

[0033]As used herein, the terms “above” and “below” and derivatives thereof are used relative to an orientation of the surface cleaning head on a surface to be cleaned and the terms “front” and “back” and derivatives thereof are used relative to a direction that a user pushes the surface cleaning base on a surface being cleaned (i.e., back to front).

[0034]As used herein, the term “leading” refers to a position in front of at least another component but does not necessarily mean in front of all other components.

[0035]As used herein, the term “user disassembly” refers to intentional disassembly by an end user of the vacuum cleaner without the user of destructive forces, including disassembly with or without the use of commonplace household tools. Unless otherwise noted, user disassembly of components from the vacuum cleaner includes the ability for such components to be reassembled to the vacuum cleaner.

[0036]As used herein, the term “debris” includes dirt, soil, dust, hair, stains, and other debris, unless otherwise noted.

[0037]Referring to FIGS. 1-2, a vacuum cleaner 10 according to one aspect of the present disclosure is shown and described. As discussed in further detail below, the vacuum cleaner 10 has a cleaning base 12 having dual agitators and dual combs, which are described in further detail below. The vacuum cleaner 10 can include at least one cleaning system, including, but not limited to, a vacuum collection system that removes debris from the surface to be cleaned and stores the collected debris within the vacuum cleaner 10.

[0038]The cleaning base 12 is adapted to move over a surface to be cleaned and includes a housing 14 with a front side 16F, and a back side 16B, left and right sides 18L, 18R, an upper side 20, and a lower or underside 22 between the front side 16F and the back side 16B. The housing 14 defines a brush chamber 24 and a suction conduit 26 having an opening 28 on the underside 22 of the housing 14. The housing 14 may comprise a single housing piece, or multiple housing pieces coupled together.

[0039]The suction conduit 26 is fluidly coupled to a dirty air inlet 30, which leads to a suction motor 32 (shown schematically in FIG. 2) either in the base 12 or another location in the vacuum cleaner 10. The suction conduit 26 is the interior space defined by interior walls in the housing 14, which receives and directs air drawn in by suction, and the opening 28 is where the suction conduit 26 meets the underside 22 of the housing 14. The suction conduit 26 can pass through at least a portion of the brush chamber 24. Although an embodiment of the housing 14 is described herein for illustrative purposes, the housing 14 and components thereof may have other shapes and configurations.

[0040]The cleaning base 12 includes dual agitators, for example, a first or main agitator 34 and a second or leading agitator 36 configured to rotate about rotating axes X, Y, respectively, that generally extend perpendicular to the intended direction of the vacuuming movement of the cleaning base 12 and/or generally parallel to the front side 16F. In at least some embodiments, the main agitator 34 is a brushroll 34 and the leading agitator 36 is a leading roller 36, and will be referred to herein as such, although it is understood that alternative agitators are possible. The rotating brushroll 34 and/or the leading roller 36 may be coupled to, and rotated about the rotating axes, by one or more motors.

[0041]The cleaning base 12 includes dual combs, for example, a first or main agitator comb 38 and a second or leading agitator comb 40, configured to remove debris (such as, but not limited to, hair, string, and the like) that may be wrapped around and/or entrained in/on one or more of the agitators as the cleaning base 12 is being operated to clean a surface and without the user having to manually remove the debris from the agitators. For example, a first comb 38 may be configured to contact the brushroll 34 and a second comb 40 may be configured to contact the leading roller 36. Debris removed by the combs 38, 40 may be release into the suction conduit 26 or another portion of the flow path F.

[0042]Referring to FIG. 2, and consistent with an embodiment of the present disclosure, the vacuum cleaner 10 can be an upright vacuum cleaner having upright body 42 coupled with the cleaning base 12 to direct the base 12 over the surface to be cleaned. The various systems and components described for the vacuum cleaner 10 can be supported by either or both the base 12 and the upright body 42, except where expressly specified to the contrary. Alternatively or additionally to the upright body 42, the vacuum cleaner 10 can have a wand and/or handle.

[0043]The vacuum collection system can include the suction conduit 26, the dirty air inlet 30, the suction motor 32, which is in fluid communication with the suction conduit 26 for generating a working air stream, a collection container 44 for separating and collecting debris from the working airstream for later disposal, and a clean air outlet (not shown). When the suction motor 32 is activated, debris-laden working air is drawn in through the suction conduit 26 and into the downstream collection container 44, where the debris is substantially separated from the working air. The airstream then passes through the suction motor 32 prior to being exhausted from the vacuum cleaner 10 through the clean air outlet.

[0044]A separator (not shown) can be formed in a portion of the collection container 44 for separating entrained debris from the working airstream. The separator can include, but is not limited to, a cyclonic separator having one or more cyclonic separation stages, a bulk separator, a filter bag, or a combination thereof. The collection container 44 can be removable from the upright body 42 or from the base 12 for emptying collected debris.

