GB2640141A

GB2640141A - Floor cleaning roller

Info

Publication number: GB2640141A
Application number: GB2404725.0A
Authority: GB
Inventors: Jonathan Harrington Russi Benjamin; Katso Niisato Peter; Brett Thompson Louis; John Wilson Alexander
Original assignee: Dyson Technology Ltd
Current assignee: Dyson Technology Ltd
Priority date: 2024-04-03
Filing date: 2024-04-03
Publication date: 2025-10-15
Also published as: GB202404725D0; WO2025210495A1

Abstract

A floor cleaning roller 20 for mounting in a cleaner head (10, fig.1) of a robotic hard floor cleaner, comprising an elongate body (34, fig.2a) defining a longitudinal axis (24, fig.2a) about which the roller rotates when mounted, wherein the elongate body comprises a non-porous outer surface 38, a polymer vane 40 projecting outwardly from the outer surface, and stiffening ribs 76 disposed along the vane, preferably extending in a radial direction from the outer surface and tapering towards a distal region 46 of the vane. The vane may extend helically along the roller and the stiffening ribs may be arranged symmetrically about a radial midplane (52, fig.2b) of the roller. The vane may project from the outer surface by a second distance less than a first distance at which a pooling vane projects. A plurality of vanes and a plurality of pooling vanes may be arranged alternately around the roller.

Description

Floor Cleaning Roller

BACKGROUND

Wet-thy hard floor cleaners with motor driven rotating cleaning rollers are becoming more popular. The performance of such cleaners is superior to traditional mops as the number of passes that a motor driven cleaning roller is able to make over a stained region of a floor in any given period of time far exceeds the number of passes possible when using a traditional mop.

Known wet floor cleaners employ cleaning rollers comprising a deformable material which deforms as it contacts the floor to be cleaned thereby compressing against the floor to remove the dirt or stain. The deformable material is typically porous and absorbent.

It is against this background that the examples of the invention have been devised.

SUMMARY

According to the invention, floor cleaning roller for mounting in a cleaner head of a hard floor cleaner is provided. A cleaner head comprising the floor cleaning roller, and a floor cleaner comprising such a cleaner head are also provided. The floor cleaning roller comprises an elongate body defining a longitudinal axis about which the roller is configured to rotate when mounted in the cleaner head, wherein the elongate body comprises a non-porous outer surface; a non-porous polymer vane projecting outwardly from the outer surface; and stiffening ribs disposed along a length of the non-porous polymer vane. Each stiffening rib may be provided on the non-porous polymer vane and extends in a radial direction from the outer surface at a root region of the non-porous polymer vane towards a distal region.

Accordingly, as the roller rotates, the stiffening ribs will resist bending against the floor surface, thereby increasing the bending stress in that region of the vane as it passes over the floor. Thus when the vane is released from the floor surface with continued roller rotation, the resultant flicking force (and therefore flicking velocity) is greater.

The stiffening ribs may be disposed on the leading side, trailing side or both leading and trailing sides of the non-porous polymer vane. Each stiffening rib is elongate where a dimension in the radial direction is longer than a dimension in the axial. Further, each stiffening rib is shorter than the non-porous polymer vane in the radial direction. In this way, each stiffening rib extends up to the interference portion of the non-porous polymer vane, but does not overlap with this interference portion. As a result, the distal region of the non-porous polymer vane remains able to flex on contact with the floor surface to allow the roller to continue to rotate without being disrupted from its mounting.

The distal end of the stiffening rib is tapered towards the non-porous polymer vane. Each stiffening rib may be fixed, bonded or integrally moulded to the non-porous polymer vane. The stiffening ribs may be evenly spaced along the length of each non-porous polymer vane and/or are arranged symmetrically about the radial midplane.

The non-porous polymer vane extends helically along the roller and may further comprises a non-porous polymer pooling vane. The non-porous polymer pooling vane projects outwardly from the outer surface by a first distance and the non-porous polymer vane projects outwardly from the outer surface by a second distance, wherein the first distance is greater than the second distance. The non-porous polymer pooling vane is parallel to the non-porous polymer vane.

A plurality of the non-porous polymer vanes may be provided and arranged equidistantly spaced around the roller body to define channels therebetween. Further, a plurality of the non-porous polymer pooling vanes may be provided and arranged equidistantly spaced around the roller body to define channels therebetween. The non-porous polymer vanes and the non-porous polymer pooling vanes are arranged alternately around the roller body.

The stiffening ribs on the non-porous polymer vanes create stiffened regions and act as the more resilient flicking vanes, while the unstiffened regions of the non-porous polymer pooling vanes act as the more flexible pooling vanes. Accordingly, the floor cleaning roller comprises non-porous polymer pooling vanes and non-porous polymer vanes which work together to wipe and flick fluid and debris from the floor, when in use.

Although the cleaner heads in the embodiments above have been described in relation to a hand operated floor cleaner, the cleaner heads may alternatively be provided on a robotic floor cleaner. There is also described herein a robotic floor cleaner comprising a cleaner head as described above.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross-sectional schematic view of a cleaner head for a wet-dry hard floor cleaner.

Figures 2a and 2b are perspective and plan views of a cleaning roller for mounting in the cleaner head shown in Figure 1.

Figure 3 is a radial cross-sectional view of the cleaning roller shown in Figures 2a and 2b Figure 4 is a plan view of a modified version of the cleaning roller shown in Figures 2a and 2b.

Figures 5a and 5b are perspective and plan views of another cleaning roller for mounting in the cleaner head shown in Figure 1.

Figures 6 and 7 are plan views of other examples of cleaning rollers for mounting in the cleaner head shown in Figure 1.

Figures 8a and 8b are perspective and plan views of another cleaning roller for mounting in the cleaner head shown in Figure 1.

Figures 8c and 8d are perspective and plan views of another cleaning roller for mounting in the cleaner head shown in Figure 1.

