CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Patent Application Serial No. 62/506,203, filed May 15, 2017, which his fully incorporated herein by reference.

FIELD

[0002] The present disclosure relates generally to robot cleaners and more specifically to side brushes for robot cleaners.

BACKGROUND

[0003] Robot cleaners (e.g., robot vacuum cleaners, robot mops, robot dusters, etc.) may clean a surface (e.g., a floor) based on one or more programmed cleaning modes (e.g., a wall- following mode, a random pattern mode, a spot mode, etc.). The cleaning modes cause the robot cleaner to traverse a floor pursuant to one or more preprogrammed instructions. While traversing the floor, the robot cleaner utilizes a cleaning instrument (e.g., a vacuum system, a mop, a dust pad, etc.) to remove debris on the floor.

[0004] For example, a robot vacuum cleaner may include one or more driven wheels, a vacuum system, and a side brush. One example of a side brush may have tufts of bristles extending from a hub and spaced apart around the periphery of the hub. Another example of a side brush may have individual bristles extending singly from the hub and continuously around the hub. The bristles may extend beyond a periphery of the robot vacuum cleaner such that the rotation of the side brush urges debris beyond the periphery of the robot vacuum cleaner in a direction of the robot vacuum cleaner. For example, the side brush may urge debris from a corner of a room into a suction inlet of the vacuum system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Features and advantages of the claimed subject matter will be apparent from the following detailed description of embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:

[0006] FIG. 1 is schematic plan view of an example of a robot cleaner including a side brush, consistent with embodiments of the present disclosure. [0007] FIG. 2A is a schematic plan view of an example of a side brush with different length bristles extending individually from a hub, consistent with embodiments of the present disclosure.

[0008] FIG. 2B is a schematic side view of an example of a side brush with bristles extending from a hub at different angles relative to the hub, consistent with embodiments of the present disclosure.

[0009] FIG. 2C is a schematic perspective view of an example of bristle strip that may be used to form the side brushes shown in FIGS. 2A and 2B, consistent with embodiments of the present disclosure.

[0010] FIG. 3 is a perspective view of another embodiment of a side brush including bristles extending individually from a hub at different lengths and angles.

[0011] FIG. 4 is a perspective view of the side brush of FIG. 3 coupled to a robot cleaner, consistent with embodiments of the present disclosure.

[0012] FIG. 5 is a bottom view of another embodiment of a robot cleaner including a side brush and side brush deflector.

DETAILED DESCRIPTION

[0013] A side brush for use with a robot cleaner, consistent with embodiments disclosed herein, includes bristles extending from a hub at different lengths and/or angles relative to the hub. The hub may be configured to rotatably couple to the robot cleaner. In some embodiments, the plurality of bristles extend individually and continuously around at least a portion of the hub. The side brush may include, for example, groups of bristles at different lengths and/or at different angles relative to the hub.

[0014] By varying one or more of the bristle length and/or the bristle angle, the performance of a robot cleaner may be improved. The longer bristles allow a longer reach and larger sweeping area, while the shorter bristles reduce interference with the items on the surface being cleaned. For example, when rotating, the side brush may engage one or more surface treatments (e.g., an area rug) residing on a floor. A side brush having bristles of the same length and extending at the same angle may have a tendency to become entangled with, for example, an area rug residing on a floor. By adjusting the length and/or angle of one or more bristles, it may become less likely that the side brush will become entangled.

[0015] FIG. 1 shows a schematic plan view of an example of a robot cleaner 100 having a body 102, a plurality of driven wheels 104, and at least one side brush 106. The driven wheels 104 are coupled to at least one drive motor 108 such that actuation of the drive motor 108 causes the driven wheels 104 to urge the robot cleaner 100 across a surface 110 (e.g., a floor). The side brush 106 is rotatably coupled to the body 102 such that a brush motor 116 coupled to the side brush 106 causes a rotation of the side brush 106. Alternatively, the side brush 106 may be coupled to the drive motor 108 such that the drive motor 108 may cause the side brush 106 to rotate.

[0016] Rotation of the side brush 106 may urge debris on the surface 110 in a direction of a vacuum inlet 118. In one example, at least a portion of the side brush 106 extends beyond a periphery of the body 102 such that debris adjacent the body 102 can be urged into the vacuum inlet 118. The vacuum inlet 118 is fluidly coupled to a vacuum motor 120 such that air is drawn from the vacuum inlet 118 through a debris collector 122 to a vacuum outlet 124. At least a portion of the debris entrained within the air drawn through the vacuum inlet 118 is deposited within the debris collector 122. In some instances, one or more filters are disposed within the airflow path extending between the debris collector 122 and the vacuum outlet 124 to collect any debris not deposited in the debris collector 122.