[0045]The suction motor 32 and other electrical components of the vacuum cleaner 10 can be electrically coupled to a power source, such as a power cord 46 plugged into a household electrical outlet. Alternatively, the power source may be a battery. While not shown for clarity, the vacuum cleaner 10 may also include one or more controllers and/or sensors disposed within and/or coupled to the upright body 42 or the base 12.

[0046]Referring to FIG. 1, a cross-sectional view of a portion of the base 12 is shown on a surface to be cleaned S. The brushroll 34 is mounted to the housing 14 within the brush chamber 24, and can be at least partially disposed within the suction conduit 26, which can pass through at least a portion of the brush chamber 24. The brushroll 34 is exposed to the flow path (e.g., arrows F) into the opening 28 and through the suction conduit 26. At least a portion of the brushroll 34 can extend through the suction conduit opening 28 to engage the surface to be cleaned. In some embodiments, the suction conduit 26 can also define at least a portion of the brush chamber 24 itself, including, but not limited to, a lower portion of the brush chamber 24.

[0047]The leading roller 36 is mounted to the housing 14 in front of the brushroll 34. The leading roller 36 can preferably be positioned in front of and spaced from the brushroll 34 and at least substantially outside the suction conduit 26. In certain embodiments, at least some of the inner upper portion of the leading roller 36 may not be exposed to the flow path F into the opening 28 of the suction conduit 26 while at least an inside of the bottom portion of the leading roller 36 is exposed to the flow path F into the opening 28 of the suction conduit 26. The leading roller 36 is received in a leading roller chamber 48, which may prevent portions of the inside upper quadrant of the leading roller 36 from being exposed to the flow path F. Other variations are possible with different portions of the leading roller 36 being exposed and not exposed to the flow path. A space between lower portions of the leading roller 36 and the brushroll 34 forms an inter-agitator air passageway 50 that may provide at least a portion of the flow path F into the opening 28 of the suction conduit 26 and allow debris to be carried into the suction conduit 26.

[0048]The housing 14 is open at the front side 16F such that a debris opening 52 is defined by a clearance between a lower end of the front side 16F and the surface S, wherein the clearance is greater than 0 mm, and optionally less than 15 mm, alternatively less than 11 mm. A space between an outside of the bottom portion of the leading roller 36 and the debris opening 52 forms a debris passageway 54 that allows debris to pass into the housing 14 and not be pushed or plowed forward. The roller 36 can substantially seal the debris passageway 54 from the flow path F into the opening 28 of the suction conduit 26 to mitigate, or prevent, suction loss at the front side 16F of the housing 14. As discussed further below, in at least some embodiments the roller 36 is soft or compressible to roll over the debris that enters through the debris opening 52.

[0049]The leading roller 36 may be positioned within the housing 14 such that a bottom contact surface 56 thereof is disposed closer to the surface S compared to a bottom contact surface 58 of the brushroll 34. This arrangement allows the leading roller 36 to contact a surface (e.g., a solid surface) without the brushroll 34 contacting the surface. The brushroll 34 is intended to primarily contact a carpet surface This arrangement allows the leading roller 36 to form a seal with the hard surface, thereby enhancing airflow and suction with the hard surface. As may be appreciated, the leading roller 36 may pick up some debris from surface while the brushroll 34 is intended to primarily move debris into the suction conduit 26.

[0050]The brushroll 34 may have bristles, fabric, or other cleaning elements, or any combination thereof around the outside of the brushroll 34. The size and shape of the bristles may be selected based on the intended application. For example, the brushroll 34 may include bristles having a length of between 15-19 mm, alternatively around 17 mm, and may be grouped in tufts having a diameter of around 6 mm at the outer end of the tuft. The bristles may be made on any material such as, but not limited to, nylon.

[0051]The leading roller 36 may include a relatively soft material (e.g., soft bristles, fabric, felt, nap, or pile). The leading roller 36 may be selected to be substantially softer than the brushroll 34. The softness, length, diameter, arrangement, and resiliency of the bristles and/or pile of the leading roller 36 may be selected to form a seal with a hard surface (e.g., but not limited to, a hard wood floor, tile floor, laminate floor, or the like), whereas the bristles of the brushroll 34 may selected to agitate carpet fibers or the like. Softness may be determined, for example, based on the pliability of the bristles or pile being used.

[0052]The size and shape of the bristles and/or pile for the leading roller 36 may be selected based on the intended application. For example, the leading roller 36 may include pile having a length of between 8-12 mm, alternatively around 10 mm, and may have a diameter of 0.01-0.04 mm. The pile may be made of any material such as, but not limited to, microfiber, silk, cotton, wool, synthetic fibers, or a combination of materials.