Figures 9a and 9b are perspective and plan views of another cleaning roller for mounting in the cleaner head shown in Figure L Figures 10a and 10b are perspective and plan views of yet another cleaning roller for mounting in the cleaner head shown in Figure 1.

Figures 11 and 12 are plan views of bi-conical cleaning rollers for mounting in a modified version of the cleaning roller shown in Figure 1.

DETAILED DESCRIPTION

In general terms, embodiments of the invention provide a non-porous cleaning roller for installation within the cleaner head of a hard floor cleaner, specifically a wet-dry hard floor cleaner. In use, the cleaning roller is powered by a motor to spin about its longitudinal axis so that, as the cleaner head is passed over a hard floor, the cleaning roller wipes the floor surface clean of debris and fluid. Unlike conventional absorbent cleaning rollers, the described cleaning roller is made from one or more non-porous materials so that it does not absorb liquids from the floor. Instead, the cleaning roller comprises an arrangement of vanes or tabs which act to wipe and/or flick debris and liquid from the floor surface and into the cleaner as the roller spins over the floor. Accordingly, embodiments of the invention provide a cleaning roller which is effective in cleaning hard floor surfaces, but which is also easy to maintain since it can be rinsed clean and quickly dried as required.

To provide context for the invention, Figure 1 shows a cross-sectional view of a cleaner head 10 for a hard floor cleaner. The cleaner head 10 is disposed at one end of the cleaner, and a handle (not shown) is arranged at the other end to allow a user to manoeuvre the cleaner head over a hard floor surface 12 from a standing position. During normal use, the cleaner head 10 is moved forward and backward over the floor 12 in the 'movement direction' as indicated by arrow M. The cleaner head 10 comprises a main housing 14 defining a cavity 16, or roller cavity, which opens onto the floor surface 12; and two elongate cleaning rollers 20 arranged in parallel within the cavity 16 to contact the floor surface 12 when the floor cleaner is arranged for use. The cleaner head 10 is generally symmetric about a central plane 22 which extends between the two parallel rollers 20 so that the floor cleaner 10 can be operated bi -directi on al 1 y.

Each cleaning roller 20 is generally cylindrical in shape and extends between two roller ends to define a longitudinal axis 24, or roller axis, about which the roller 20 is configured to rotate when mounted. In use, the rollers 20 are mounted within the cavity 16 with their roller axes 24 generally parallel to the floor surface 12 and perpendicular to the in use direction of movement M of the cleaner head 10.

The rollers 20 are powered to rotate or spin about their respective roller axes 24 by one or more motors (not shown) When in use, the rollers 20 are powered to rotate in opposite directions so that the innermost sides 26 of the rollers 20 rotate upwardly away from the floor surface 12, while the outermost sides 28 of the rollers 20 rotate downwardly towards the floor surface 12. In the context of this description, it will be understood that the innermost side 26 of a roller 20 is the portion of that roller 20 which is between the roller axis 24 and the central plane 22 of the cleaner head, while the outermost side 28 is the other side of the roller opposite from the innermost side 26. With reference to the view shown in Figure 1, the left hand roller 20 is configured to rotate anticlockwise (as shown by arrow RA) and the right hand roller 20 is configured to rotate clockwise (as shown by arrow Etc). As such, in use, the rollers 20 rotate against the floor surface 12 to push debris and moisture tangentially towards the central plane 22 into the housing cavity 16, as indicated by arrows T. The floor cleaner is specifically a 'wet-My' floor cleaner, meaning that it comprises a hydration system which circulates cleaning fluid through the roller cavity 16 for wetting the floor surface 12 and cleaning the rollers 20. As such, the hydration system comprises a pair of fluid inlets 30 (one for each roller), each mounted in the housing 14 to deliver cleaning fluid to the cavity 16 above each roller 20.

The cleaner head 10 further comprises a catchment tray arrangement 32 positioned within the housing 14 between the two rollers 20 and configured to collect dirty fluid and debris from the rollers 20 as they rotate. A pump (not shown) is arranged to remove fluid from the catchment tray 32 for filtering and recirculation.

With reference to Figures 2a, 2b and 3, one of the cleaning rollers 20 will now be described in more detail.

As indicated above, the roller 20 comprises an elongate body 34 which defines a longitudinal axis 24, or roller axis, about which the roller 20 is configured to rotate when mounted in the cleaner head 10. Arrow R indicates the direction in which the roller 20 rotates when in use, i.e. the spin direction.

The body 34 extends from a first body end 36 to a second body end 36' to define a tubular form having a constant annular cross section with an outer radius (r) (see Figure 3). The tubular form allows for one of the motors to be installed therein, but in other examples the body 34 may be a solid cylindrical form.

Alternatively, the body 34 may be tapered towards each end 36, 36' so that the outer radius r at the ends 36, 36' of the body 34 is smaller than in the middle of the body 34. The tapered form may be symmetric about a radial midplane. In other words, the body 34 may have the form of a bicone or a truncated bicone. As will be appreciated, during normal use, threadlike debris such as hair may be drawn into the housing cavity 16 and wrapped around the roller 20 as the roller 20 rotates. The tapered form of the body 34 allows any wrapped hair to loosen from the body 34 by moving towards the tapered ends 36, 36'. Therefore, as the roller 20 rotates, any wrapped hair will naturally corkscrew its way towards the nearest end 36, 36' of the roller 20 where it will gather in a ball for removal.

In other examples, the body 34 may he tapered towards one end only 36, 36 and such examples are described in more detail below with reference to Figures 11 and 12.

The body 34 is structurally rigid and comprises an outer surface 38 made from a non-porous polymer material such as silicone. The outer surface 38 may be integrally formed with the main body 34 so that the body 34 is all made from the same material.