[0017] FIG. 2A shows a schematic plan view of a side brush 200 with different length bristles, which may be an example of the side brush 106 of FIG. 1. As shown, the side brush 200 includes a hub 202 and a plurality of bristles 204 extending individually away from a peripheral surface 206 of the hub 202. The bristles 204 may be coupled to the hub 202 such that the bristles 204 extend continuously around the hub 202 forming a full or partial circular brush configuration. As used herein, bristles 204 are defined as extending continuously around the hub 202 if the plurality of bristles 304 collectively extend from and around at least 80% of the perimeter (e.g., circumference) of the hub 302 and the separation distance 210 between each bristle 204 and at least one adjacent bristle 204 is less than or equal to twice a width of widest bristle 204 of the plurality of bristles 204. For example, the separation distance 210 may be less than or equal to one width of the widest bristle 204 of the plurality of bristles 204, in a range of one-half to twice the width of the widest bristle 204 of the plurality of bristles 204, and/or at least a portion of each bristle 204 may be directly adjacent (e.g., contacting) at least one other bristle 204. The separation distance 210 may be measured between the ends of adjacent bristles 204 and/or between the bases of adjacent bristles 204.

[0018] Each of the bristles 204 may be coupled to and extend from a common carrier or substrate (e.g., a bristle strip) that at least partially circumscribes the peripheral surface 206 of the hub 202. In some instances, the bristles 204 completely circumscribe the hub 202. In the illustrated example, the bristles 204 extend from the hub 202 as individual bristles, rather than tufts of bristles. [0019] In the illustrated embodiment, a first plurality of bristles 212 has a first bristle length 214 and a second plurality of bristles 216 has a second bristle length 218. As used herein, the length of the bristles 204 is measured between the periphery surface 206 of the hub 202 and the distal most end of the bristles 204. In the illustrated embodiment, the first bristle length 214 measures less than the second bristle length 218. A ratio of the first bristle length 214 to the second bristle length 218 may, for example, be in a range of 5:6 to 1:3. By way of further example, a ratio of the first bristle length 214 to the second bristle length 218 may be in a range of 2:3 to 1 :2. By way of even further example, a ratio of the first bristle length 214 to the second bristle length 218 may be 1 : 1.

[0020] Although the illustrated embodiment includes groups of bristles with two different lengths, individual bristles and/or groups of bristles may have more than two different lengths in other embodiments. In some instances, each bristle of the plurality of bristles 204 may have a bristle length measuring different from that of an adjacent bristle of the plurality of bristles 204. In other words, the length of the bristles 204 vary as the bristles 204 extend along the peripheral surface 206 of the hub 202. In these instances, the bristles 204 may be arranged according to their length such that distal ends 220 of the bristles 204 collectively define a waveform- shaped pattern. Example waveform-shaped patterns may include a sinusoidal waveform pattern, a square waveform pattern, a trapezoidal waveform pattern, and/or any other waveform pattern.

[0021] In the illustrated embodiment, the first plurality of bristles 212 extends around the hub 202 for a first circumferential distance 221 and the second plurality of bristles 216 extends around the hub 202 for a second circumferential distance 223. A ratio of the first circumferential distance 221 to the second circumferential distance 223 may measure in a range of 8: 1 to 1 :2. By way of further example, a ratio of the first circumferential distance 221 to the second circumferential distance 223 may measure in a range of 4: 1 to 1 : 1. By way of even further example, a ratio of the first circumferential distance 221 to the second circumferential distance 223 may measure in a range of 3: 1 to 1: 1

[0022] A swept area 222 of the side brush 200 may be defined as the area through which at least one of the bristles 204 passes upon a full rotation of the side brush 200. A proportion of the swept area 222 occupied by the bristles 204 may influence the cleaning effectiveness of the side brush 200. For example, the bristles 204 may occupy at least 40% of the swept area, at least 50% of the swept area, at least 60% of the swept area, at least 70% of the swept area, at least 80% of the swept area, at least 90% of the swept area, or any other suitable proportion. [0023] FIG. 2B shows a schematic plan view of an example of a side brush 201 with bristles at different angles relative to the hub 202. The side brush 201 may have bristles of all the same length or different lengths as describe above. As shown, the side brush 201 is rotatably coupled to the robot cleaner 100 within a well 224 such that the side brush 201 rotates about a rotation axis 226 extending generally perpendicular to a floor 228. The well 224 defines a recessed region within the robot cleaner 100 that extends from a floor facing surface 230 of the robot cleaner 100 in a direction away from the floor 228.

