具体实施方式：
[0033]The disclosure generally relates to brushes for surface cleaning apparatus that clean floor surfaces, including bare floors such as hardwood, tile, and stone, and soft surfaces such as carpets and rugs. Various embodiments of an edge cleaning brush are described below. As will be appreciated from the description herein, the edge cleaning brush may have multiple applications, but is generally provided on a housing of a floor cleaner that is adapted to move over a surface to cleaned, the edge cleaning brush located on the housing in a position to clean hard-to reach spaces such as along edges and in corners of a room, including edges or corners created by walls, baseboards, cabinetry, furniture, etc. At least some embodiments of the edge cleaning brush provided herein with a tension element that applies downward force on a cleaning implement in contact with a surface to be cleaned. In another aspect, drive systems for edge cleaning brushes are described below.
[0034]The functional systems of the surface cleaning apparatus can be arranged into any desired configuration, such as an upright device having a base and an upright body for directing the base across the surface to be cleaned. Other configurations include a canister device having a cleaning tool connected to a wheeled base by a vacuum hose, a portable device adapted to be hand carried by a user for cleaning relatively small areas, an autonomous or robotic device, or a commercial device. Any of the aforementioned cleaners can be adapted to include a flexible vacuum hose, which can form a portion of the working air conduit between a nozzle and the suction source. Any of the aforementioned cleaners can be adapted for cordless or corded operation, optionally including an on-board battery for cordless operation.
[0035]In one embodiment, the surface cleaning apparatus can be a vacuum cleaner including at least a vacuum collection system for creating a partial vacuum to suck up debris from a floor surface and collect the removed debris in a space provided on the apparatus for later disposal. The term “debris” encompasses dirt, dust, soil, hair, stains, and other debris, unless otherwise noted.
[0036]In another embodiment, the surface cleaning apparatus can be a sweeper including a sweeping system for removing dry debris from the surface to be cleaned, without the use of suction, and collect the removed debris in a space provided on the apparatus for later disposal.
[0037]In yet another embodiment, the surface cleaning apparatus can be an extraction cleaner or deep cleaner, and can include a fluid delivery system for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned and a fluid recovery system for removing the cleaning fluid and debris from the surface to be cleaned and storing the recovered cleaning fluid and debris. The fluid delivery system may be configured to delivery liquid, steam, mist, or vapor to the surface to be cleaned.
[0038]In still another embodiment, the surface cleaning apparatus can be a wet mopping or sweeping apparatus, including a fluid delivery system for storing cleaning fluid and delivering the cleaning fluid to the surface to be cleaned and a mopping or sweeping system for removing cleaning fluid and debris from the surface to be cleaned without the use of suction. The fluid delivery system may be configured to delivery liquid, steam, mist, or vapor to the surface to be cleaned.
[0039]FIG. 1 is a perspective view of a portion of a surface cleaning apparatus according to one aspect of the present disclosure, shown as an upright floor cleaning apparatus, and more specifically an upright vacuum cleaner, and generally designated 10. As discussed in further detail below, the vacuum cleaner 10 is provided with various features and improvements, including at least one edge cleaning brush 60, described in further detail below. The at least one edge cleaning brush 60 can clean hard-to reach spaces such as along edges and in corners of a room, including edges or corners created by walls, baseboards, cabinetry, furniture, etc. As illustrated herein, the vacuum cleaner 10 has a housing that includes an upright handle assembly or body 12 and a cleaning foot or base 14 mounted to or coupled with the upright body 12 and adapted for movement across a surface to be cleaned. The vacuum cleaner 10 includes a vacuum collection system, which is described in further detail below, and which can include components supported on either one or both of the body 12 and base 14.
[0040]For purposes of description related to the figures, the terms “upper,”“lower,”“right,”“left,”“rear,”“front,”“vertical,”“horizontal,”“inner,”“outer,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1 from the perspective of a user behind the vacuum cleaner 10, which defines the rear of the vacuum cleaner 10. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary.