[0053]The leading roller 36 may have an outside diameter DL that is smaller than the outside diameter DB of the brushroll 34. For example, the roller diameter DL may be greater than zero and less than 1× the brushroll diameter DB, or in the range of 0.5× to 0.75× the brushroll diameter DB. As an illustrative example, the brushroll 34 may have an outside diameter of 50-80 mm, alternatively 57-70 mm, alternatively 67 mm and the leading roller 36 may have an outside diameter of 40-50 mm, alternatively 45 mm. In other embodiments, the roller diameter DL may be equal to or greater than the brushroll diameter DB.

[0054]In at least one embodiment, the brushroll 34 and the leading roller 36 rotate in the same direction, for example counterclockwise when viewed from the perspective of FIG. 1. The brushroll 34 and the leading roller 36 may rotate at same speed or at different speeds.

[0055]Referring to FIG. 3, the brushroll 34 and roller 36 are driven to rotate by at least one drive mechanism. In one non-limiting example of a drive mechanism, the brushroll 34 may be coupled to an electrical motor 60 (either AC or DC) to cause the brushroll 34 to rotate. The drive motor 60 is shown in phantom line in FIG. 3 and may be housed within the cleaning base 12.

[0056]A drive transmission can operably connect the motor 60 with the brushroll 34 and can comprise one or more drive belts, pulleys, gears, or the like for transmitting rotational motion of the motor 60 to the brushroll 34. The leading roller 36 may be driven from the same drive mechanism (e.g., motor 60) used to drive the brushroll 34, and may be coupled with the brushroll 34 by way of or more drive belts, pulleys, gears, or the like. Other drive mechanisms are possible and within the scope of the present disclosure. For example, the leading roller 36 may be rotated by a different motor.

[0057]According to an embodiment, the cleaning base 12 includes a sole plate 62 removably attached on the underside 22 of the housing 14. The sole plate 62 defines at least a portion of the suction conduit 26, for example at least a portion of the opening 28 on the underside 22 of the housing 14. The sole plate 62 can be fully removable from the housing 14, or may be partially removable, such as by being hingedly coupled with the housing 14. The sole plate 62 faces the surface to be cleaned S (e.g., the floor, FIG. 4) when in a working position.

[0058]According to some embodiments, the sole plate 62 is removable by the use of simple tools, such as a screwdriver, or without the use of tools. The removability of the sole plate 62 with simple or no tools allows for the user of the vacuum cleaner 10 to clean, service, and/or replace components of the cleaning base 12, rather than having a service expert perform such operations. For example, removable of the sole plate 62 can permit access to one or more of the brushroll 34, roller 36, brush chamber 24, suction conduit 26, leading roller chamber 48, combs 38, 40, and/or agitator drive mechanism(s). In one embodiment, the sole plate 62 is attached on the underside 22 of the housing 14 by one or more fasteners, e.g., screws (not shown).

[0059]The sole plate 62 can secure the brushroll 34 in a working position on the housing 14. As described in further detail below, in one embodiment the leading roller 36 can be removed from housing 14 without removing the sole plate 62, although in other embodiments the sole plate 62 can also secure the roller 36 in a working position on the housing 14.

[0060]FIG. 3 shows one example of a user disassembly process for the cleaning base 12. The cleaning base 12 is configured so that the user can disassemble one or more parts for access, maintenance, and/or replacement. For example, the brushroll 34, the leading roller 36, the sole plate 62, or any combination thereof, may be removable from the base 12, such as by being removably mounted to the housing 14 of the base 12. In one non-limiting example, the brushroll 34, the leading roller 36, and the sole plate 62, may be removable from the housing 14 of the base 12 without removal or disassembly of the combs 38, 40.

[0061]For example, to remove the leading roller 36, one end of the roller 36 may be unsecured/uncoupled from the rest of the housing 14, thereby allowing the other end of the leading roller 36 to disengage from a drive coupling 64, which is operably coupled with the motor 60, and allowing the leading roller 36 to be removed from a leading roller chamber 48. One embodiment of a roller release mechanism for releasing the leading roller 36 from the housing 14 of the cleaning base 12 includes a user accessible push button 66, which may be located on either side 18R, 18L of the housing 14. To remove the leading roller 36, the user may apply a force to the push button 66 to disengage an internal block (not shown) from mechanical engagement with the roller 36, thereby allowing the leading roller 36 to be removed from the chamber 48. Other ways of removably coupling the leading roller 36 within the housing 14 are also possible and within the scope of the present disclosure, including, but not limited to, requiring removal of the sole plate 62 prior to removal of the leading roller 36.