The roller 20 further comprises a plurality of vanes 40 which project outwardly from the outer surface 38 of the body 34, radially away from the roller axis 24. Each vane 40 is elongate and extends from a first vane end 42 to a second vane end 43 along a length of the roller body 34 to define a vane length. The vanes 40 are made from non-porous polymer material which may be the same or different from the material of the outer surface, depending on the type of vane, which will be discussed in more detail below.

Figure 3 shows a radial cross section of the roller 20. As shown, each vane 40 extends radially away from the outer surface 38 of the roller body 34 by a projection distance (d). In more detail, each vane 40 extends widthwise from a root region 44, which is joined to the outer surface 38 of the body 34, to a distal region 46, which is free, to define a bladelike cross-section having leading and trailing sides 48, 50 extending between the root and distal regions 44, 46.

The leading side 48 refers to the side (or surface) of a vane 40 which is foremost (i.e. leading) in the spin direction R as the roller 20 rotates, while the trailing side 50 refers to the side of a vane 40 which is rearmost (i.e. trailing) in the spin direction R as the roller 20 rotates. In the view shown in Figure 3, the roller 20 is configured to rotate in the anticlockwise direction, meaning that the anti-clockwise side of each vane 40 is the 'leading' side 48, while the clockwise side of each vane is the 'trailing' side 50. The dimension from the leading side of a vane to its trailing side may be referred to as the vane thickness (t). In the example shown, the thickness (t) of each vane 40 tapers in the radial direction so that the root region 44 is thicker than the distal region 46.

For each vane 40, the projection distance (d) is such that, when the roller 20 is mounted in the cleaner head 10 and rotated about the roller axis 24, the distal region 46 of the vane 40 contacts the floor surface 12 with each rotation of the roller 20. As such, with each pass over the floor surface 12, the vanes 40 act to push fluid and debris from the floor surface 12 into the cleaner head 10 towards the catchment tray 32.

There are two distinct types of vane 40 comprised in the arrangement shown in Figures 2a and 2b: the first vane type may be referred to as pooling vanes (or more flexible vanes) 40', and the second vane type may be referred to as flicking vanes (or more resilient vanes) 40". The vanes 40 are arranged so that the roller 20 is symmetric about a radial midplane 52. Generally, the pooling vanes 40' are configured to wipe fluid from the floor surface 12 and channel it towards the radial midplane 52 so that it collects in 'pools', or puddles, on the floor surface 12 as the roller 20 rotates. Meanwhile, the flicking vanes 40" are configured to scoop and flick fluid from the pools upwardly away from the floor 12 towards the catchment tray 32 as the roller 20 rotates. As such, the arrangement of vanes 40 is generally configured to draw fluid from the floor surface 12 into the cleaner head 10 as the roller 20 rotates.

Each vane 40 is made from a non-porous polymer material, such as silicone, which is suitable for spinning over hard floor surfaces without causing damage or scuff marks. The pooling vanes 40' and the flicking vanes 40" are configured to have different bending stiffnesses. More specifically, the flicking vanes are stiffer so that, when they contact the floor as the roller rotates, the bending stress in the vane 40" is greater which, in turn, provides a higher flicking velocity as the flicking vane 40" is released from the floor surface 12.

For example, the pooling vanes 40' and the flicking vanes 40" may be made from different polymer materials, with the pooling vanes 40' being made from a softer, or more flexible, polymer material, and the flicking vanes 40" being made from a harder, or more resilient (i.e. stiffer), polymer material. In other words, the material of the flicking vanes 40" has a higher Shore hardness than that of the pooling vanes 40'. For example, the pooling vanes 40' may have a Shore hardness of 20 to 40 Shore, while the flicking vanes 40" have a greater Shore hardness, for example, from 70 to 90 Shore. In other examples, the flicking and pooling vanes 40', 40" may be made from the same material and but their geometries may be different to provide differing stiffnesses.

Referring again to Figure 3, and for the purposes of the following description, the distance between the roller axis and the floor surface when the roller is mounted within the cleaner head may be referred to as the floor clearance distance (D). The sum of the outer radius (r) of the roller body 34 and the projection distance (d) for a vane may be referred to as the vane rotation radius.

The flicking vanes 40" project outwardly from the outer surface 38 of the roller body 34 such that the vane rotation radius is slightly greater than the floor clearance distance (D). As such, the flicking vanes 40" interfere slightly with the floor surface 12 as the roller 20 rotates. The portion of the vane which extends beyond the floor clearance distance may be referred to as the 'interference portion' 56, and the radial length of this portion may be referred to as the interference length. In the example shown, the flicking vanes 40" make 1mm of interference with the floor; i.e. the interference length is lmm.

Therefore, it will be understood that, as the roller 20 rotates, friction between the floor 12 and the interference portion 56 causes the vane 40" to flex so that the distal region 46 of the vane 40" drags along the floor 12. Continued roller 20 rotation pulls the flicking vane 40" upwards away from the floor surface 12 thereby reducing the friction between the interference portion 56 and the floor 12 until the vane 40" springs back to an unbent resting position. This springing motion is enhanced by the relative stiffness, of the flicking vanes 40" and serves to flick fluid and debris upwardly away from the floor 12 and towards the catchment tray 32.

The pooling vanes 40' project outwardly from the outer surface 38 of the roller body 34 by a projection distance (d) that is greater than the projection distance (d) of the flicking vanes 40", i.e so that the vane rotation radius is greater than the floor clearance distance (D). As such, the interference length of the pooling vanes 40' is longer than the flicking vanes 40". In the example shown, the pooling vanes 40' make 4mm of interference with the floor; i.e. the interference length is 4mm.