[0041]The upright body 12 can comprise any type of elongated handle or body suitable for the purposes described herein and can comprise a handle or be otherwise configured for a user to maneuver the vacuum cleaner 10 over a surface to be cleaned. The upright body 12 can be adapted to pivot about one or more axes through a range of angles relative to the surface to be cleaned. Optionally, the upright body 12 can be configured so as to swivel about its longitudinal axis in addition to pivoting relative to the base 14.
[0042]With additional reference to FIG. 2, the vacuum collection system can include a working air path or recovery pathway through the housing, including one or both of the body 12 and base 14. The recovery pathway can include at least a dirty inlet 16 and a clean air outlet 18. The pathway can be formed by, among other elements, a suction nozzle 20 defining the dirty inlet, a suction source 22 in fluid communication with the suction nozzle 20 for generating a working air stream, a debris collector 24 for collecting debris from the working airstream for later disposal, and at least one exhaust vent 26 defining the clean air outlet 18.
[0043]The suction source 22, which can be a motor/fan assembly including a vacuum motor 28 and a fan 30, is provided in fluid communication with the collector 24. The motor/fan assembly 22 can be fluidly upstream of the air outlet, and can define a portion of the working air path. The motor/fan assembly 22 can be positioned downstream of the collector 24 in the recovery pathway. In other embodiments, the motor/fan assembly 22 may be located fluidly upstream of the collector 24.
[0044]The collector 24 can also define a portion of the working air path and can comprise a separator (not shown) for separating debris from the working airstream. Some non-limiting examples of the separator include at least one cyclonic or centrifugal separator, filter screen, foam filter, HEPA filter, flexible and air-permeable filter bag, or combinations thereof.
[0045]The collection system can also be provided with one or more additional filters upstream or downstream of the suction source 22. For example, in the illustrated embodiment, a pre-motor filter 32 is provided in the recovery pathway downstream of the collector and upstream of the suction source 22. A post-motor filter 34 can be provided in the recovery pathway downstream of the suction source 22 and upstream of the clean air outlet 18. The collection system can further include various conduits, ducts, or tubes for fluid communication between the various components of the vacuum collection system.
[0046]Referring to FIG. 2, the suction nozzle 20 can be provided on the base 14 can be adapted to be adjacent the surface to be cleaned as the base 14 moves across a surface. A brushroll 36 or other agitator can be provided adjacent to the suction nozzle 20 for agitating the surface to be cleaned so that the debris is more easily ingested into the suction nozzle 20. The suction nozzle 20 shown herein is positioned to confront the surface to be cleaned to remove debris from the surface. In other embodiments, the suction nozzle 20 can be positioned in close proximity to the brushroll 36 to collect debris directly from the brushroll 36.
[0047]In the 60L, 60R embodiment shown herein, the suction nozzle 20 is provided between two edge cleaning brushes 60L, 60R. In other embodiments, the suction nozzle 20 can be provided to the rear of the edge cleaning brushes 60L, 60R. In either case, the edge cleaning brushes 60L, 60R can sweep debris under the base 14 and toward the suction nozzle 20.
[0048]The vacuum cleaner 10 can include a brush chamber 38 in which the brushroll 36 is mounted. The brushroll 36 is mounted for rotation about a substantially horizontal axis X, relative to the surface over which the base 14 moves. The suction nozzle 20 can be formed at a lower side of the brush chamber 38. The edge cleaning brushes 60L, 60R can be located outwardly of the lateral sides or ends of the brush chamber 38
[0049]In the present example, brushroll 36 can be a bristleless brushroll or roller. The brushroll 36 shown in FIG. 2 comprises a core 42 and a plurality of chevron vanes 44 extending from the core 42, although a variety of different vane shapes can be used. The vanes 44 can be integrally formed with the core42, such as through injection molding, additive manufacturing, or another suitable process. The core 42 and vanes 44 can be constructed of a polymeric material such as acrylonitrile butadiene styrene (ABS), polypropylene or styrene, or any other suitable material such as plastic, wood, or metal.
[0050]Other embodiments of the brushroll 36 are possible. For example, the brushroll 36 can comprise tufted bristles or a soft and compressible material, such as microfiber. In still other embodiments, the brushroll 36 can comprise nylon fiber, foam, elastomeric blades and paddles. Additionally, while a single horizontally-rotating brushroll 36 is shown herein, in some embodiments, dual horizontally-rotating brushrolls can be provided on the vacuum cleaner 10.