[0062]To remove the brushroll 34, the sole plate 62 is detached from the housing 14 (e.g., by unscrewing fasteners). Next, the brushroll 34 can be removed from the housing 14. For example, to remove the brushroll 34, one end of the brushroll 34 may be unsecured/uncoupled from the rest of the housing 14, thereby allowing the other end of the brushroll 34 to disengage from a drive coupling 68, which is operably coupled with the motor 60, and allowing the brushroll 34 to be removed from the brush chamber 24 and suction conduit 26. Other ways of removably coupling the brushroll 34 within the housing 14 are also possible and within the scope of the present disclosure.

[0063]According to another aspect of the disclosure, a method of user disassembly may comprise providing any of the devices described herein, removing the sole plate 62, and removing the brushroll 34, where one or both of the combs 38, 40 remain in place on the housing 14. Optionally, the method further comprises removing the leading roller 36 before removing the sole plate 62. The removing may optionally comprise unscrewing the sole plate 62 from the underside 22 of the housing 14.

[0064]In one embodiment, the sole plate 62 includes a rear frame wall 70, a left side frame wall 74 and a right side frame wall 76, which can form a generally U-shaped frame that is open toward the front. The U-shaped frame is beneficial for a dual agitator cleaning base since the sole plate 62 does not block or impede airflow through the inter-agitator air passageway 50. Although an embodiment of the sole plate 62 is described herein for illustrative purposes, the sole plate 62 may have other shapes and configurations.

[0065]The suction conduit opening 28 to the suction conduit 26 can be bordered by the rear frame wall 70 and the side frame walls 74, 76, and the space between the frame walls 70, 74, 76, can define the opening 28. The rear frame wall 70 can have a leading edge 72 that defines a rear peripheral edge of the suction conduit opening 28. The rear frame wall 70 can, in some embodiments, extend partially below the brushroll 34 (see FIG. 1).

[0066]The cleaning base 12 may include one or more wheels 80, 82 for supporting the housing 14 on the surface to be cleaned and maneuvering the vacuum cleaner 10 over a surface to be cleaned. In one embodiment one set of wheels 80 is mounted to the sole plate 62 for rollably supporting the cleaning base 12 on the surface to be cleaned and a set of larger wheels 82 is mounted at or near the back side 18 of the housing 14. Other arrangements for the wheels of the vacuum cleaner 10 are possible.

[0067]The wheels 80, 82 may provide the primary contact with the surface being cleaned and thus primarily support the cleaning base 12. When the cleaning base 12 is positioned on the surface being cleaned, the sole plate 62 may sit above the surface being cleaned (see FIG. 1). When the cleaning base 12 is positioned on the surface being cleaned, the leading roller 36 may also rest on the surface being cleaned. In other embodiments, the leading roller 36 may be positioned such that the leading roller 36 sits just above the surface being cleaned.

[0068]According to an embodiment, a sealing strip 84 is located on the sole plate 62 on a rear side of the opening 28 to the suction conduit 26. The sealing strip 84 may contact the surface to be cleaned behind the brushroll 34 to seal against the surface together with the leading roller 36 contacting the surface in front of the brushroll 34. The sealing strip 84 may include soft bristles, fabric material, rubber material, or other material capable of contacting the surface being cleaned to substantially prevent air flow into the opening 28 from the rear side. The sealing strip 84 may also include a combination of elements or materials. The sealing strip 84 may enhance sealing between the base 12 and the floor, thereby enhancing the vacuum efficiency. Providing the sealing strip 84 on the removable sole plate 62 allows the sealing strip 84 to be cleaned, serviced, or replaced conveniently. In one embodiment, the sealing strip 84 extends from the rear frame wall 70 of the sole plate 62, and can be disposed on the rear frame wall 70 adjacent the leading edge 72. Other arrangements for the sealing strip are possible.

[0069]In one embodiment, to secure the brushroll 34 in a working position on the housing 14, the sole plate 62 may include at least one cradle 86 that presses against a non-rotating portion of the brushroll 34 to support the brushroll 34 horizontally and holds the brushroll 34 in its working position within the brush chamber 24 and/or suction conduit 26.

[0070]Referring to FIG. 4, in one aspect of the disclosure, the cleaning base 12 includes an agitator cover 88 on the housing 14. The agitator cover 88 at least partially covers the brushroll 34 and includes the agitator combs 38, 40.

[0071]In addition, the cover 88 can have at least one wall, such as a first wall 90, defining a portion of the brush chamber 24 and spaced outwardly from the brushroll 34. The first wall 90 can have an inner surface 92 confronting an outer surface 94 of the brushroll 34. The first wall 90 may be spaced outwardly from at least one of a top side of the brushroll 34 and a leading side of the brushroll 34. A gap may be present between the inner surface 92 of the wall 90 and the outer surface 94 of the brushroll 34 to prevent debris from getting stuck between the fixed wall 90 and rotating brushroll 34. In order to maintain suction performance within the suction conduit 26, the gap is preferably small, for example about 2 to 4 mm, alternatively 3 mm or less.