The more flexible configuration of the pooling vanes 40' relative to the flicking vanes 40" allows them to flex easily on contact with the floor 12 so that the roller 20 can continue to rotate in its mounted position. Therefore, as the roller 20 rotates, the distal region 46 of the pooling vanes 40' contact the floor surface 12 and the resulting friction causes the leading side 48 to drag along the floor surface 12 in a wiping action which pushes debris and fluids towards the central plane 22 of the cleaner head 10. This wiping action is effective at removing stains and more viscous fluids from the floor due to the larger contact area between the leading side 48 and the floor 12 provided by the longer interference portion 56.

Turning back to Figures 2a and 2b, the example shown includes five pairs of pooling vanes 40' arranged symmetrically about the radial midplane 52, that is, with one of the pair arranged on one side of the radial midplane 52 and the other of the pair arranged on the other side of the radial midplane 52. Each pooling vane 40' extends lengthwise from one end 36 of the roller body 34, along the outer surface 38 of the roller body 34, towards the radial midplane 52 in a helical manner. The pairs of pooling vanes 40' are arranged equidistantly spaced in the circumferential direction around the outer surface 38 of the roller body 34 to define channels 58 between circumferentially adjacent pairs of pooling vanes 40' and the outer surface 38 of the body 34. The innermost end 43' of each pooling vane 40' is axially offset from the radial midplane 52 to define an axial gap 60 between the innermost ends 43' of the pooling vanes 40' in a pair.

In the example shown in Figure 4, the innermost end 43' is angled towards the radial midplane 52 so that tip region 46 is closer to the radial midplane 52 and the root region 44 is further away from the radial midplane 52. Accordingly, the gap 60 is wider closer to the outer surface 38 than away from the outer surface 38. This configuration helps ensures that detritus stuck to the pooling vane 40' is directed away from the pooling vane 40' as it is removed by the centrifugal force of the roller 10 rotating. As a result, the risk of the vane 40' retaining detritus and spreading it over the floor 12 is reduced.

The pooling vanes 40' arranged on one side of the radial midplane 52 extend in an anti-clockwise helical direction, while the pooling vanes 40' arranged on the other side of the radial midplane 52 extend in a clockwise helical direction. The helical lengthwise extension of each pooling vane 40' is such that the end of the vane 40' nearest to the radial mid-plane 52 of the roller 20 (i.e. the innermost end 43') trails behind the other end of the vane 40', that is, the end of the vane nearest to an end 36, 36' of the roller body 34 (i.e. the outermost end 42'), as the roller 20 rotates when in use. In other words, the outermost end 42' of each vane 40' is rotationally in front of the innermost end 43', having regard to the spin direction (R) of the roller 20.

Thus, when viewing the roller 20 from the forward side (i.e. the side which moves downwardly towards the floor 12 as the roller rotates) as in Figure 2b, the pooling vanes 40' on the left of the radial midplane 52 extend in an anti-clockwise helical direction, while the pooling vanes 40' on the right extend in a clockwise helical direction.

Accordingly, as the roller 20 rotates, the outermost end 42' of each pooling vane 40' contacts the floor surface 12 before the innermost end 43'. So, as the roller 20 rotates, the leading side 48 of each pooling vane 40' guides fluid along the corresponding channel 58 (much like an Archimedes screw) and through the corresponding gap 60 at the radial midplane 52 of the roller 20. As such, pools of water are formed on the floor surface 12 at and around the radial midplane 52 as the roller 20 rotates.

The example shown in Figures 2a, 2b and 3 includes five flicking vanes 40" arranged equidistantly spaced in the circumferential direction around the outer surface 38 of the roller body 34. Each flicking vane 40" is arranged in one of the channels 58 between adjacent pairs of pooling vanes 40' so that there is one flicking vane 40' per channel 58.

In contrast to the pooling vanes 40', each flicking vane 40" extends lengthwise in the axial direction so that the leading and trailing sides 48, 50 of the vane 40" are substantially perpendicular to the radial midplane 52 of the roller 20. In other words, the flicking vanes 40" are straight along their length, rather than helical. However, as can be seen in the example of Figure 4, the ends 42", 43" of the flicking vanes 40" may be curved away from the axial direction to define a lip 62 at either end of the vane 40" which gives the leading surface 48 a tray like form for scooping pooled fluid from the floor surface 12.

Each flicking vane 40" is positioned midway along the length of the roller body 34 so that it is symmetric about the radial midplane 52, extending lengthwise to axially overlap with the gaps 60 defined between paired pooling vanes 40' and the innermost ends 43' of the pooling vanes 40'. Accordingly, as the roller 20 rotates, the flicking vanes 40" sweep over the pools of fluid formed at and around the radial midplane 52 and flick the fluid towards the catchment tray arrangement 32. Axial overlapping of the pooling vane 40' and flicking vane 40" geometries prevent witness marks from forming on the floor surface 12 at the vane ends 42, 43.

Figures 5a and 5b show another example of a cleaning roller 20. As shown, the cleaning roller 20 comprises a body 34 as described above but with a different arrangement of vanes 40. The arrangement of vanes 40 comprises vanes 40 of one type only, meaning that all of the vanes 40 are made from the same material and project outwardly from the outer surface 38 of the roller body 34 by the same projection distance. In other words, all of the vanes are of the same Shore hardness and make the same interference with the floor 12. In this example, all of the vanes 40 are relatively flexible with a hardness of 30 Shore and a projection distance which provides a floor interference of 4mm.

As shown, each vane 40 has a tab-like form in which the leading and trailing surfaces 48, 50 are substantially rectangular and the radial cross-section of the tab 40 is constant. In this particular example, the thickness of each tab 40 is constant. With reference to one tab 40, the tab extends from root region 44 to distal region 46 to define a tab width, and longitudinally from one end 42 to the other 43 to define a tab length (akin to vane length). The ratio of the tab width to the tab length is no greater than 1:2. In other words, the tab is no longer than twice its width. In this particular example, the length of each tab is less than its width.

In this example, each tab 40 extends perpendicularly from the outer surface 38 of the roller body 34 so that the tab width is equal to its projection distance (d). However, in other examples, the tabs 40 may extend angularly away from the outer surface 38 so that the tab width is longer than the tab projection distance (d).