[0024] The side brush 201 includes a plurality bristles 204 extending away from the peripheral surface 206 of the hub 202. As shown, one or more of the bristles 204 forms a first angle Θ with the peripheral surface 206 of the hub 202, the rotation axis 226, and/or an axis perpendicular to the floor 228, while at least another one of the bristles 204 forms a second angle a with the peripheral surface 206, the rotation axis 226, and/or an axis perpendicular to the floor 228. The first angle Θ and second angle a are both measured vertically between the bristles 204 and the peripheral surface 206 and/or the rotation axis 226 as generally illustrated. The first angle Θ may be selected such that the bristles 204 extend from the hub 202 in a direction generally towards the floor facing surface 230 of the robot cleaner 100. In some instances, at least a portion of at least one bristle 204 engages (e.g., contacts) the floor facing surface 230. The second angle a may be selected such that the bristles 204 extend from the hub 202 in a direction generally towards the floor 228. In some instances, at least a portion of at least one bristle 204 engages (e.g., contacts) the floor 228. Although the schematic illustration shows two bristles and two different angles, individual bristles and/or groups of bristles may extend from the hub 202 at more than two different angles.

[0025] In the illustrated embodiment, the first angle Θ measures less than the second angle a. For example, the first angle Θ may measure less than 90° and the second angle a may measure greater than 90°. By way of more specific example, the first angle Θ may measure in a range of 40° to 90° and the second angle a may measure in a range of 90° to 140°. The bristles 204 may extend from the hub 202 at angles that vary within these ranges. As such, the bristles 204 may generally be described as defining a waveform- shaped pattern extending around the hub 202. For example, the bristles 204 may extend around the hub 202 such that a sinusoidal waveform pattern, a square waveform pattern, a trapezoidal waveform pattern, and/or any other waveform pattern is formed.

[0026] FIG. 2C shows a schematic perspective view of an example of a bristle strip that may be used to form the side brush. The bristle strip includes the plurality of bristles 204 extending from a carrier or substrate 208, which may be coupled around the hub 202. In some instances, the substrate 208 is coupled to the peripheral surface 206 of the hub 202 such that the bristles 204 extend from the hub 202. For example, the substrate 208 may be adhesively coupled to the peripheral surface 206. In some instances, at least a portion of the substrate 208 is received within a groove within the hub 202 such that the bristles 204 extend along a peripheral edge of the hub 202. In other embodiments, each bristle 204 may be coupled directly to the hub 202. In some instances, the hub 202 may include a plurality of openings capable of receiving at least a portion of a corresponding bristle 204. Additionally, or alternatively, one or more of the bristles 204 may be formed from or molded into the hub 202.

[0027] FIG. 3 shows a perspective view of a side brush 300 with bristles having both different lengths and different angles, which may be an example of the side brush 106 of FIG. 1. The side brush 300 includes a hub 302, a plurality of bristles 304, and a connector 306. The connector 306 is configured to rotatably couple the side brush 300 to a robot cleaner (e.g., the robot cleaner 100 of FIG. 1). As shown, the connector 306 extends from the hub 302 such that the connector 306 can be received within a corresponding receptacle in the robot cleaner. Alternatively, the connector 306 may be a receptacle extending at least partially through the hub 302 such that the connector 306 can receive a corresponding protrusion extending from the robot cleaner.

[0028] As shown, when coupled to the hub 302, a first plurality of bristles 308 extend in a direction of the robot cleaner and a second plurality of bristles 310 extend in a direction away from the robot cleaner. In other words, the first plurality of bristles 308 and the second plurality of bristles 310 extend in generally opposing directions along a rotation axis 312 of the hub 302 (e.g., up and down). The different angles of the bristles 308, 310 may be formed, for example, by bending or permanently deforming the bristles, by having the bristles extend at the different angles from the hub 302 or from the carrier (e.g., substrate 208 in FIG. 2C), and/or by having a structure (e.g. a protrusion) extending from the hub 302.