[0051]In another embodiment, the brushroll 36 can be a hybrid brushroll suitable for use on both hard and soft surfaces, and for wet or dry vacuum cleaning. Such a hybrid brushroll can include a combination of bristles and microfiber. One example of a suitable hybrid brushroll is disclosed in U.S. Pat. No. 10,092,155, issued Oct. 9, 2018, which is incorporated herein by reference in its entirety.
[0052]The suction nozzle 20 can be in fluid communication with the collector 24 through a conduit 46. In embodiments where the collector 24 is located on the upright body 12, the conduit 46 can pass through the joint assembly between the base 14 and upright body 12, and can be flexible to accommodate the movement of the upright body 12 relative to the base 14.
[0053]The base 14 can include a base housing 48 supporting at least some of the components of the collection system, such as the brushroll 36 and edge cleaning brushes 60L, 60R in the embodiment shown herein. A pair of wheels 50 can be attached to the base housing 48 for moving the vacuum cleaner 10 over the surface to be cleaned. The wheels 50 can be provided on rearward portion of the base housing 48, rearward of components such as the suction nozzle 20, the brushroll 36, the edge cleaning brushes 60L, 60R, or any combination thereof. A second pair of wheels 52 can be attached to the base housing 48, forward of the first pair of wheels 50.
[0054]The vacuum cleaner 10 shown includes two edge cleaning brushes 60L, 60R on the underside 54 of the base 14, for example on an underside of the base housing 48. The edge cleaning brushes 60L, 60R are mounted for rotation about a substantially vertical rotational axis V1, V2 respectively, relative to the surface over which the base 14 moves. In being substantially vertical, the rotational axis V1, V2 can deviate up to 5 degrees from vertical, up to 10 degrees from vertical, up to 20 degrees from vertical, or up to 45 degrees from vertical. In some embodiments, the rotational axis V1, V2 is configured to maximize the contact area between the edge cleaning brush 60L, 60R and the surface to be cleaned. In the present embodiment, two edge cleaning brushes 60L, 60R are provided, and arranged at opposite lateral sides, i.e. left and right sides, of the base 14 so that the vacuum cleaner 10 can edge clean on either side of the base 14 without changing the orientation of the base 14. In other embodiments, only one edge cleaning brush 60 is provided.
[0055]Advantageously, the edge cleaning brushes 60L, 60R sweep debris under the base 14 and toward the suction nozzle 20. The direction of rotation for each edge cleaning brush 60L, 60R is indicated in FIG. 3 by arrows R1 and R2. As is illustrated in FIG. 2, the edge cleaning brushes 60L, 60R can counter-rotate such that debris is swept towards the suction nozzle 20 by both brushes 60L, 60R, and the suction source 22 can transport the debris to the collector 24. The left side edge cleaning brush 60L rotates in a clockwise direction R1 as viewed from bottom. The right side edge cleaning brush 60R rotates in a counterclockwise direction R2 as viewed from bottom. In one example, at least a portion of the edge cleaning brushes 60L, 60R 60 extend beyond a periphery of the base housing 48 such that debris adjacent the base 14 of the vacuum cleaner 10 can be swept toward the suction nozzle 20. In the embodiment shown herein, the edge cleaning brushes 60L, 60R are mounted at a forward or leading end 56 of the base 14, forwardly of the suction nozzle 20, and sweep debris toward the center and rear of the base 14, i.e. toward the suction nozzle 20. The edge cleaning brushes 60L, 60R are also mounted forwardly of the axis X of the brushroll 36, and sweep debris toward the brushroll 36 which can aid in collecting the debris. In other embodiments, the edge cleaning brushes 60L, 60R can be mounted at another location on the base 14, along only the left side of the base 14, or along only the right side of the base 14.
[0056]In other embodiments of the apparatus 10, the collection system can be configured as a sweeping or mechanical collection system that mechanically collects debris and liquid without the use of suction, such as by the action of the brushroll 36 and edge cleaning brushes 60L, 60R mechanically propelling debris directly into the collector 24. In such an embodiment, the edge cleaning brushes 60L, 60R can sweep debris under the base 14 and toward a debris inlet on the base 14.
