Pad assembly for floor cleaning

Abstract

A pad assembly having an easily removable / replaceable surface cleaning textile material incorporating low denier fiber constituents held in a hook and loop type engagement with a nonwoven fiber connector pad disposed between the cleaning textile material and a rotating scrubber driver. The surface cleaning textile material contacts the floor during use while the connector pad provides structural integrity and operatively connects to the scrubber driver apparatus. The surface cleaning textile material is held in place across the intermediate connector pad using the gripping behavior between the textile material and an irregular surface of the connector pad. The friction in pure shear is extremely high while the peel strength between the surface cleaning textile material and connector pad may be relatively low to facilitate removal and replacement of the surface cleaning textile material after use.

Description

PAD ASSEMBLY FOR FLOOR CLEANINGCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This nonprovisional application claims the benefit of prior US provisional application No. 63 / 637,754 filed on 23 April 2024. The contents of such prior application and all other documents reference herein are hereby incorporated by reference in their entirety as if fully set forth herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to cleaning systems for floors and other surfaces. More particularly, this disclosure relates to a pad system for use with commercial auto scrubbers of the type used to clean floors and other surfaces in environments such as hospitals, hotels, and the likeBACKGROUND

[0003] Auto scrubber systems using rotational or orbital movement of cleaning pads for floor cleaning are well known. By way of example only, some exemplary floor scrubbers are illustrated and described in US patents 5,355,542 to Greek et al. and 8,234,749 to Mitchell et al. each of which is incorporated herein by reference in its entirety. Scrubbing systems were originally developed to apply relatively abrasive treatment to surfaces such as vinyl composition tile (stripping wax), concrete, terrazzo and the like. Such materials are not prone to damage by the relatively abrasive pads currently used. Unfortunately, floor care cleaning practices have been carried forward into the present market and are now being used in cleaning and maintenance of materials such as LVF (luxury vinyl flooring) which can be damaged by abrasive treatment. In this regard, current cleaning pads are typically formed from relatively coarse denier (>100), low density, resin bonded nonwoven. The bonding resin contains aggregate in different amounts designated by the color of the pad.

[0004] The inventors have studied the compatibility of LVF and various commercial pads with varying levels of grit size / aggregate. Based on these studies, it has been found that a relatively short run time of 120 seconds on LVF tile will increase the surface gloss by 4 points on a standard Gloss Unit scale, which is enough to be detected by the naked eye. Thus, even a relatively short treatment period may alter the flooring appearance.

[0005] LVF surface topography is made up of numerous peaks and valleys along with an embossing pattern that often mimics wood grain. Current commercial pads may flatten the peaks of the wear layer thereby causing a viewer to perceive a change in gloss. Since the change in gloss will not be consistent across the flooring, the floors will begin to look worn. Additionally, most flooring manufacturers try and exceed the ADA standard for Static Coefficient of Friction (COF) of 0.6. When wet, a smoother surface caused by abrasive wear may lower the COF. Such a reduction thus increases the possibility of slipping. Finally, the coarse denier fiber used in current pads may be too large reach into the floor embossing to emulsify and remove dirt during a wet extraction cleaning process.SUMMARY

[0006] The present disclosure offers advantages and / or alternatives over the prior art by providing a pad assembly having an easily removable / replaceable surface cleaning textile material incorporating low denier fiber constituents held in a hook and loop type engagement with a nonwoven fiber connector pad disposed between the cleaning textile material and a rotating scrubber driver. The surface cleaning textile material contacts the floor during use while the connector pad provides structural integrity and operatively connects to the scrubber driver apparatus. The surface cleaning textile material is preferably held in place across the intermediate connector pad exclusively by the gripping behavior between the textile material and an irregular surface of the connector pad formed by flame singeing or other heat activation of fibers at the connector pad surface. In this regard, the peel strengthbetween the surface cleaning textile material and connector pad may be relatively low to facilitate removal and replacement of the surface cleaning textile material after use. However, the friction in pure shear is extremely high thereby securing the surface cleaning textile material in a fixed relative position relative to the connector pad during use.

[0007] In accordance with one exemplary aspect, the present disclosure provides a layered composite adapted for use in a rotary scrubber in place of brushes or abrasive pads during a floor cleaning operation. The layered composite includes a fibrous felt connector pad including low melting point fiber constituents. The connector pad further includes a plurality of higher melting point fibers. The connector pad includes at least a first face with a plurality of irregular surface nodules of heat softened and resolidified fiber material. A second face projects away from the first face and may include a plurality of surface loops. A removable cleaning textile layer adapted to contact a floor surface being cleaned is disposed in juxtaposed relation to the surface nodules. The cleaning textile layer includes a plurality of microfiber yarns adapted to engage the surface nodules in a self- supporting hook and loop connection without the need for adhesive assistance. The connection between the connector pad and the cleaning textile layer has a shear strength greater than its peel strength. The cleaning textile layer optionally also includes a plurality of heat fused non-microfiber polypropylene yarns with the microfiber yams and non-microfiber yams arranged in a striped pattern across the cleaning textile layer.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings which are incorporated in, and which constitute a part of this specification, illustrate exemplary constructions and procedures in accordance with the present disclosure and, together with the general description of the disclosure given above, and the detailed description set forth below, explain the principles of the disclosure wherein:

[0009] FIG. 1 illustrates an exemplary conventional rotary scrubber as will be well known to those of skill in the art;

[0010] FIG. 2 is a view similar to FIG. 1 illustrating use of a cleaning textile and intermediate pad in place of scrubbing brushes in accordance with the present disclosure;

[0011] FIG. 3 is a partial view of an exemplary layered composite of cleaning textile and intermediate pad with the cleaning textile partially peeled away;

[0012] FIG. 4 is an elevation view of an exemplary intermediate pad structure with the cleaning textile fully removed illustrating a connecting face for the cleaning textile; and

[0013] FIG. 5 is a schematic sectional view of the exemplary intermediate pad structure illustrating surface nodules of resolidified polymer disposed across a connecting face.

