Floor finish removal pad assembly and method for removing floor finish

Abstract

A floor finish removal pad assembly and a method of removing floor finish with the floor finish removal pad assembly are described.SOLUTION: The floor finish removal pad assembly includes a compressible backing pad and a plurality of discontinuously arranged non-rigid coated abrasives or a discontinuously patterned and substantially coextensive single coated abrasive. Methods of using such floor finish removal pad assemblies can effectively remove floor finishes without the use of chemical strippers.SELECTED DRAWING: Figure 1

Description

[Background technology]

[0001] Protective floor finishes are subject to scratches, scuffs, and abrasions when exposed to the environment, feet, and traffic (e.g., carts) in commercial buildings. To reapply the floor finish, it must be removed to expose the bare substrate underneath. Caustic chemicals are traditionally required to soften the hard finish so that it can be removed by abrasion. Summary of the Invention

[0002] In one aspect, the present specification relates to a floor finish removal pad assembly. In particular, the floor finish removal pad assembly includes a compressible backing pad having first and second major surfaces, and a plurality of discontinuously arranged, non-rigid coated abrasive articles attached to the first major surface of the compressible backing pad.

[0003] In another aspect, the present disclosure relates to a method for removing floor finishes, particularly the method for removing floor finishes, comprising contacting a plurality of discontinuously arranged, non-rigid coated abrasive articles attached to a major surface of a compressible backing pad with a coated hard floor surface, and optionally repeating the contacting step, wherein the contacting step is performed in the absence of an effective amount of a chemical stripper.

[0004] In yet another aspect, the present specification relates to a floor finish removal pad assembly. In particular, the floor finish removal pad assembly includes a compressible backing pad having a first major surface and a second major surface, and a discontinuously patterned, non-rigid coated, abrasive article substantially coextensive with the compressed backing pad and attached to the first major surface of the compressible backing pad. [Brief explanation of the drawings]

[0005] [Figure 1] 1A-1C are bottom views of an exemplary floor finish removal pad assembly including several exemplary shapes of coated abrasive articles. [Figure 2] 1 is a schematic perspective view of an exemplary abrasive grain shape. [Figure 3] 1 is a schematic elevation view of an exemplary system for removing floor finish using a floor finish removal pad assembly. [Figure 4] 1 is a schematic plan view of an exemplary abrasive pattern. DETAILED DESCRIPTION OF THE INVENTION

[0006] In the field of floor care, floor stripping refers to the complete removal of old wax, finish, stains, and debris found on a floor. Floor stripping is known to be one of the most time-consuming and labor-intensive tasks in floor maintenance and care, or even throughout the professional cleaning industry. Generally, applying a wax or floor finish to a floor substrate helps keep the floor visually attractive, shiny, and free of scratches and stains. Typically, these finishes or waxes are applied in multiple layers or coats. However, over time, especially with heavy foot traffic or other traffic, these layers wear down, become embedded with dirt or debris, and cannot be cleaned or repaired by normal conventional maintenance. In these cases, the floor finish or wax must be completely removed in order to apply a new finish coat.

[0007] The traditional floor stripping process involves four distinct steps. First, floor finish stripping chemicals are applied to the floor surface and allowed to sit for approximately 10 minutes. Second, a floor stripping pad is used to buff away the loose and / or softened floor finish. Third, the stripping solution, now contaminated with dirt and floor finish particulates, must be removed from the floor. Finally, the bare floor must be cleaned and dried before the floor finish can be reapplied.

[0008] Due to the messy, smelly, and potentially dangerous nature of conventional processes, it has been desirable to use chemical-free floor stripping methods. However, current methods require multiple passes to remove even a single layer of floor coating. Considering that most floor coatings recommend multiple coats (e.g., two or four), currently available chemical-free stripping solutions are impractical given the additional labor costs involved.

[0009] The floor finish removal pad assemblies described herein are surprisingly effective at removing layers of floor finish without the use of chemical floor strippers. In some embodiments, the floor finish removal pad assemblies utilize specially shaped and aligned abrasive grains. In some embodiments, the floor finish removal pad assemblies utilize a non-rigid coated abrasive article that is discontinuously disposed on a compressible backing pad. All floor surfaces have some degree of unevenness, and such compressibility and non-rigidity can help these assemblies reach low points on uneven floors and remove the floor finish coating thereon.

[0010] 1 is a bottom view of an exemplary floor finish removal pad assembly including several exemplary shapes of coated abrasive articles. Floor finish removal pad assembly 100 includes a compressible backing pad 110, optional mounting holes 112, and exemplary discretely arranged coated abrasive articles 120a, 120b, 120c, and 120d.