Each tab 40 extends along the outer surface 38 of the roller 20 in the axial direction such that the leading and trailing surfaces 48, 50 are perpendicular to the radial midplane 52. In other words, each tab 40 is axially aligned with the roller body 34. Therefore, as the roller rotates, the whole length of a tab's distal region 46 contacts the floor surface 12 at once. Accordingly, when a tab 40 contacts the floor surface 12 as the roller rotates, the friction between the tab 40 and the floor 12 is substantially constant along the length of the tab 40 so that no part of the distal region 44 drags behind another part of the distal region 44.

Thus, as the roller 20 continues to rotate, the distal region 44 suddenly and completely springs away from the floor 12, thereby acting in a flicking motion to flick debris and fluid towards the catchment tray 32.

All of the tabs 40 in the arrangement are the same shape, size and orientation, and are arranged in a helical pattern around the outer surface 38 of the body 34. In more detail, a number of tabs 40 are arranged in a series 64 so that the middle of their root regions 44 align along a helical path 66 extending between the ends 36, 36' of the roller body 34. The arrangement comprises a plurality of such series 64, each arranged so that the helical paths 66 run parallel to each other around the outer surface 38. In the example shown, there are 21 tabs 40 in each series 64 and five series 64 in the arrangement. The five series 64 (and the helical paths 66 thereof) are spaced equidistantly apart from each around the circumference of the body 34.

The helical paths 66 are relatively loose with a helix angle (a) between 45° and 90° such that the pitch of the helical path 66 is longer than the roller body 34. As will be understood, the helix angle (a) is the angle between the helical path 66 and a plane extending radially through the roller (e.g. the radial midplane 52). In this example, the helical paths 66 extend clockwise around the roller body 34 and the helix angle (a) is between 70° and 80° The tabs 40 in a series 64 are arranged along the helical path 66 so that the ends 42, 43 of adjacent tabs in the series are axially spaced apart. Accordingly, an axial gap 60 is defined between adjacent tabs 40 in a series 64. These axial gaps 60 allow the tabs to flex freely against the floor surface 12, without interfering with adjacent tabs 40. In other words, as the roller 20 rotates, each tab 40 flexes independently against the floor surface 12. The tabs 40 are of equal shore hardness, equal thickness, and equal floor interference. This ensures one contact point at a time to reduce noise and down force against the floor surface 12. In this example, each tab 40 has a hardness of 80 Shore, a thickness of 1.5mm, a length in the axial direction of 10, and a floor interference of 1.5mm. However, in other examples, each tab 40 may be made from a softer material (i.e. having 30 to 40 Shore hardness) and be thicker so as to maintain a relatively stiff construction which provides a suitably high flicking velocity.

The shorter the tabs 40 are in the longitudinal direction, the less likely they are to encounter large variations in floor height over their length, meaning that they are more likely to maintain continuous contact with the floor surface 12 as they rotate past. In contrast, longer tabs 40 are more likely to bridge between high points in the floor surface 12 as they rotate past, thereby leaving areas of the floor surface 12 unwiped.

Axial spacing between adjacent tabs 40 is such that the axial length of each axial gap 60 is minimised and at least axially shorter than the length of each tab 40. Furthermore, the tabs 40 of one series 64 in the arrangement are axially misaligned with the tabs 40 of at least one other series 64 in the arrangement so that the gaps 60 in one (i.e. a first) series 64 are axially misaligned with the gaps 60 in another (i.e. a second) series 64. In this way, witness marks that may be left on the floor surface 12 by the gaps 60 in the first series 64 of tabs 40 are subsequently wiped away by the tabs 40 in the second series 64, as the roller 20 rotates.

In another example, the tabs 40 in a series 64 overlap with one another in the axial direction so that hair is less likely to get caught between them. In yet another example, the series 64 of tabs 40 are arranged in a chevron pattern so that water is channelled to the centre of the roller 20. With this format, the roller 10 contacts the floor surface 12 in two places at any one time, thereby providing a greater reaction and lift force which is, in part, dependent on the tab width and floor interference.

Figure 6 shows a variation of the roller 20 shown in Figures 5a and 5b. As above, this roller 20 comprises various series 64 of tab-like vanes 40 arranged along helical paths 66. However, in this example, the tabs 40 extend lengthwise to align with their corresponding helical path 66, i.e. the tabs 40 are not arranged to axially align with the roller body 34.

This arrangement may alternatively be described as comprising a plurality of axially discontinuous helical vanes 40. Furthermore, the helical paths 66 are more tightly wound around the roller body 34 so that the helical pitch is shorter.

As shown, half of the series 64 in the arrangement extend from one end 36 of the roller body 34 in a clockwise helical direction to the radial midplane 52, and the other half of the series 64 in the arrangement extend from the other end 36' of the roller body 34 in an anticlockwise helical direction to the radial midplane 52. Referring to the view shown in Figure 6, the series 66 extending from the left end 36 of the roller 20 may be referred to as clockwise series 64, and the series 64 extending from the right end 36' of the roller 20 may be referred to as anti-clockwise series 64.

Each series 64 extends from an outer series end 68 at the end of the roller to an inner series end 70 at (or close to) the radial midplane 52 of the roller 20. The clockwise series 64 are arranged with their helical paths 66 parallel to each other and equidistantly spaced around the circumference of the roller 20. Similarly, anti-clockwise series 64 are arranged with their helical paths 66 parallel to each other and equidistantly spaced around the circumference of the roller 20. The clockwise and anti-clockwise series 64 are circumferentially spaced relative to each other so that intersections of each series 64 with the radial midplane 52 are equidistantly spaced around the circumference of the body 34.

