Upright vacuum cleaner

Abstract

A vacuum cleaner brushroll having a pulley with a generally circular pulley surface surrounding at least one opening located radially inward of the pulley surface, and an elongated shaft passing through the central opening. The pulley may surrounds and be captured in place by a mounting portion of the elongated shaft that is formed as continuous single structure. A mounting portion of the shaft comprising a continuous structure having a reduced cross section into which the pulley fits may be located within and on either side of the pulley's central opening. A process for making a brushroll is also provided.

1 . A vacuum cleaner brushroll comprising:
 a pulley comprising a generally circular pulley surface surrounding at least one opening located radially inward of the pulley surface; and   an elongated shaft passing through the central opening;   wherein the pulley surrounds and is captured in place by a mounting portion of the elongated shaft that comprises a continuous single structure.   
   
   
       2 . The vacuum cleaner brushroll of  claim 1 , wherein the pulley comprises a material having a relatively high melting point, and the mounting portion comprises a material having a relatively low melting point. 
   
   
       3 . The vacuum cleaner brushroll of  claim 1 , wherein the at least one opening comprises radially-extending ribs that extend into corresponding slots in the mounting portion. 
   
   
       4 . The vacuum cleaner brushroll of  claim 1 , wherein the at least one opening comprises a plurality of openings. 
   
   
       5 . The vacuum cleaner brushroll of  claim 1 , wherein the at least one opening comprises a non-circular profile. 
   
   
       6 . The vacuum cleaner brushroll of  claim 1 , wherein the pulley surface comprises a crowned surface adapted to receive a flat belt or a ribbed belt. 
   
   
       7 . The vacuum cleaner brushroll of  claim 1 , wherein the pulley surface comprises a plurality of teeth that are adapted to receive a cogged belt. 
   
   
       8 . The vacuum cleaner brushroll of  claim 1 , wherein the pulley surface comprises a continuous surface that extends entirely around the elongated shaft. 
   
   
       9 . A vacuum cleaner brushroll comprising:
 a pulley comprising a generally circular pulley surface surrounding at least one opening located radially inward of the pulley surface; and   an elongated shaft passing through the at least one central opening;   wherein a mounting portion of the elongated shaft located within and on either side of the central opening comprises a continuous structure having a reduced cross section into which the pulley fits.   
   
   
       10 . The vacuum cleaner brushroll of  claim 9 , wherein the pulley comprises a material having a relatively high melting point, and the mounting portion comprises a material having a relatively low melting point. 
   
   
       11 . The vacuum cleaner brushroll of  claim 9 , wherein the at least one opening comprises radially-extending ribs that extend into corresponding slots in the mounting portion. 
   
   
       12 . The vacuum cleaner brushroll of  claim 9 , further comprising:
 an opening located at a first end of the elongated shaft;   a bearing cup that at least partially fits within the opening;   a bearing that at least partially fits within the opening; and   one or more pins at least partially positioned within the opening and between the opening and an outer surface of the bearing cup to thereby hold the bearing cup in the opening.   
   
   
       13 . The vacuum cleaner brushroll of  claim 9 , further comprising a plurality of edge cleaning bristles protruding from the elongated shaft and away from the pulley at an angle of about 45 degrees to 80 degrees relative to the central axis of the elongated shaft. 
   
   
       14 . The vacuum cleaner brushroll of  claim 13 , wherein the edge cleaning brushrolls protrude from a beveled end portion of the elongated shaft. 
   
   
       15 . The vacuum cleaner brushroll of  claim 9 , wherein the pulley surface comprises a crowned surface adapted to receive a flat belt or a ribbed belt. 
   
   
       16 . The vacuum cleaner brushroll of  claim 9 , wherein the pulley surface comprises a plurality of teeth that are adapted to receive a cogged belt. 
   
   
       17 . The vacuum cleaner brushroll of  claim 9 , wherein the pulley surface comprises a continuous surface that extends entirely around the elongated shaft. 
   
   
       18 . A vacuum cleaner brushroll manufactured by a process comprising:
 forming a pulley having a generally circular pulley surface and at least one opening located radially inward of the pulley surface;   forming an elongated shaft from a continuous piece of material that passes through the at least one opening and at least partially surrounds the pulley to structurally interlock the pulley in place on the elongated shaft.   
   
   
       19 . The vacuum cleaner brushroll manufactured by the process of  claim 18 , wherein the pulley comprises a material having a relatively high melting point, and the elongated shaft comprises a material having a relatively low melting point. 
   
   
       20 . The vacuum cleaner brushroll manufactured by the process of  claim 18 , further comprising forming radially-extending ribs in the at least one opening.