[0072]In addition, the cover 88 can at least partially cover the roller 36. For example, the cover 88 can have a second wall 96, defining a portion of the roller chamber 48 and spaced outwardly from the roller 36. The second wall 96 can have an inner surface 98 confronting an outer surface 100 of the roller 36. The second wall 96 may be spaced outwardly from at least one of a top side of the roller 36 and a trailing side of the roller 36. A gap may be present between the inner surface 98 of the wall 96 and the outer surface 100 of the roller 36, and the gap is preferably smaller than the gap around the brushroll 34, for example 1.0 mm or less alternatively around 0.25 mm.

[0073]Referring to FIG. 1, the second wall 96 can separate at least an upper portion of the roller 36 from an upper portion of the brushroll 34, such that the upper portion of the roller 36 is substantially outside of the flow path F to the suction conduit 26.

[0074]The combs 38, 40 can be coupled to the first wall 90 of the cover 88. In one embodiment, the first and second combs 38, 40 are joined by the wall 90, with the first comb 38 at a rear end 102 of the wall 90 and the second comb 40 at a forward end 104 of the wall 90.

[0075]In one aspect, the cover 88 comprises a unitary, monolithic part including at least the first wall 90, the first comb 38, and the second comb 40. The unitary, monolithic part can also include the second wall 96. The unitary, monolithic part can also have mounting features for the cover, for example screw bosses 106 used for attaching the cover 88 by the fasteners to the housing 14. Additional features for the unitary, monolithic part are possible.

[0076]In the illustrated example, the combs 38, 40 are integrally formed with the cover 88 and, thus, would be considered as being “coupled to the wall 90” during the formation process of the cover 88, which can, for example, be an injection molding process or an additive manufacturing process. The cover 88 can be formed from a rigid plastic that can maintain its shape during operation of the vacuum cleaner. Other materials and manufacturing techniques are possible.

[0077]Referring to FIG. 4, the cover 88 can have a rear edge 108 that mates with a main chamber wall 110, the main chamber wall 110 defining an inner surface 112 of the main agitator chamber 24. At least a portion of the inner surface 112 can be rearward of the main agitator axis X, such that the main chamber wall 110 forms an upper rear section of the chamber 24. As shown in FIG. 1, the main chamber wall 110 can further extend to and/or form the dirty air inlet 30. For example, the main chamber wall 110 can define or mate with an upper edge of the dirty air inlet 30. A lower edge of the dirty air inlet 30 can be defined by or may mate with the sole plate 62.

[0078]The first wall 90 and main chamber wall 110 can be curved and can mate to form a substantially continuous inner surface of the brush chamber 24 (e.g., formed by at least inner surfaces 92 and 112). The first wall 90 can curve from the first comb 38 downwardly and forwardly to the second comb 40. The inner surface 92 of the first wall 90 can curve and meet the inner surface 112 of the chamber wall 110.

[0079]The cover 88 can have a forward edge 114 that mates with a leading chamber wall 116, the leading chamber wall 116 defining an inner surface 118 of the leading agitator chamber 48. At least a portion of the inner surface 118 can be forward of the leading agitator axis Y, such that the leading chamber wall 116 forms an upper front section of the chamber 48. As shown in FIG. 1, the leading chamber wall 116 can further extend to and/or form the debris opening 52 or a portion of the debris passageway 54.

[0080]The second wall 96 and leading chamber wall 116 can be curved and can mate to form a substantially continuous inner surface of the leading chamber 48 (e.g., formed by at least inner surfaces 98 and 118). The second wall 96 can curve from the second comb 40 upwardly and forwardly to meet the wall 116 of the leading agitator chamber 48. One or both of the inner surfaces 98, 118 can lie in close relationship to the outer surface 100 of the roller 36, which can help limit airflow in the roller chamber 48.

[0081]In one aspect, the cover 88 is interior to the housing 14 of the base 12. For example, the housing 14 can have an exterior cover part 120 defining an exterior surface 122 of the vacuum cleaner 10. The exterior surface 122 may be, for example, an upper exterior surface defining the upper side 20 of the base 12. The exterior cover part 120 is attached over the cover 88 to enclose the cover 88 within the interior of the housing 14. The cover 88 may be fastened to the exterior cover part 120 by one of more fasteners (not shown), optionally using the screw bosses 106 if present. The exterior cover part 120 can form other features of the base 12, including, but not limited to, the main chamber wall 110. The use of an exterior cover part 120 allows the inner cover 88 to be optimized for performance (e.g., with combs 38, 40 and/or with walls 90, 96 of the agitator chambers) while the exterior cover part 120 can be selected based on aesthetics. Additionally, if the combs 38, 40 become damaged, the cover 88 can be replaced without having to replace the outer cover part 120. In another embodiment, the cover 88 can form an exterior surface of the base 12.