[0057]In yet another alternative or additional collection mechanism, the apparatus 10 can include a mopping or dusting assembly for removing moistened debris from the surface to be cleaned. Such a mopping or dusting assembly can optionally include at least one mopping or dusting pad and one or more edge cleaning brushes 60L, 60R that can sweep debris under the base 14 and toward the pad. The pad can be stationary or rotatable.
[0058]The edge cleaning brush 60L, 60R may comprise one or more different agitation or cleaning implements configured to brush, sweep, dust, mop, or otherwise move debris on the surface to be cleaned. Some non-limiting examples of cleaning implements for the edge cleaning brush 60L, 60R comprise blades, bristles, paddles, blades, flaps, microfiber material, fabric, dusting pads, and the like.
[0059]The embodiment of the edge cleaning brush 60L shown in FIG. 3 includes a rotational body 62 configured to rotate with respect to the base housing 48 and a cleaning implement 64 coupled with the rotational body 62 for rotation therewith. By being “coupled with” the rotational body 62, the cleaning implement 64 can be attached to, formed with, or otherwise suitably joined to the rotational body 62 for rotation therewith. The cleaning implement 64 can be configured to brush, sweep, dust, mop, or otherwise move debris on the surface to be cleaned. As discussed above, the cleaning implement 64 can move debris on the surface to be cleaned toward the suction nozzle 20 or other debris inlet on the housing 48.
[0060]The cleaning implement 64 can comprise a plurality of bristle sets 66, each bristle set 66 comprising a plurality of bristles. The bristles can be constructed of nylon, polybutylene terephthalate (PBT), or any other suitable synthetic or natural fiber. The bristle sets 66 can project radially from the rotational body 62 as shown, or can project tangentially or at another angle in other embodiments.
[0061]Portions of the cleaning implement 64 can project beyond the forward or leading end 56 of the base 14 and/or can project beyond a lateral side 68 of the base 14. For example, distal ends of some of the bristle sets 66 can extend outside the base housing 48 as shown in FIG. 3, including forwardly and laterally of the base housing 48.
[0062]The length of the bristle sets 66 can be equal to each other as shown, or bristle sets of different lengths can be provided. It is also noted that the bristles in each set 66 are shown as having the same length, however in other embodiments of the edge cleaning brush 60L, the length of individual bristles within one set 66 may vary.
[0063]The bristle sets 66 can be spaced equally about the rotational axis V1. For example, in the embodiment of the edge cleaning brush 60L shown, the cleaning implement 64 can comprise six bristle sets 66 which are spaced approximately 60° from each other. Other bristle set numbers and spacing are possible, such as, but not limited to, nine bristle sets 66 which are spaced approximately 40° from each other. In yet another embodiment, rather than being arranged in discrete sets, bristles can be arranged substantially continuously about the rotational body 62.
[0064]The rotational body 62 can comprise a hub configured to rotate on the rotational axis V1. Optionally, the rotational body 62 can comprise a peripheral surface that is disposed radially outwardly from the rotational axis V1, and the bristle sets 66 can project radially with respect to the peripheral surface. In other embodiments, the bristle sets 66 can project tangentially or at another angle from the peripheral surface.
[0065]Referring to FIG. 4, the base housing 48 can be made up of one or more separate pieces, casings, or housings. In one non-limiting example, the base housing 48 can include at least a lower cover 70 and an upper cover 72 enclosing components of the base 14 therebetween. The upper cover 72 is shown exploded from the lower cover 70 in FIG. 4.
[0066]In one embodiment, the brushroll 36 and both edge cleaning brushes 60L, 60R can be operably coupled to and driven by a drive assembly including a brushroll motor or brush motor 74 in the base 14. Alternatively, the vacuum motor 28 (FIG. 3) can provide both vacuum suction and rotate one or more of the brushes 36, 60L, 60R. In another alternate embodiment, a motor (not shown) separate from the brush motor 74 can be provided in the base 14 for driving the edge cleaning brushes 60L, 60R, with both edge cleaning brushes 60L, 60R operably coupled to and driven by the common, separate motor. In yet another alternate embodiment, individual motors (not shown) separate from the brush motor 74 can be provided in the base 15 for driving each of the edge cleaning brushes 60L, 60R, with each edge cleaning brush 60L, 60R operably coupled to and driven by one of the individual, separate motor.