[0011] Floor finish removal pad 100 may be of any overall shape and size. In some embodiments, floor finish removal pad 100 may be round or disk-shaped if intended to be attachable to a rotary machine. In some embodiments, floor finish removal pad 100 may be rectangular or square if intended to be attachable to a square-type sander or orbital sander.

[0012] The compressible backing pad 110 may similarly be of any suitable shape, size, and thickness. In some embodiments, the compressible backing pad may be of any suitable thickness, for example, between 0.25 and 10 cm. A thickness of 1 inch (2.54 cm) is common. In some embodiments, the compressible backing pad may have a standard size and shape for attachment to existing floor cleaning and treatment equipment. For example, 20-inch (50.8 cm) floor pads are common, but sizes from 10 inches (25.4 cm) to 24 inches (60.96 cm) in diameter may be suitable for these applications.

[0013] The compressible backing pad 110 may be formed from any suitable material or materials. In some embodiments, the compressible backing pad 110 is urethane foam rubber or natural latex foam rubber. In some embodiments, the compressible backing pad 110 is open-cell ethylene-vinyl acetate. Any compressible natural material, polymeric material, or blend thereof can be used. In some embodiments, the compressible backing pad is a high-loft nonwoven pad. In these embodiments, the material used for the particular nonwoven fabric need not be compressible itself, but the high-loft pad may be configured to be compressible when the fibers can flex under stress. The fibers may include natural and synthetic fibers. In some embodiments, the fibers may be or include natural fibers (e.g., plant fibers such as hemp and jute, and animal hair fibers such as pig hair), polyamides (e.g., nylon), polyesters (e.g., polyethylene terephthalate or polyethylene isophthalate), rayon, polyethylene, polypropylene, synthetic fibers, or combinations thereof. Synthetic fibers include polymers derived from natural sources, such as corn-derived polylactic acid. The fibers may be adhered to one another at the junctures of mutual contact by a binder and / or by being melt bonded.

[0014] The compressible backing pad 110 includes optional mounting holes 112. The optional mounting holes may be of any suitable size or shape and may be adapted or designed to allow the floor finish removal pad assembly 100 to be used or attachable to any desired floor treatment or maintenance machine.

[0015] Discretely arranged coated abrasive articles 120a, 120b, 120c, and 120d can be any suitable shape and size, although in many embodiments, it is desirable for such coated abrasive articles to fit completely within the confines of compressible backing pad 110 when attached. As can be seen from the various shapes represented by 120a, 120b, 120c, and 120d, there are many possible suitable configurations. In some embodiments, the coated abrasive articles are all the same shape, and in some embodiments, the coated abrasive articles are different shapes. In some embodiments, the coated abrasive articles are the same size or area, and in some embodiments, the coated abrasive articles are different sizes or areas. Suitable shapes include round, oval, elliptical, polygonal, square, rectangular, trapezoidal, diamond, rhombus, and the like. Irregular, curved, and other shapes are also possible and may be suitable for particular applications. The coated abrasive article is non-rigid, meaning that it has at least some freedom to bend recoverably without cracking or fracturing. In some embodiments, the coated abrasive article may include a fabric or texture backing, or a thin or flexible polymer backing. In some embodiments, the coated abrasive article may include a nonwoven backing or a foam backing. In some embodiments, the coated abrasive article may be removably attachable to a compressible backing pad and may include an adhesive or hook-and-loop (or other physical interconnection) mechanism for attachment.

[0016] The coated abrasive article is coated with or includes at least a plurality of abrasive grains. In some embodiments, the plurality of abrasive grains includes one type of abrasive material. In some embodiments, the plurality of abrasive grains includes a plurality of abrasive materials or a blend of abrasive materials. In some embodiments, the plurality of abrasive grains includes only one of abrasive grains of substantially the same shape. In some embodiments, the plurality of abrasive grains includes abrasive grains of multiple shapes. The abrasive grains can be any of the abrasive particulate materials described herein, such as aluminum oxide, ceramic aluminum oxide, heat-treated aluminum oxide, silicon carbide, co-fused alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel derived abrasive particles, novaculite, pumice, rouge, sand, corundum, sandstone, tripoli, powdered feldspar, staurolite, ceramic iron oxide, glass powder, steel particles, and blends thereof. The abrasive coating can also include a resin. Exemplary resins suitable for use include melamine resins, polyester resins such as the condensation products of maleic anhydride and phthalic anhydride with propylene glycol, synthetic polymers such as styrene-butadiene (SBR) copolymers, carboxylated-SBR copolymers, phenol-aldehyde resins, polyesters, polyamides, polyureas, polyvinylidene chloride, polyvinyl chloride, methyl acrylate methacrylate copolymers, acetal copolymers, polyurethanes, and mixtures and crosslinked versions thereof.