[0029] FIG. 4 shows an example of the side brush 300 coupled to a robot cleaner 400, which may be an example of the robot cleaner 100 of FIG. 1. The side brush 300 may be rotatably coupled to the robot cleaner 400 proximate a bumper 402 such that at least a portion the bristles 308 and/or the bristles 310 extends beyond the robot cleaner 400. In other embodiments, the bristles 308 and/or bristles 310 may not extend beyond the periphery of the robot cleaner 400. [0030] In the illustrated embodiment, the first plurality of bristles 308 extends in a direction of the robot cleaner 400. In some instances, at least a portion of the first plurality of bristles 308 engage (e.g., contact) a bottom surface 404 of the robot cleaner 400. As such, as the side brush 300 rotates, the first plurality of bristles 308 slide along the bottom surface 404 of the robot cleaner 400. The second plurality of bristles 310 may extend in a direction away from the robot cleaner 400 such that at least a portion of the second plurality of bristles 310 engages a surface (e.g., a floor). As such, as the side brush 300 rotates, the second plurality of bristles 310 may urge debris residing on a surface in a direction of the robot cleaner 400 (e.g., in a direction of a vacuum inlet).

[0031] In some embodiments, the robot cleaner 400 includes one or more sensors. The sensors may include, for example, a cliff sensor 406 capable of detecting a change in height of a surface on which the robot cleaner 400 is traveling. The cliff sensor 406 may be used to prevent the robot cleaner 400 from traversing a region having a sudden change in elevation greater than a predetermined value. For example, when the robot cleaner 400 approaches the edge of a stairwell, the robot cleaner 400 may stop and/or turn away from the stairwell such that the robot cleaner 400 does not fall down one or more stairs.

[0032] In the illustrated embodiment, the longer bristles 310, but not the shorter bristles 308, pass between the cliff sensor 406 and a surface when the side brush 300 rotates. As such, the rotation of the side brush 300 does not interfere with the operation of the cliff sensor. In other embodiments where the side brush includes bristles of the same length, the bristles may extend individually from the hub with a spacing between the individual bristles that allows the cliff sensor to operate when the bristles pass between the cliff sensor 406 and the surface.

[0033] As also shown in FIG. 4, in some instances, the bristles 304 extend continuously around the hub 302 without completely circumscribing the hub 302. For example, the bristles 304 may extend around at least 80% of the hub 302, at least 90% of the hub 302, at least 95% of the hub 302, at least 99% of the hub 302, or any other suitable circumferential distance. Further, while the hub 302 has been generally illustrated herein as having a circular cross- section, such a configuration is non-limiting. For example, the hub 302 may have a square- shaped cross section, a rectangle-shaped cross section, a triangular-shaped cross section, an octagonal- shaped cross section, a pentagonal- shaped cross section, or any other suitable cross section.

[0034] Although the illustrated embodiments show multiple groups of bristles with different lengths and/or angles, a side brush may include only one group of bristles with one length and/or angle and one group of bristles with the other length and/or angle. Although the exemplary embodiments show bristles extending individually and continuously around a hub, a side brush with bristles having different lengths and/or angles relative to the hub may also be formed by tufts of bristles extending from a hub.

[0035] FIG. 5 shows an example of one embodiment of a robot cleaner 100 including one or more side brush debris deflectors 500. The robot cleaner 100 may include a body 102, a plurality of driven wheels 104, and at least one side brush 106. The driven wheels 104 are coupled to at least one drive motor 108 (not shown for clarity) such that actuation of the drive motor 108 causes the driven wheels 104 to urge the robot cleaner 100 across a surface 110 (e.g., a floor). The side brush 106 is rotatably coupled to the body 102 such that a brush motor 116 (not shown for clarity) and/or drive motor 108 coupled to the side brush 106 causes a rotation of the side brush 106.

[0036] The side brushes 106 may include any side brush design known to those skilled in the art. In at least one embodiment, one or more of the side brushes 106 may include one or more tufts 505 of bristles 204 extending from the hub 202 as generally illustrated in FIG. 5. In the illustrated embodiment, the side brush 106 includes a plurality of tufts 505 of bristles 204 having the same length; however, it should be appreciated that one or more of the bristles 204 in a tuft 505 may have a different length and/or that one or more of the plurality of tufts 505 may have bristles 204 having a different length than the bristles 204 of another one of the plurality of tufts 505. Alternatively, one or more of the side brushes 106 may include any of the side brushes 106 described herein. For example, one or more of the side brushes 106 may include a plurality of bristles 204 which extend continuously around the hub 202. At least one of the plurality of bristles 204 may form a first angle with the peripheral surface of the hub 202 and at least one of the plurality of bristles 204 may form a second angle with the peripheral surface of the hub 202 which is greater than the first angle and/or at least one of the plurality of bristles 204 may have a first bristle length and at least one of the plurality of bristles 204 has a second bristle length, the first bristle length is less than the second bristle length.