[0082]It is noted that in the present embodiment, the cover 88 is not configured for removal or disassembly by the user. Instead, components of the cleaning base that may need cleaning, servicing, and/or replacement are accessible from the underside of the base 12, with removal of the sole plate 62 permitting access to one or more of the brushroll 34, roller 36, brush chamber 24, suction conduit 26, leading roller chamber 48, and/or agitator drive mechanism(s). In another embodiment, the cover 88 can be removable from the housing 14 by the user.

[0083]Referring to FIG. 4, an embodiment of the agitator combs 38, 40 is shown and may include a plurality of teeth 124, 126 (e.g., spaced projections or tines). The plurality of teeth 124, 126 may provide numerous contact points with the brushroll 34 and roller 36, respectively, to remove debris therefrom, while also reducing potential damage to the bristles and/or pile thereof. The leading comb 40 may also help prevent air flow to a top of the leading roller 36 such that the top of the leading roller 36 is not exposed to the flow path F to the suction conduit 26.

[0084]The comb 38 for the brushroll 34 may be located within the brush chamber 24 and/or within the suction conduit 26, such that the teeth 124 contact the brushroll 34 in a region where bristles 128 of the brushroll 34 are moving generally upward (e.g., away from the surface S) and/or forwardly (e.g., toward the front side 16F of the base 12). For example, the comb 38 may be disposed above an upper portion of the dirty air inlet 30. In at least one embodiment, the brushroll 34 may be removable from the housing 14 and the comb 38 may be coupled to the housing 14 such that the comb 38 remains with the housing 14 when the brushroll 34 is removed.

[0085]The comb 40 for the roller 36 may be located within the roller chamber 48, such that the teeth 126 contact the roller 36 in a region where a pile 130 of the roller 36 is moving generally upward (e.g., away from the surface S) and/or forwardly (e.g., toward the front side 16F of the base 12). For example, the comb 40 may be disposed proximate to an upper rear portion of the chamber 48. In at least one embodiment, the roller 36 may be removable from the housing 14 and the comb 40 may be coupled to the housing 14 such that the comb 40 remains with the housing 14 when the roller 36 is removed.

[0086]The teeth 124, 126 are spaced from each other and extend from a respective supporting surface, which in the embodiment shown comprises the inner surface 92 of the first wall 90 and the inner surface 98 of the second wall 96, respectively. As such, the supporting surfaces for the teeth 124, 126 define portions of the chamber 24, 48 for the agitators 34, 36. Alternatively the supporting surfaces can be mounted outside the chambers 24, 48 with the teeth 124, 126 projecting into the chambers 24, 48 to contact the agitators 34, 36.

[0087]Referring to FIG. 5, when the housing 14 is supported on the surface to be cleaned S, the main agitator axis X has a clearance H1 from the surface S, the leading agitator axis Y has a clearance H2 from the surface S, and the brushroll clearance H1 can be greater than the roller clearance H2. This difference in clearance may be due in part to the greater diameter of the brushroll 34 and/or due in part to the bottom contact surface 56 of the roller 36 being closer to the surface to be cleaned S than the bottom contact surface 58 of the brushroll 34.

[0088]When the housing 14 is supported on the surface to be cleaned S, the first comb 38 has a clearance H3 from the surface to be cleaned S and the second comb 40 has a clearance H4 from the surface to be cleaned S, and the first comb clearance H3 can be greater than the second comb clearance H4. The clearance of combs 38, 40 can be measured from the surface S to a point of contact between the comb 38, 40 and the agitator 34, 36, respectively. For example, the point of contact maybe between one of the teeth 124, 126 thereof and the agitator 34, 36, respectively.

[0089]The clearance H3, H4 of each comb 38, 40 may be greater than the axis clearance H1, H2 of the associated agitator 34, 36, respectively, such that the comb 38, 40 contact the agitator 34, 36 at a point above their axis X, Y. This locates the comb 38, 40 in a region where the outer surface of the agitator 34, 36 is moving upward and/or forwardly. For the brushroll 34, this positions the comb 38 just past to the dirty air inlet 30, so that hair and other debris captured by the comb 38 can be released into the flow path F without reattachment. Similarly, for the roller 36, this positions the comb 40 above the inter-agitator air passageway 50, so that hair and other debris captured by the comb 40 can be released into the flow path F without reattachment. Other locations for the combs 38, 40 are possible. For example, in another embodiment, the brushroll comb 38 can be closer to the dirty air inlet 30 while still being integrated with the cover 88. In yet another embodiment, the comb 38 can be provided separately from the cover 88, for example at the lower end of the dirty air inlet 30 near or with the sole plate 62.