The inner ends 70 of all the series 64 axially overlap to prevent witness marks on the floor surface 12, as described above. As in the example shown in Figures 5a and 5b, the gaps 60 between adjacent tabs 40 are axially misaligned from other gaps 60 to ensure full wiping coverage of the tabs 40 over the floor surface 12 as the roller 20 rotates.

Figure 7 shows another example of a cleaning roller 20 comprising an arrangement of vanes 40 which are geometrically arranged like the flexible (pooling) vanes 40' in the example described above with reference to Figures 2a and 2b. That is to say, the vanes 40 extend helically along the roller 20 and are arranged symmetrically about the radial midplane 52 to provide a chevron-like pattern of channels 58 over the outer surface 38.

The arrangement includes a combination of continuous and discontinuous vanes 40 arranged alternately around the circumference of the roller body 20. In this example, the radial width of the discontinuous vanes 40" varies along the length of the vane 40. Specifically, the discontinuous vanes 40" taper in the widthwise direction to become narrower towards the radial midplane 52.

The continuous vanes 40' comprise nodules 72 disposed along the length of the distal region 46. More specifically, these nodules 72 are disposed on the leading side 48 of the continuous vane 40. These nodules contact the floor as the roller rotates and thereby act to raise the leading surface of the continuous vane 40' slightly away from the floor surface 12. Accordingly, as the continuous vane 40' passes over the floor surface 12, the leading side of the continuous vane 40' remains offset from the floor surface 12, thereby defining a shallow slot between the floor surface 12 and the leading surface of the vane 40'. Fluid collected on the floor surface 12 in front of the continuous vane 40' is then free to pass through the slot between the continuous vane 40' and the floor surface 12 as the roller rotates. Any fluid which passes through is then flicked away by the following discontinuous vane 40".

Holding the discontinuous vane 40" away from the floor surface 12 allows the leading surface of the vane to spread out larger (i.e. deeper) pools of fluid into shallower sheet-like pools which extend along the length of the roller. In turn, this means that the fluid is more evenly distributed in front of the following discontinuous vane 40". Such even distribution of fluid prevents any one of the tabs in the discontinuous vane from becoming overwhelmed by pools of fluid which are too voluminous to flick away with a single pass of the vane.

Figures 8a and 8b show another example in which the vanes 40 are arranged in the chevron pattern as described above with reference to Figures 2a, 2b, 4 and 7. Continuous vanes 40' and series of tab-like vanes 64 are arranged alternately around the circumference of the outer surface 38 such that the arrangement is symmetric about the radial midplane 52. In this example, the vanes 40' are arranged in symmetric pairs with axial gaps 60 defines between the inner ends of each vane 40' in a pair. However, in other examples, the vanes 40' may be continuous so that there is no gap 60 at the radial midplane 52. In other words, the vanes 40' in a pair may be joined together.

In this example, the tabs 40" arranged away from the radial midplane 52 have a variable thickness which tapers towards the radial midplane 52 such that the inner end 43 of the tab 40" is thinner than the outer end 42 of the tab 40". More specifically, with reference to one tab 40", the inner leading edge of the tab 40" is chamfered to define a ramped surface 74 between the trailing and leading sides 44, 46. The tabs 40" arranged at the radial midplane 52 have a constant radial cross-section. The tabs 40" in a series 64 overlap with one another in the axial direction to ensure full wiping coverage of the tabs 40" over the floor surface 12 as the roller 20 rotates. This arrangement also reduces the likelihood of hair being caught between them. The series of tab-like vanes 64 may be equidistance between two adjacent vanes 40' or arranged closer to the leading side of the vanes 40' as shown in Figures 8a and 8b for improved hair migration. By arranging the tabs 40" closer to the leading side of the vanes 40' which is wider than the tabs 40", there is a reduced chance of hair being trapped between the tabs 40".

Figures 8c and 8d show another example of a cleaning roller 20 that is similar to Figures 8a and 8b. In this example, the vanes 40' are continuous so that there is no gap 60 at the radial midplane 52. In other words, the vanes 40' in a pair are joined together. The series of tab-like vanes 64 are arranged alternately around the circumference of the outer surface 38 such that the arrangement is symmetric about the radial midplane 52. Accordingly, an axial gap is defined between adjacent tabs 40" in a series 64. Similar to the example shown in Figures 5a and 5b, these axial gaps allow the tabs to flex freely against the floor surface 12, without interfering with adjacent tabs 40". In other words, as the roller 20 rotates, each tab 40" flexes independently against the floor surface 12. The tabs 40" are of equal shore hardness, equal thickness, and equal floor interference. In another example, the tabs 40" in a series 64 overlap with tabs in an adjacent series 64 in the axial direction to ensure full wiping coverage of the tabs 40" over the floor surface 12 as the roller 20 rotates. Similar to example in Figures 8a and 8b, the series of tabs 64 are arranged closer to the leading side of the vanes 40' to reduce chance of hair being trapped between the tabs 40". In another example, the series of tabs 64 may be arranged equidistance between two adjacent vanes 40'.

It is observed that the chevron arrangement of the vanes 40' as shown in Figures 2a, 2b, 4, 7, 8a, and 8b has an effect of migrating threadlike debris to the ends 36, 36' of the roller 20 while pooling fluid from the ends 36, 36' to the radial midplane 52.

Figures 9a and 9b show an example of a cleaning roller 20 comprising an arrangement of vanes 40 similar to that of the example shown in Figures 5a and 5b. As seen, in this example, the arrangement includes continuous vanes 40' and series 64 of tab-like vanes 40" arranged alternately around the circumference of the roller body 34. Each continuous vane 40' and each series 64 of tabs 40" extend between the ends 36, 36'of the roller 20 along parallel, helical paths 66. The tab like vanes 40" are each axially aligned with the roller body 34, as in the example of Figures 5a and 5b. The helical paths 66 extend clockwise around the roller body 34 and with a pitch that is shorter than the length of the roller 20. In the example shown, the continuous vanes 40' are equidistantly spaced and the series 64 are equidistantly spaced, but each series 64 is positioned closer to the vane 40' on its leading side. In other examples, the series 64 and the vanes may all be equidistantly spaced so that there is one series 64 centrally positioned between adjacent continuous vanes 40. Alternatively, each series 64 may be positioned closer to the continuous vane 40' on its trailing side. The vanes 40' are wider than the tab-like vanes 40" and hence there is a reduced chance of hair being trapped between the tab-like vanes 40" when the tabs are closer to the leading side of the vanes 40'.

