Vacuum Cleaner Roller Brush with Integrated Crushing Mechanism for Deep Cleaning

Patent & Production

At a glance

What the claims cover, in plain language

Claim 1 defines a vacuum cleaner roller brush assembly comprising a mounting frame, a coupling assembly at each end, a roller brush inserted into the couplings, a crushing roller positioned above the brush, and a cutting assembly slidably mounted in guide ways. The frame includes a drive mechanism with a motor and gears that rotate both the brush and the crusher. The coupling assembly uses a spring and push plate for quick attachment/detachment. The cutting assembly includes blades and a cleaning block that aligns with recesses on the brush surface.

Claim 2 specifies that the top cover includes two symmetrically arranged partition plates and a flow guide port where the crushing roller is located.

Claim 3 adds a scraping plate at the bottom of the installation frame and rollers at the bottom of the protective shell to aid movement or sealing.

Claim 4 introduces a rubber parting strip fixed between the mounting frame and partition plate to prevent dust leakage into gaps.

This is a simplified reading for orientation only. The legal scope is defined by the exact claim wording in the official Chinese document.

What this means for US production

This patent was filed in China and is currently in force. Making or selling this specific design in China would require permission from the patent owner. However, the public record shows no US counterpart or foreign family members. Therefore, this patent does not restrict the manufacture or sale of this design in the United States.

Two issues are worth settling first:

• Other patents may exist. Vacuum cleaner technology is a crowded field with extensive prior art from major global manufacturers. We recommend a freedom-to-operate (FTO) review before launch, to check whether the gear ratio, quick-release coupling or crushing roller arrangement reads on existing US patents held by competitors like Dyson, Shark or iRobot.
• Component sourcing. The precision required for the gear meshing and the spring-loaded coupling suggests tight tolerances. Sourcing reliable motors and molded plastic parts that meet these specifications will be critical for performance consistency.

Customization and manufacturing

What can be customized

Things to plan for (US market)

• UL 60335-2-2 - Safety standard for household electric appliances, specifically vacuum cleaners. Electrical insulation and fire resistance of the motor housing must comply.
• RoHS / REACH - Restrictions on hazardous substances in plastics and electronics.
• CPSC Guidelines - General safety requirements for consumer products, particularly regarding sharp edges on the cutting assembly and pinch points in the gears.
• Energy Star - If applicable to the final appliance, the motor efficiency contributes to overall energy ratings.

How a project runs

1. Inquiry - Define compatibility with target vacuum models and desired performance specs.
2. Design - CAD modeling of the gear train, coupling assembly, and housing integration.
3. Prototype - 3D printed housings and machined gears for fit and function testing.
4. Pilot Run - Injection molding of final tooling, assembly, and endurance testing.
5. Production - Mass manufacturing of molds, motors, and assembly lines.

Quantities & timeline

Tooling for the injection-molded housing and gears represents the primary upfront cost. Motor sourcing lead times depend on volume. Certification testing typically takes 4-6 weeks. Send us your target vacuum model, quantity, and certification needs and we will reply with options.

Production notes

Tooling and process

The housing and brush base likely require multi-cavity injection molds to manage costs. Gears need precision stamping or powder metallurgy for durability. The motor assembly involves automated winding and balancing.

Cost drivers

The high part count from the separate crushing roller, cutting assembly and complex gear train is likely a major cost driver. Mold complexity for the interlocking frames and spring-loaded couplings typically increases tooling expenses significantly.

Prototyping path

Start with SLA 3D printing for the housing to check fit. Machined gears are typically used to test meshing accuracy before committing to metal tooling. Functional samples will likely verify the one-to-four drive ratio.

What we would change before tooling

We might simplify the spring-loaded push plate mechanism if it proves prone to fatigue. Reducing the number of distinct plastic parts in the cutting assembly could lower mold counts and assembly time.

Common failure points

Thin walls in the housing may warp under heat from the motor. Gear teeth wear out if alignment is off. The spring in the coupling could lose tension over repeated use, leading to loose brushes.

Patent drawings

Drawings reproduced from the public patent document for reference.

Frequently asked questions

How does the crushing roller work?

It is driven by the same motor as the main brush but rotates independently. As the main brush sweeps debris forward, the crushing roller catches it and breaks down clumps or hard particles before they enter the suction tube, reducing clogs.

Is the brush easy to clean?

Yes. The coupling assembly uses a spring-loaded push plate. By pressing the plate, you release the positioning pin, allowing you to pull the roller brush out without any tools. This makes it easy to remove wrapped hair or replace the brush.

Can it handle long pet hair?

The design includes a sliding cutting assembly with blades. You can slide this assembly into place to cut through hair that has already wrapped around the brush, restoring functionality without disassembling the entire unit.

Does the extra weight affect maneuverability?

The addition of the crushing roller and second gear set increases the head’s weight slightly. However, the balanced one-to-four drive system distributes torque evenly, which helps maintain stability and traction on various floor types.

What materials are used?

The patent does not specify exact materials. Typically, such assemblies use durable plastics like ABS or PP for the housing, nylon for bristles, and metal alloys for gears and blades. Specific grades are confirmed during the design phase.

Is there a risk of damaging floors?

According to the patent, the crushing roller is designed for debris breakdown, not direct floor contact in the same way as the brush. Proper calibration of the height adjustment is crucial to ensure the crushing mechanism does not scratch delicate surfaces.

Can this design be made and sold in the US?

The patent is in force in China, but the public record shows no US counterpart. Therefore, this specific patent does not restrict manufacturing or selling in the US. However, a freedom-to-operate check is recommended to avoid infringing other existing US patents in the vacuum cleaner sector.

Are you affiliated with the patent owner?

No. IP2M is an independent design and manufacturing service working from the public patent document.

Request a quote

Click Request a Quote below to see our email address - copy it, or open your email app with a ready-made message. Please mention patent CN115299808B in the subject.

Helpful details to include:

• Your company and channel (vacuum brand, commercial equipment maker, aftermarket supplier)
• Target vacuum model or interface specifications
• Desired brush type (bristle material, hardness)
• Volume estimates and target price per unit
• Certification requirements (UL, CE, etc.)
• Timeline - when you would like prototypes and first production run

You can also reach us at (332) 203-9997.