[0067]In the embodiment shown, the brush motor 74 is configured to drive the brushroll 36 about rotational axis X, the first or left-side edge cleaning brush 60L about rotational axis V1, and the second or right-side edge cleaning brush 60R about rotational axis V2. Drive couplings or transmissions couple the brush motor 74 to each of the brushes 36, 60L, 60R. Each drive coupling can comprise one or more belts, gears, shafts, pulleys or combinations thereof.
[0068]The rotational axes V1, V2 of the edge cleaning brushes 60L, 60R can be disposed at opposing ends of the brushroll 36. In the embodiment shown, the rotational axes V1, V2 of the edge cleaning brushes 60L, 60R are spaced from each end of the brushroll 36. As shown in bottom view of FIG. 2, the rotational axes V1, V2 of the edge cleaning brushes 60L, 60R can disposed forwardly of the rotational axis X. In other embodiments, the rotational axes V1, V2 can intersect the rotational axis X.
[0069]The rotational axes V1, V2 of the edge cleaning brushes 60L, 60R can be substantially perpendicular to the rotational axis X of the brushroll 36. In being substantially perpendicular, the rotational axes V1, V2 can deviate up to 5 degrees from perpendicular, up to 10 degrees from perpendicular, or up to 20 degrees from perpendicular. The rotational axes V1, V2 of the edge cleaning brushes 60L, 60R can be parallel to each other, or non-parallel.
[0070]In the embodiment shown in FIG. 4, the brushroll 36 is operably coupled to and driven by a drive assembly including the brush motor 74 and a drive coupling or transmission 76 between the brushroll 36 and the brush motor 74. The first edge cleaning brush 60L is operably coupled to and driven by a drive assembly including the brush motor 74 and a drive coupling or transmission 78 between the brush 60L and the brushroll 36. The second edge cleaning brush 60R is operably coupled to and driven by a drive assembly including the brush motor 74 and a drive coupling or transmission 80 between the brush 60R and the brushroll 36.
[0071]The edge brush drive couplings 78, 80 for each edge cleaning brush 60R, 60L can be configured to reduce the drive speed of the brushes 60R, 60L, such that the edge cleaning brushes 60R, 60L move at slower speeds than the brushroll 36. If not reduced, the edge cleaning brushes 60R, 60L may fling debris away from the base 14 instead of sweeping debris toward the suction nozzle 20. In one example, the brushroll 36 is driven at 3000-4375 rpm, inclusive, alternatively at 3100-3700 rpm, inclusive, and the edge cleaning brushes 60R, 60L are driven at 110 rpm, alternatively at 135 rpm, alternatively at 120-140 rpm, inclusive, alternatively at 150-175 rpm, inclusive.
[0072]Referring to FIGS. 5-6, in one embodiment the brushroll drive coupling 76 can include a drive belt 82 frictionally engaging a drive wheel 84 coupled with an output of the brush motor 74 and a driven wheel 86 on the brushroll 36, and which transmits the rotational force provided by the motor 28 to the brushroll 36.
[0073]The edge brush drive coupling 78 can include a gear train having an input gear coupled with the brushroll 36 or with the transmission between the brushroll 36 and the brush motor 74. In the embodiment shown in FIG. 5-6, the gear train for the first edge cleaning brush 60L includes a worm 90 operably coupled with brushroll 36 for rotation therewith, a two-stage driven gear having a first or worm gear 92 enmeshed with the worm 90 and a second gear 94 coupled with the first gear 92 for rotation therewith, an edge brush belt 96 coupled with the second gear 94 to transmit the rotational force of the two-stage gear to a driven gear 98. The driven gear 98 is coupled with the edge cleaning brush 60L to drive the brush 60L for rotation about the axis V1.