The continuous vanes 40' and the tabs 40" may be made from the same material and may project from the outer surface 38 by the same projection distance so that each makes the same interference with the floor 12 as the roller 20 rotates. Alternatively, the continuous vanes 40' may have a 'flexible vane' construction (i.e. lower stiffness and higher floor interaction) while the tabs 40" of each series 64 may have a 'resilient vane' constructions (i.e. higher stiffness and lower floor interaction).

Figures 10a and 10b show an example of a cleaning roller comprising an arrangement of vanes 40 arranged in a chevron-like pattern as described with reference to Figures 2a, 2b, 4, 7, 8a, and 8b. In this example, each vane 40 is continuous along the whole length of the elongate body 34, i.e. so that there is no gap between symmetric vanes at the radial midplane 52.

As seen, each vane comprises a plurality of stiffening ribs, or struts, 76 arranged along its length. Each stiffening rib 76 is provided on the vane itself 40 and extends in the radial direction from the outer surface 38 at the root region 44 of the vane 40 towards the distal region 46. In this way, each rib 76 takes an elongate form in which its dimension in the radial direction is longer than either dimension in the axial or circumferential directions.

The distal end of each rib 76 is offset from the distal region 46 of the vane 40, i.e. the ribs 76 are narrower (or shorter) than the vanes 40 in the radial direction. More specifically, each rib 76 extends up to the interference portion 56 of the vane 70, but does not overlap with this interference portion 56. As a result, the distal region 46 of the vane 40 remains able to flex on contact with the floor surface 12 to allow the roller 20 to continue to rotate without being disrupted from its mounting. Although this example shows the ribs 76 to take a substantially rectangular cuboid form, the distal ends and / or the sides may be tapered towards the vane to reduce stress concentrations.

Each rib 76 is fixed to the vane 40 along its radial length. The ribs 76 may be bonded to the vanes or integrally moulded with the vanes 76. In this example, the vanes are provided on the leading side of the vanes, but in other examples they may be provided on the trailing side. In yet further examples, the ribs 76 may be formed to project from both the leading and trailing sides.

The ribs 76 are evenly spaced along the length of each vane 40 and are arranged symmetrically about the radial midplane 52. Although this example comprises a chevron arrangement of vanes, it will be appreciated that ribs 76 may be applied to continuous vanes arranged in other ways, for example, as in the helical arrangements described with reference to Figures 6, 9a and 9b.

As will be understood, the ribs 76 act to stiffen each continuous vane at intervals along its length. Each rib 76 stiffens the vane by providing additional thickness in the circumferential direction. Thus, each vane comprises a plurality of stiffened regions (i.e. those regions comprising the increased thickness) and a plurality of flexible regions (i.e. those regions comprising the 'baseline' thickness of the vane 40), the flexible regions extending between the stiffened 'ribbed' regions. In more general terms, each vane is of variable stiffness along its length.

In this way, as the roller rotates, the stiffened regions acts as the more resilient 'flicking vanes' described above, while the unstiffened regions act as the more flexible 'pooling vanes' described above. In more detail, as the roller rotates, the ribs 76 will resist bending against the floor surface 12, thereby increasing the bending stress in that region of the vane as it passes over the floor. Thus when the vane is released from the floor surface with continued roller rotation, the resultant flicking force (and therefore flicking velocity) is greater. That is to say, each stiffer region of the vane which is supported by a rib 76 primarily acts to flick fluid and debris away from the floor surface as the roller 20 rotates.

Meanwhile, the regions of unsupported vane which stretch between the ribs are more able to flex against the floor surface and therefore provide the wiping action described above in relation to pooling vanes. Of course, the flexibility of the vane will be highest in the middle of adjacent ribs; i.e. the vane will be less able to flex closest to a rib. Therefore, the ribs 76 are sufficiently spaced to allow the middle of each unsupported region to properly wipe against the floor surface 12.

In another example, there are two distinct types of vane 40 comprised in the arrangement shown in Figures 10a and 10b: the first vane type referred to as pooling vanes (or more flexible vanes), and the second vane type referred to as flicking vanes (or more resilient vanes). The two types of vanes are arranged alternately around the circumference of the outer surface 38 such that the arrangement is symmetric about the radial midplane 52. The first vane projects outwardly from the outer surface by a first distance and the second vane projects outwardly from the outer surface by a second distance, wherein the first distance is greater than the second distance. In one example, the stiffening ribs 76 are provided on the flicking vanes. In another example, stiffening ribs 76 are provided on both pooling and flicking vanes. However, thicker and/or longer stiffening ribs are provided on the flicking vanes such that flicking vanes are stiffer than the pooling vanes.

Figures 11 and 12 show an example of a pair of cleaning rollers 20. Each roller 20 in the pair is frustoconical in shape, tapering towards one end 36 along the respective longitudinal axis 24. When mounting in the cleaner head 10, both rollers 20 are cantilevered from opposing sides of a wedge-shaped hub portion 78 of the cleaner head 10 at the larger of their two ends 36'. As described above in relation to tapered single rollers, the tapering of the roller body 34 serves to encourage hair and other threadlike debris to work its way towards the smaller ends 36 of each roller 20 in a screwing motion.