[0017] Shaped abrasive grains can be particularly useful in certain embodiments. Shaped abrasive grains can be molded abrasive grains containing shapes not found in abrasives supplied by conventional methods, which are essentially random. Shaped abrasive grains can also be more uniform in shape. Methods for making shaped abrasive grains are known and are described, for example, in U.S. Pat. No. 8,142,531 (B2) (Adefris et al.). Suitable shaped abrasive grains can be of any suitable shape (discussed in more detail in connection with FIG. 2) and any suitable size. In some embodiments, the average or characteristic dimensions of the abrasive grains (whether shaped or not) can be 0.01-0.1 mm, 0.1-0.5 mm, 0.5-1 mm, or 1 mm-5 mm. In some embodiments, the plurality of abrasive grains can include a blend of sizes. Abrasive grains or abrasive grains mixed with or in any other ingredients to make an abrasive slurry can be coated onto a backing by any suitable method, including spray coating or roll coating. Lubricants or other additives may be incorporated or included.

[0018] In some embodiments, any of the abrasive grains described in conjunction with the discontinuous, non-rigid coated abrasive article can be present in any other portion of the floor finish removal pad assembly, such as on a compressible backing pad.

[0019] In some embodiments, the single coated abrasive article, including the backing, is coextensive or substantially coextensive with the compressible backing pad. The backing of the single coated abrasive article can be patterned to create areas of abrasive adjacent to areas that do not contain abrasive. Any suitable abrasive or combination of abrasives can be used for any of the discontinuously coated abrasive articles described above.

[0020] FIG. 2 is a schematic perspective view of exemplary abrasive grain shapes. Equilateral triangular grain shape 222a has faces that approximate an equilateral triangle. Right-angled triangular grain shape 222b has faces that approximate a right-angled triangle. Shapes such as those shown in FIG. 2 may be particularly suited to a particular type of floor finish or may be generally applicable to a variety of floor finishes, and the shape may be selected based on the application and desired performance. In some embodiments, shapes other than those depicted herein or variations on shapes may be used. For example, the length or angle of the sidewalls may be varied.

[0021] FIG. 3 is a schematic elevation view of an exemplary system for removing floor finish using a floor finish removal pad assembly. To remove floor finish from a coated floor 340, a floor device 330 incorporates a floor finish removal pad assembly 310. The floor device 330 may be an automatic scrubber. In some embodiments, the floor device 330 may be an orbital sander or a square sander. The floor device 330 is configured to facilitate contacting the floor finish removal pad assembly 310 against the coated floor 340. In some embodiments, contacting the floor finish removal pad assembly 310 against the coated floor 340 includes rotating the floor finish removal pad assembly. The coated floor 340 may be any coated hard surface, including vinyl composition tile (VCT), solid vinyl tile, stone floor, or any other suitable natural or manufactured floor surface. In FIG. 3, the coated floor 340 is shown with broken lines to indicate that the coated floor 340 may be of any large or small size. The coated floor may also include any number of coatings (typically less than 10) of any wax, floor coating, or protectant. In some embodiments, contacting the floor finish removal pad assembly against the coated floor includes translating the floor finish removal pad assembly laterally relative to the coated floor. In some embodiments, contacting the floor finish removal pad assembly against the coated floor occurs in the absence of a chemical stripper. In some embodiments, contacting the floor finish removal pad assembly against the coated floor occurs in the absence of water. In some embodiments, the contacting steps are optionally repeated. In some embodiments, removing a 25-micrometer thick coating of floor finish requires fewer than 10 contacting steps.

[0022] Example Floor finish removal pad assembly samples were prepared by coating an abrasive material onto a film backing. The samples were tested for abrasion and finish removal. Unless otherwise stated, all parts, percentages, ratios, etc. in the examples and elsewhere in this specification are by weight. Unless otherwise stated, all other reagents were obtained or are available from chemical suppliers, such as Sigma-Aldrich Company of St. Louis, Missouri, or can be synthesized by known methods.

[0023] [Table 1]

[0024] Example 1 MAKE1 was continuously coated onto BACK1 with a notch bar at a weight of 24 particles per 4 inch x 6 inch (10 x 15 cm) area.