[0037] In any case, rotation of the side brush 106 is intended to urge debris on the surface 110 in a direction of a vacuum inlet 118. In one example, at least a portion of the side brush 106 extends beyond a periphery of the body 102 such that debris adjacent the body 102 can be urged towards the vacuum inlet 118. As may be appreciated, however, the side brushes 106 may contact debris and inadvertently cause the debris to be spun around the side brush 106 (e.g., between the side brush 106 and the driven wheels 104 and/or between the driven wheels 104 and the vacuum inlet 118) and ejected beyond the robot cleaner 100. As a result, the debris may not be urged towards the vacuum inlet 118, and thus may not be picked up by the robot cleaner 100.

[0038] To address this problem, the robot cleaner 100 may include one or more side brush deflectors 510 configured to reduce and/or eliminate debris from being inadvertently spun around the side brush 106 and ejected beyond the robot cleaner 100. The side brush deflector 510 may therefore be configured to trap and/or collect debris in an area 512 under the robot cleaner 100 and in front on the vacuum inlet 118. As a result, debris propelled by the side brushes 160 will be directed towards the vacuum inlet 118 and ultimately drawn through the vacuum inlet 118 and deposited within the debris collector 122.

[0039] The side brush deflector 510 may include a strip of flexible material and/or a plurality of bristles 512 (also referred to as deflector bristles) extending downwardly from the floor facing surface 230 of the robot cleaner 100 generally towards the floor. The side brush deflector 510 may be sufficiently flexible to allow the side brush deflector 510 to generally conform to varying surface contours. The side brush deflector 510 may extend downwardly from the floor facing surface 230 partially and/or all the way towards the floor. Some or all of the bristles 204 of the side brush 106 may pass through at least a portion of the side brush deflector 510. Alternatively (or in addition), some or all of the bristles 204 of the side brush 106 may pass below at least a portion of the side brush deflector 510.

[0040] In the illustrated embodiment, the side brush deflector 510 is shown as a substantially continuous strip of flexible material and/or a plurality of bristles 512; however, it should be appreciated that the side brush deflector 510 may not be continuous. For example, the side brush deflector 510 may be formed by a plurality of discrete and/or discontinuous sections. The side brush deflector 510 may have a linear or non-linear configuration. The side brush deflector 510 may be extend within all or a portion of a region between the side brushes 106 and the vacuum inlet 118 and/or an agitator 514; however, a portion of the side brush deflector 510 may also extend in a region forward of the side brushes 106 (i.e., closer to the front of the robot cleaner 100 than the side brushes 106) and/or behind the vacuum inlet 118 and/or an agitator 514 (i.e., closer to the rear of the robot cleaner 100 than the vacuum inlet 118 and/or an agitator 514).

[0041] One or more of the side brush deflectors 510 may be arranged with a longitudinal axis Ld that is either parallel to or non-parallel to the longitudinal axis Lr and/or the forward direction F of the robot cleaner 100. In the illustrated embodiment, the robot cleaner 100 is shown having two side brush deflectors 510 arranged with longitudinal axes Ld that are non- parallel to the longitudinal axis Lr and/or the forward direction F of the robot cleaner 100. For example, the side brush deflector 510 may be arranged to form a debris chute or channel 512. The debris chute or channel 512 is defined as an area extending laterally between the side brush deflectors 510 and extending vertically between the floor facing surface 230 of the robot cleaner 100 and floor. The debris chute or channel 512 may be configured to generally direct debris towards the vacuum inlet 118 and/or an agitator 514 (which may be disposed at least partially within vacuum inlet 118 and/or separately from the vacuum inlet 118). According to one embodiment, the debris chute or channel 512 may have generally tapered configuration in which the lateral dimension of the debris chute or channel 512 (i.e., the left to right dimension) becomes smaller when moving closer to the vacuum inlet 118 and/or an agitator 514. The tapered configuration of the debris chute or channel 512 may aid in directing debris towards the vacuum inlet 118 and/or an agitator 514 while also allowing the side brushes 106 to be disposed further apart laterally from each other (thus increasing the sweep area 222 (FIG 2A) of the side brushes 106. The taper of the debris chute or channel 512 may be either linear or nonlinear. While the illustrated embodiment of the robot cleaner 100 is shown having two side brush deflectors 510, it should be appreciated that the robot cleaner 100 may have only one side brush deflector 510 or more than two side brush deflectors 510.

[0042] While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. It will be appreciated by a person skilled in the art that a vacuum attachment may embody any one or more of the features contained herein and that the features may be used in any particular combination or sub-combination. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.