[0090]In one embodiment, the second comb 40 is above and/or outside the inter-roller air passageway 50. For example, the clearance H4 of the second comb 40 can place the second comb 40 substantially outside the flow path F and/or above the inter-roller air passageway 50, so that the second comb 40 does not block or impede airflow through the inter-roller air passageway 50, whereby debris that is either picked up by (and/or removed from) the leading roller 36 is free to be entrained in the flow path F and/or to be picked up by the brushroll 34. Debris that does manage to wrap around and/or become entrained in/on the roller 38 can be removed by the comb 40.

[0091]The combs 38, 40 may be disposed above and/or rearwardly of the axes X, Y. In the embodiment, shown, the first comb 38 is disposed substantially above the brushroll 34 and may contact the brushroll 34 at or in front of a vertical plane V1 that is perpendicular to the axis X. The second comb 40 is disposed substantially above the roller 36 and may contact the roller 36 behind a vertical plane V2 that is perpendicular to the axis Y.

[0092]With continued reference to FIG. 5, the leading roller 36 may be spaced apart a distance G (which is greater than 0 mm) from the brushroll 34 such that the leading roller 36 does not contact the brushroll 34. The distance G allows for the passageway 50 between lower portions of the brushroll 34 and the leading roller 36, which provides at least a portion of the flow path F into the opening 28 of the suction conduit 26. The passageway 50 allows for debris that is either picked up by (and/or removed from) the leading roller 36 to be entrained in the flow path F and/or to be picked up by the brushroll 34.

[0093]Referring to FIG. 3, the plurality of teeth 124 of the first comb 38 can be spaced across a distance C1 that is least 80% of a length L1 of the brushroll 34, alternatively at least 85%, alternatively at least 90%, alternatively at least 95%. The plurality of teeth 126 of the second comb 40 can be spaced across a distance C2 that is at least 80% of a length L2 of the leading roller 36, alternatively at least 85%, alternatively at least 90%, alternatively at least 95%. The plurality of teeth 124, 126 provide numerous contact points along a substantial length of the agitators to remove debris therefrom. The teeth 124, 126 can be spaced from each other by gaps, and the gaps between teeth 124, 126 may be greater than the thickness of individual teeth.

[0094]FIG. 6 is an enlarged view showing the first comb 38 and brushroll 34. In one embodiment, the brushroll 34 has a plurality of bristles 128 that extend radially outward from a sidewall 132 of the brushroll 34. For example, the bristles 128 may extend radially up to 19 mm beyond the sidewall 132, e.g., between 15 mm and 19 mm beyond the sidewall 132. Additionally or alternatively, the bristles 128 may extend up to 3 mm below the sole plate 62, e.g., between 1.0 mm and 3.0 mm below the sole plate 62. The bristles 128 can extend past the teeth 124. The teeth 124 may be configured to contact the bristles 128 and/or the sidewall 132 as the brushroll 34 is rotated about the axis X. Alternatively, the teeth 124 may be configured to pass between the bristles 128 and out of contact with the sidewall 132 as the brushroll 34 rotates. The sidewall 132 may be a continuous sidewall of the brushroll 34, e.g., a circumferential sidewall.

[0095]The comb teeth 124 can be protrusions extending from a supporting surface of the cover 88, which in the embodiment shown comprises the inner surface 92 of the first wall 90. One or more of the teeth 124 can have a root 134 at the supporting surface and a tip 136 at an opposite end from the root 134. At least the tips 136 of the teeth 124 may contact the bristles 128 and/or pass between the bristles 128 as the brushroll 34 rotates to remove hair and other debris entangled on the bristles 128.

[0096]Various dimensions of the teeth 124 are possible, including the teeth 124 being wider at the root 134 than at the tip 136, e.g., by narrowing or tapering in a direction from root to tip. The teeth 124 can have a thickness from side to side, and the width at the root 134 and/or at the tip 136 can be greater than the side-to-side thickness.

[0097]Various profiles for the teeth 124 are possible, including one or more teeth having a triangular profile, a square profile, a rectangular profile, or a curved profile. The teeth 124 may have angled or hooked ends to aid in capturing debris. As shown, one or more of the teeth 124 can have a leading edge 138 and a trailing edge 140. A bottom edge 142 can join the leading edge and trailing edge at the tip 136. The leading edge 138 and trailing edges can be straight (e.g., parallel or coincident with the vertical plane V1), angled (e.g., oblique to the vertical plane V1), or curved. In the embodiment shown, the leading edge is angled and the trailing edge is straight. The trailing and bottom edges may be arranged at an angle A1 that is in the range of 85-110 degrees, for example 90 degrees, so that hair and other debris on the brushroll 34 effectively pulls against the teeth 124 in the direction of rotation and can be released from the brushroll 34. The leading and bottom edges may be arranged at an obtuse angle to provide rigidity.