[0025] MIN1 was coated onto BACK1 by a continuously moving electrostatic coater at a total mineral weight of 60 particles per 4" x 6" (10 x 15 cm) area. A second mineral, MIN4, was also applied by electrostatic coater at a weight of 20 particles per 4" x 6" (10 x 15 cm) area.

[0026] The material was cut into approximately 40-inch lengths and placed in a batch oven. The oven was operated at 175°F for 30 minutes, 195°F for 30 minutes, and 210°F for 70 minutes.

[0027] The material was removed from the batch oven and passed through a roll coater to apply SIZE 1 at a coverage of 483 grams per square meter using a 75 cm paint roller, and the resulting product was cured at 90°C for 60 minutes and then at 102°C for an additional 8 hours.

[0028] Example 2 The sample preparation of Example 1 was repeated except that MIN2 was used instead of MIN1.

[0029] Example 3 The sample preparation of Example 1 was repeated except that MIN3 was used instead of MIN1.

[0030] Example 4 A - Preparation of Laminated Loop Backing

[0031] [Table 2]

[0032] The NET MESH was laminated to one layer of 72 grams per square meter of BOSTIK using an iron press with a contact time of about 2 seconds, thus creating a continuous film on the loop backing.

[0033] B-Phenol Resin Preparation The components of the phenolic resins used to prepare the abrasive articles described herein are listed in Table 2.

[0034] [Table 3]

[0035] The curable compositions were prepared by blending B7 with U0 under high speed dispersion using a high shear blade at 600 rpm to 900 rpm until a homogeneous mixture was obtained, then adding D1, GEO, COL, SIC, FIL2, ANT, and gradually adding FIL5 under shear.

[0036] C-Stencil Printing Process Using a patterned 3-mil polyester stencil (patterned as shown in Figure 4) placed on top of the continuous film on laminated loop backing, curable composition B—phenolic resin—was stenciled by contacting the backing with the stencil, applying the curable composition to the side of the stencil opposite the backing, forcing the curable composition through a screen / stencil using a blade mechanism, and then separating the stencil and backing to leave a coating of curable composition on the backing. The amount of curable composition coated was 100 gsm, with a film thickness of 100 microns. Next, while the curable composition was still wet, 50 gsm of a blend of 70% AP180 and 30% MIN5 was electrostatically coated (Spellman SL 150). The entire construction was then thermally pre-cured for 30 minutes in a batch oven at 80°C and final-cured for 4 hours in a batch oven at 103°C. During this final step, the curable composition cures, the BOSTIK melts, and the loop backing fibers and screen wick, reopening many of the original holes in the backing. In this example, a minimum of 90% of the original holes were reopened.

[0037] Comparative Example 1 3M High Productivity Pad 7300 (available from 3M Company (St. Paul, MN)) Comparative Example 2 3M Black Stripper PAD 7200 (available from 3M Company (St. Paul, MN)) Comparative Example 3 SCOTCH-BRITE Surface Preparation Pad Plus (available from 3M Company (St. Paul, MN))

[0038] Test results 1. Schiefer denudation test A Schiefer abrasion test was conducted to evaluate the relative abrasion properties of the articles of the present invention. The test was conducted in a manner generally similar to that described in U.S. Pat. No. 5,626,512 (Palaikis et al.). Examples 1-3 were laminated with a layer of hook material (APIX220 hook) and then cut into circular pads (8.25 cm diameter). A 3M 96 abrasive pad (available from 3M Company, St. Paul, MN) was cut into a circle of the same size. After attaching the hook side of the article to the 3M 96 scouring pad, the entire assembly was secured to the drive plate of a Schiefer abrasion tester (available from Frasier Precision Company, Gaithersburg, Maryland). All workpieces were approximately 10.16 cm in diameter and 0.317 cm thick. The initial dry weight of each workpiece was recorded, and the workpieces were secured to the lower turntable of the testing machine using double-sided foam tape. The test was conducted under a 2.26 kg load for a total of 2,000 revolutions with water applied to the surface of the acrylic disc at 40-60 drops per minute. The test was stopped every 500 revolutions. The workpiece was dried and weighed. The weight loss of the acrylic disc during the test is shown as the results (reported in grams) in Table 3. Examples showing higher weight loss have higher ablation rates.