In the embodiment shown in Figure 11, each conical cleaning roller 20 comprises a vane arrangement in which the vanes 40 are arranged in the chevron pattern as described above with reference to Figures 2a and 2b. Similar to Figures 2a and 2b, there are two distinct types of vane 40 comprised in the arrangement shown in Figure 11: the first vane type referred to as pooling vanes (or more flexible vanes) 40', and the second vane type referred to as flicking vanes (or more resilient vanes) 40-. The pooling vanes 40' are disconnected proximate the end with larger diameter 36', forming a gap 60 therebetween. Generally, the pooling vanes 40' are configured to wipe fluid from the floor surface 12 and channel it towards the gap 60 so that it collects in 'pools', or puddles, on the floor surface 12 as the roller 20 rotates. Meanwhile, the flicking vanes 40" are configured to scoop and flick fluid from the pools upwardly away from the floor 12 towards the catchment tray 32 as the roller 20 rotates. As such, the arrangement of vanes 40 is generally configured to draw fluid from the floor surface 12 into the cleaner head 10 as the roller 20 rotates. Stiffness and Shore hardness of the first and second vanes in embodiment shown in Figure 11 are same as that described above in relation to Figures 2a and 2b.

Figure 12 shows another example of a pair of frustoconi cal cleaning rollers 20 as described with reference to Figure 11. Each roller 20 in the pair comprises continuous vanes 40 equidistantly spaced around the circumference of the elongate body 34 and extending helically from the end having smaller diameter 36 to the end having larger diameter 36'. The rollers 20 in the pair are mirror opposites of each other: the roller on the left in Figure 12 has vanes 40 extending clockwise along its length when viewed from its end with a smaller diameter 36, while the roller 20 on the right has vanes extending anticlockwise along its length when viewed from its end with a smaller diameter 36. As such, when the rollers 20 are mounted in the cleaner head 10, the vane arrangements of the two rollers 20 align to provide a chevron-like pattern as previously described to direct water along the channels 58 towards the middle of the two rollers 20. As the rollers rotate, the inner ends of opposite vanes 40 come together at the radial midplane 52 of the pair arrangement to flick pooled fluid away and into the catchment tray 32.

Figures 11 and 12 show arrangement of a pair of conical cleaning rollers 20 being cantilevered from opposing sides of a wedge-shaped hub portion 78 of the cleaner head 10 at the larger of their two ends 36'. In other example, the pair of conical cleaning rollers 20 may be reversed such that the pair of conical cleaning rollers 20 are being cantilevered from opposing sides of a wedge-shaped hub portion 78 of the cleaner head 10 at the smaller of their two ends 36. In another example, a single conical cleaner roller 20 may be implemented.

It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

CLAIMS1. A floor cleaning roller for mounting in a cleaner head of a hard floor cleaner,the roller comprising: an elongate body defining a longitudinal axis about which the roller is configured to rotate when mounted in the cleaner head, wherein the elongate body comprises a nonporous outer surface; a non-porous polymer vane projecting outwardly from the outer surface; and stiffening ribs disposed along a length of the non-porous polymer vane.
2. The floor cleaning roller according to claim 1 wherein each stiffening rib is provided on the non-porous polymer vane and extends in a radial direction from the outer surface at a root region of the non-porous polymer vane towards a distal region.
3. The floor cleaning roller according to claim 1 or 2 wherein the stiffening ribs are disposed on the leading side of the non-porous polymer vane.
4. The floor cleaning roller according to any one of claims 1-3 wherein the stiffening ribs are disposed on the trailing side of the non-porous polymer vane.
5. The floor cleaning roller according to any one of claims 1-4 wherein each stiffening rib is elongate where a dimension in the radial direction is longer than a dimension in the axial.
6. The floor cleaning roller according to any one of claims 1-5 wherein each stiffening rib is shorter than the non-porous polymer vane in the radial direction.
7. The floor cleaning roller according to any one of claims 1-6 wherein the distal end is tapered towards the non-porous polymer vane.
8. The floor cleaning roller according to any one of claims 1-7 wherein each stiffening rib is fixed to the non-porous polymer vane.
9. The floor cleaning roller according to any one of claims 1-8 wherein each stiffening rib is bonded to the non-porous polymer vane or integrally moulded with the non-porous polymer vane.
10. The floor cleaning roller according to any one of claims 1-9 wherein the stiffening ribs are evenly spaced along the length of each non-porous polymer vane.
11. The floor cleaning roller according to any one of claims 1-10 wherein the stiffening ribs are arranged symmetrically about the radial midplane.
12. The floor cleaning roller according to any one of claims 1-11 wherein the non-porous polymer vane extends helically along the roller.
13. The floor cleaning roller according to any one of claims 1-12 further comprising a non-porous polymer pooling vane.
14. The floor cleaning roller according to claim 13, wherein the non-porous polymer pooling vane projects outwardly from the outer surface by a first distance and the non-20 porous polymer vane projects outwardly from the outer surface by a second distance, wherein the first distance is greater than the second distance.
15. The floor cleaning roller according to any one of claims 13 to 14, wherein the non-porous polymer pooling vane is parallel to the non-porous polymer vane.
16. The floor cleaning roller according to any one of claims 13 to 15 further comprising a plurality of non-porous polymer vanes arranged equidistantly spaced around the roller body to define channels therebetween.
17. The floor cleaning roller according to any one of claims 13 to 15 further comprising a plurality of non-porous polymer pooling vanes arranged equidistantly spaced around the roller body to define channels therebetween.
18. The floor cleaning roller according to claims 16 and 17, wherein the non-porous polymer vanes and the non-porous polymer pooling vanes are arranged alternately around the roller body.
19. A cleaner head for a hard floor cleaner comprising the cleaning roller according to any preceding claim.
20. A floor cleaner comprising a cleaner head according to claim 19.
21. The floor cleaner according to claim 20, wherein the floor cleaner is a robotic floor cleaner.