[0074]The driven gear 98 can be coupled with a drive shaft 100 of the edge cleaning brush 60L. The driven gear 98 outputs a driving force to the drive shaft 100 and rotates at a predetermined speed. The drive shaft 100 can define the axis of rotation V1 of the edge cleaning brush 60L. Optionally drive shaft 100 can be joined with or otherwise coupled to the rotational body 62 (FIG. 3) of the edge cleaning brush 60L. The edge cleaning brush 60L can be fixedly or removably mounted to the drive shaft 100. With a removable mounting, the edge cleaning brush 60L can be an aftermarket or replacement component for existing edge cleaning brushes on vacuum cleaners and other floor cleaning devices.
[0075]The gear train described with respect to FIGS. 5-6 can reduce rotational speed of the edge cleaning brush 60L relative to the brushroll. In one embodiment, the gear reduction ratio from the worm 90 to the driven gear 98 can be 1:30.
[0076]The gear train can be coupled with the driven wheel 86 of the brushroll 36 for driving the worm gear 90. In the embodiment shown in FIG. 6, a splined driven member 102 is coupled with the worm 90, and the driven wheel 86 of the brushroll 36 can comprise a splined drive member 104 configured to mate axially with the splined driven member 102. The splined members 102, 104 have teeth, wedges, or other shaped members that enmesh when the splined members 102, 104 are axially engaged. The splined members 102, 104 thus form a splined connection between the worm 90 and driven wheel 86 to transfer torque to the worm 90. Other couplings between the brushroll 36 and gear train are possible.
[0077]The gear train configuration described with respect to FIGS. 5-6 can save space at the front side of the base 14, allowing the rotational axis V1 of the edge cleaning brush 60L to be closer to the forward end 56 of the base 14. Rather than directly driving the brush 60L via the worm gear 90, the use of the belt 96 to indirectly drive the brush 60L via the worm gear 90 allows the rotational axis V1 to be disposed farther from the brushroll rotational axis X. In an alternate embodiment, the worm 90 be coupled directly with the driven gear 98 attached to the drive shaft 100, with the belt 96 and other gears 92, 94 not provided.
[0078]The edge brush drive coupling 80 for the other edge cleaning brush 60R can be substantially similar, save for that the gear train can be coupled with a splined drive member 114 at the non-driven end of the brushroll 36 for driving the worm gear 90. In the embodiment shown in FIG. 9, the splined drive member 102 coupled with the worm 90 can enmesh with the splined drive member 114 to transfer torque to the worm 90. Other couplings between the brushroll 36 and gear train are possible.
[0079]With additional reference to FIG. 7, the edge brush drive coupling 78 can be housed within the base housing 48 or can be housed within a separate gear casing 106 that is formed with or otherwise coupled to the housing 48. To improve noise and vibration, the gear train of the drive coupling 78 can be located in a gear casing 106 as a module with more precise tolerance. The gear casing 106 can include an aperture 108 through which the drive shaft 100 extends to connect the drive coupling 78 with the edge cleaning brush 60. The gearbox for the edge cleaning brush 60L, i.e. the gear drive coupling 78 and its casing 106, can be disposed internal or external to the base housing 48, and may be removable from the base 14. With a non-removable gearbox, a portion of the edge cleaning brush 60L, such as its cleaning implement, can fixedly or removably mounted to the drive shaft 100.
[0080]The gear casing 106 can be made up of one or more separate pieces, casings, or housings. In one non-limiting example, the gear casing 106 can include at least a lower gear housing 110 and an upper gear cover 112 enclosing components of the edge brush drive coupling 78 therebetween. Gear upper cover 112 is shown exploded from the gear housing 110 in FIG. 7.
[0081]In one embodiment, a modular unit comprising the edge brush drive coupling 78, gear casing 106, and optionally also comprising the edge cleaning brush 60L, is removably mounted to the base 14. With the modular unit shown in FIGS. 7-8, the edge brush drive coupling 78 and the edge cleaning brush 60L are simultaneously mountable to the base 14 by attachment of the gear casing 106 to the base 14 for easy assembly with the vacuum cleaner 10. Likewise, the edge brush drive coupling 78 and the edge cleaning brush 60L are simultaneously removable from the base 14 by removal of the gear casing 106 to the base 14, allowing for cleaning, repair, or replacement of the modular unit or components of the modular unit. With a modular unit or gearbox, the edge cleaning brush 60L can be an aftermarket or replacement component for existing edge cleaning brushes on vacuum cleaners and other floor cleaning devices. While the modular unit is shown as comprising the edge brush drive coupling 78 described with respect to FIGS. 5-6, it is understood that other edge brush transmissions are possible.