[0039] [Table 4]

[0040] 2.Floor finish removal test Vinyl composition tile (VCT) floor test areas were first stripped and then coated with one layer of Signature floor finish (available from Sealed Air, Charlotte, NC 28273) at 2000 square feet per gallon. After drying, five marker lines were drawn on each tile. Four layers of Signature floor finish were then coated over the marker lines and allowed to cure for seven days before testing. Examples 1-4 were laminated with a layer of hook material (Aplix 220 hooks) and then cut into 3-inch by 9-inch (7.6 x 23 cm) strips. The hook sides of six strips were attached to a 14-inch by 20-inch (35.6 x 51 cm) 3M Red Buffer floor pad in three rows, and the entire assembly was mounted on a 14-inch by 20-inch square scrubbing machine (EBG-20 / C PIVOT, manufactured by Square Scrub). The square scrubbing machine was moved back and forth across the tested tiles. The number of passes was counted until 95% of the marker line was removed. A before and a after was counted as two passes. Table 4 shows the test results. The example requiring fewer passes to remove four layers of Signature floor finish is more efficient.

[0041] [Table 5]

[0042] The terms and expressions used are used as terms of description rather than limitation, and when using such terms and expressions, there is no intention to exclude equivalents of the features shown and described or portions thereof, and it is understood that various modifications are possible within the scope of the embodiments of the present invention. Thus, although the present invention has been specifically disclosed by certain embodiments and optional features, it should be understood that modifications and variations of the concepts disclosed herein may be resorted to by those skilled in the art, and such modifications and variations are considered to be within the scope of the embodiments of the present invention. In addition to the embodiments, the following aspects are noted. (Appendix 1) a compressible backing pad having a first major surface and a second major surface; a plurality of discontinuously arranged, non-rigid coated abrasive articles attached to the first major surface of the compressible backing pad; 1. A floor finish removal pad assembly comprising: (Appendix 2) 10. The floor finish removal pad of claim 1, wherein a plurality of discontinuously arranged, non-rigid coated abrasive articles are removably attached to the first major surface of the compressible backing pad. (Appendix 3) 10. The floor finish removal pad assembly of claim 1, wherein the coated abrasive article comprises aluminum oxide particles. (Appendix 4) 10. The floor finish removal pad assembly of claim 1, wherein the coated abrasive article comprises equilateral triangular particles. (Appendix 5) 10. The floor finish removal pad assembly of claim 1, wherein the coated abrasive article comprises right-angled triangular particles. (Appendix 6) 2. The floor finish removal pad assembly of claim 1, wherein the compressible backing pad is a high-loft nonwoven pad. (Appendix 7) 2. The floor finish removal pad assembly of claim 1, wherein the compressible backing pad is a foam pad. (Appendix 8) 10. The floor finish removal pad assembly of claim 1, wherein the compressible backing pad comprises abrasive grains. (Appendix 9) 10. The floor finish removal pad assembly of claim 1, wherein the coated abrasive article comprises a lubricant. (Appendix 10) 1. A method for removing a floor finish, comprising: contacting a plurality of discretely arranged, non-rigid coated abrasive articles attached to a major surface of a compressible backing pad with the coated hard floor surface; and optionally repeating the contacting step; wherein the contacting step is performed in the absence of an effective amount of a chemical stripper. method. (Appendix 11) 11. The method of claim 10, wherein the contacting step is performed in the absence of water. (Appendix 12) 11. The method of claim 10, wherein removing a 25 micrometer thick coating of acrylic floor finish requires fewer than 10 contacting steps. (Appendix 13) 11. The method of claim 10, wherein the method includes attaching the compressible backing pad to a scrubber or sander prior to the contacting step. (Appendix 14) 14. The method of claim 13, wherein the compressible backing pad is attached to an automatic scrubber. (Appendix 15) 14. The method of claim 13, wherein the compressible backing pad is attached to an orbital sander. (Appendix 16) a compressible backing pad having a first major surface and a second major surface; a discontinuously patterned, non-rigid coated abrasive article substantially coextensive with the compressible backing pad and attached to the first major surface of the compressible backing pad; 1. A floor finish removal pad assembly comprising: (Appendix 17) 17. The floor finish removal pad assembly of claim 16, wherein the coated abrasive article comprises aluminum oxide particles. (Appendix 18) 17. The floor finish removal pad assembly of claim 16, wherein the coated abrasive article comprises equilateral triangular particles. (Appendix 19) 17. The floor finish removal pad assembly of claim 16, wherein the coated abrasive article comprises right-angled triangular particles. (Appendix 20) 17. The floor finish removal pad assembly of claim 16, wherein the compressible backing pad is a lofty nonwoven pad or a foam pad.

Claims

[Claim 1] a compressible backing pad having a first major surface and a second major surface; a plurality of discontinuously arranged, non-rigid coated abrasive articles attached to the first major surface of the compressible backing pad; 1. A floor finish removal pad assembly comprising:

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