[0098]FIG. 7 is an enlarged view showing the second comb 40 and roller 36. In one embodiment, the roller 36 has a pile 130 that extend radially outward from a sidewall 144 (FIG. 4) of the roller 36. For example, the pile 130 may extend radially 8-12 mm beyond the sidewall 144, alternatively around 10 mm beyond the sidewall 144. Additionally or alternatively, the pile 130 may extend up to 4 mm below the sole plate 62, e.g., between 3.5 mm and 4.0 mm below the sole plate 62.

[0099]The pile 130 can extend past the teeth 126. The teeth 126 may be configured to contact the pile 130 and/or the sidewall 144 as the roller 36 is rotated about the axis Y. Alternatively, the teeth 126 may be configured to press into the pile 130 and pass out of contact with the sidewall 144 as the roller 36 rotates. The sidewall 144 may be a continuous sidewall of the roller 36, e.g., a circumferential sidewall.

[0100]The comb teeth 126 comprising protrusions extending from a supporting surface of the cover 88, which in the embodiment shown comprises the inner surface 98 of the second wall 96. One or more of the teeth 126 can have a root 146 at the supporting surface and a tip 148 at an opposite end from the root 146. At least the tips 148 of the teeth 126 contact the roller 36 and can compress the pile 130 as shown in FIG. 7. The teeth 126 can protrude from the inner surface 98 at or near where the second wall 96 meets the first wall 90. As such, the comb 40 can depend from a lower and/or rear end of the second wall 96.

[0101]Various dimensions of the teeth 126 are possible, including the teeth 126 being wider at the root 146 than at the tip 148, e.g., by narrowing or tapering in a direction from root to tip. The teeth 126 can have a thickness from side to side, and the width at the root 146 and/or at the tip 148 can be greater than the side-to-side thickness.

[0102]Various profiles for the teeth 126 are possible, including one or more teeth having a triangular profile, a square profile, a rectangular profile, or a curved profile. The teeth may have angled or hooked ends to aid in capturing debris. As shown, one or more of the teeth 126 has a leading edge 150 and a trailing edge 152. A bottom edge 154 can join the leading edge 150 and trailing edge 152 at the tip 148. The leading edge 150 and trailing edges 152 can be straight (e.g., parallel or coincident with the vertical plane V1), angled (e.g., oblique to the vertical plane V1), or curved. In the embodiment shown, the leading edge 150 is angled and the trailing edge 152 forms a concave curve. In one embodiment, the comb 40 can be positioned so that the leading edge 152 faces the roller 36 and the trailing edge 152 faces the brushroll 34. The trailing and bottom edges 152, 154 may be arranged at an angle A2 that is in the range of 45-90 degrees, for example 60 degrees, so that hair and other debris on the roller 36 effectively pulls against the teeth 126 in the direction of rotation and can be released from the roller 36. The leading and bottom edges may be arranged at an obtuse angle to provide rigidity.

[0103]Although specific embodiments of the cleaning base with dual agitators and dual combs are shown, other embodiments of the cleaning base with dual agitators and dual combs are within the scope of the present disclosure. The cleaning base with dual agitators and dual combs may be used in different types of vacuum cleaners including, without limitation, an “all in the head” type vacuum, upright vacuum cleaners having a cleaning base and an upright body for directing the base across the surface to be cleaned, canister vacuum cleaners having a cleaning implement connected to a wheeled base by a vacuum hose, stick vacuum cleaners, portable vacuum cleaners adapted to be hand carried by a user for cleaning relatively small areas, robotic vacuum cleaners, and central vacuum systems. The cleaning base with dual agitators and dual combs may also be used in vacuum cleaners having liquid and/or steam delivery. may be similarly removable.

[0104]The terms “comprising” or “comprise” are used herein in their broadest sense to mean and encompass the notions of “including,” “include,” “consist(ing) essentially of,” and “consist(ing) of. The use of “for example,” “e.g.,” “such as,” and “including” to list illustrative examples does not limit to only the listed examples. Thus, “for example” or “such as” means “for example, but not limited to” or “such as, but not limited to” and encompasses other similar or equivalent examples.

[0105]The above description relates to general and specific embodiments of the disclosure. However, various alterations and changes can be made without departing from the spirit and broader aspects of the disclosure as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. As such, this disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the disclosure or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. Any reference to elements in the singular, for example, using the articles “a,” “an,” “the,” or “said,” is not to be construed as limiting the element to the singular.

[0106]Likewise, it is also to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments that fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and/or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.