[0082]To assemble the modular unit or gearbox with the base 14, the gear casing 106 can be assembled with the lower cover 70, with the splined members 102, 104 enmeshing to couple the drive coupling 78 with the driven wheel 86 of the brushroll 36. The gear casing 106 can be attached to the lower cover 70 using any suitable attachment method, such as be using screws or other fasteners to mount the gear casing 106 on the lower cover 70. After securement of the gear casing 106, the top cover 72 (FIG. 4) can be mounted on the lower cover 70. The top cover 72 can cover at least a portion of the gear casing 106, as shown in FIG. 1.
[0083]A similar gear casing 106 for the right-side edge brush drive coupling 80 can be provided, as shown in FIGS. 4 and 9. The brushroll 36 and brush chamber 38 can be disposed in between the two gear casings 106. The top cover 72 can cover at least a portion of both gear casings 106, when installed on the lower cover 70.
[0084]FIGS. 10-15 show details of another embodiment of an edge cleaning brush, generally designated 160. The edge cleaning brush 160 can be provided on the vacuum cleaner 10 shown in FIGS. 1-9 in place of one or both of the edge cleaning brushes 60L, 60R, or can be provided on another surface cleaning apparatus to clean hard-to reach spaces such as along edges and in corners of a room, including edges or corners created by walls, baseboards, cabinetry, furniture, etc. The edge cleaning brush 160 can be configured rotate about a substantially vertical rotational axis V.
[0085]The edge cleaning brush 160 can include a rotational body 162 configured to rotate with respect to the base housing 48 (FIG. 1), or other floor cleaner housing, and a cleaning implement 164 coupled with the rotational body 162 for rotation therewith. By being “coupled with” the rotational body 162, the cleaning implement 164 can be attached to, formed with, or otherwise suitably joined to the rotational body 162 for rotation therewith. The cleaning implement 164 can be configured to brush, sweep, dust, mop, or otherwise move debris on the surface to be cleaned. As discussed above, the cleaning implement 164 can move debris on the surface to be cleaned toward the suction nozzle 20 (FIG. 2) or other debris inlet on a floor cleaner.
[0086]The edge cleaning brush 160 can include a tension element, such as a tensioner hub 166 that applies downward force F (see FIG. 11) on the cleaning implement 164 to force the cleaning implement 164 against a surface S to be cleaned. The tensioner hub 166 also provides structural support, allowing the cleaning implement 164 to be fabricated from materials and/or in shapes that may otherwise be too flexible or flimsy to effectively move debris on the surface to be cleaned toward the suction nozzle 20 (FIG. 2) or other debris inlet.
[0087]The tensioner hub 166 can be interposed between the rotational body 162 and the cleaning implement 164. The tensioner hub 166 can be assembled with the cleaning implement 164 to form a subassembly, and the rotational body 162 is subsequently assembled to the subassembly. For example, in one embodiment the tensioner hub is glued to the cleaning implement 164. In another embodiment the tensioner hub 166 can be integrally formed with the rotational body 162 to form a subassembly, and then subsequently affixed to the cleaning implement 164, such as by adhesive bonding, heat-staking, or overmolding, for example. In yet another embodiment the tensioner hub 166 can be overmolded on the cleaning implement 164 to form a subassembly, and the rotational body 162 is subsequently assembled to the subassembly.
[0088]The rotational body 162 can comprise an attachment hub 168 configured to rotate on rotational axis V. Optionally, the rotational body 162 can comprise a peripheral surface 170 that is disposed radially outwardly from the rotational axis V, and the cleaning implement 164 can project radially with respect to the peripheral surface 170.
[0089]The rotational body 162 can be coupled with a drive shaft, such as drive shaft 100 (FIG. 6) for rotation of the edge cleaning brush 160. The attachment hub 168 can have an opening 172 for receiving an end of the drive shaft 100. It is noted that the drive assem