[0014] While features of the disclosure have been illustrated and will hereinafter be described in connection with certain exemplary embodiments and practices, it is to be understood that in no event is the disclosure to be limited to such illustrated and described embodiments and practices. On the contrary, it is intended that the present disclosure shall extend to all alternatives and modifications as may embrace the general principles of this disclosure within the full and true spirit and scope thereof.DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0015] Reference will now be made to the drawings, wherein corresponding elements are designated by corresponding reference numerals in the various views. FIG. 1 illustrates an exemplary rotary scrubber 10 incorporating a pair of drivemotors 12 operatively engaging rotary disk brushes 14 via an intermediate rotating driver disk 16 in a manner well known to those of skill in the art. As will be appreciated by those of skill in the art, it is also known to substitute brushes 14 with abrasive pads for some environments of use.

[0016] Referring to FIG. 2, an exemplary embodiment consistent with the present disclosure substitutes brushes 14 (or abrasive pads) with a layered composite 20 operatively engaging driver disk 16. By way of example only, and not limitation, layered composite may be a two-layered structure incorporating a cleaning textile 30 adapted to contact the floor or other surface being cleaned in juxtaposed contacting relation to a supporting fibrous connector pad 32. The size and shape of the cleaning textile 30 and supporting fibrous connector pad 32 are preferably substantially coextensive with one another to permit full coverage without substantial overhang. By way of example only, both cleaning textile 30 and supporting fibrous connector pad 32 may have a substantially annular construction with a circular or elliptical perimeter. However, other geometries including polygonal geometries such as squares, hexagons and the like may be used if desired. As will be appreciated, such polygonal geometries may be useful in reducing waste when cutting from larger sheets of material.

[0017] As noted previously, engagement between the fibrous connector pad 32 and surface cleaning textile 30 may be maintained exclusively by frictional gripping engagement between an irregular surface of connector pad 32 and fibers in surface cleaning textile 30. However, it is also contemplated that a light pressure adhesive or other gripping aid may also be used if desired.

[0018] In accordance with one exemplary practice, surface cleaning textile 30 may be a terry warp knit formed by using an alternating pattern of relatively high denier yam and multifilament microfiber yam characterized by a denier per filament level of less than 1 . By way of example only, and not limitation, in one exemplary construction 6 ends of a 180 denier 36 filament polypropylene scrub yam may be knit in alternated patterning with six ends of a DTY (drawn textured yam) split microfiber polyester yam with a denier per filament less than 1 in a warp knit patternto provide a basis weight of about 275 grams per square meter. The exemplary fabric may thereafter undergo heat bonding treatment causing the polypropylene to soften and stiffen upon cooling to form a pattern of scrubbing bands 34 between microfiber bands 36. Of course, different yarns and / or patterns may be used as desired. The microfiber in the auto scrubber application has proven to be a success for cleaning and maintaining LVF. Results show a change in gloss of less than 1 .5 points. Such levels are not visible to the naked eye. Additionally, microfiber yam provides excellent mechanical removal of dirt from the embossing.

[0019] As illustrated, an intermediate fibrous connector pad 32 acts as a connector between driver disk 16 and surface cleaning textile 30. Connector pad 32 drives the surface cleaning textile 30 and provides the backing for easy change out. As best illustrated in FIG. 5, in accordance with one exemplary construction, connector pad 32 may incorporate a modified hook connection surface on one face which engages yarn components on surface cleaning textile 30 to establish a modified hook and loop connection. By way of example only, in one exemplary construction connector pad 32 may be a carded fleece 40 formed from a fiber blend of about 50% 4 denier PET core / sheath bicomponent fiber with a sheath of low melting point polyester surrounding a core of higher melting point standard PET in combination with about 50% 40 denier standard PET fiber. This larger denier standard fiber preferably has a melting point greater than the low melting point bicomponent sheath material. In accordance with one exemplary construction, connector pad 32 may have a thickness of 0.5 inch to 1 inch and a basis weight 600- 1200 GSM. However, other dimensions and weights may also be used.

[0020] In accordance with one exemplary practice, connector pad 32 may be flame singed on one side by a natural gas burner to form an irregular surface of large surface nodules 42 (FIG. 5) of heat softened and resolidified fiber across fleece 40 for engagement with the microfiber in surface cleaning textile 30. In this regard, it will be understood that the low melting point bicomponent constituent may be preferentially softened and resolidified. However, a portion of the standard PET polyester may also undergo at least some degree of softening and resolidification during the heating and subsequent cooling. It is likewise contemplated that localizedheating processes such as high intensity radiant heating or the like may be used in place of flame treatment if desired. Regardless of the treatment process used, the resulting irregular nodule surface provides much greater connection to surface cleaning textile 30 in the shear direction (x direction) vs peel (z direction), thereby enhancing grip during cleaning while permitting the user to easily disengage the pad from surface cleaning textile 30 for changeout.

[0021] In accordance with one exemplary practice, connector pad 32 may be formed on a Garnett line, which specializes in moving more fiber in the Z direction. Using the Garnett line and exemplary fiber blend, it has been found that the larger denier fiber forms a loop pile across the side which is not singed. This loop pile facilitates a strong connection with the large hooks (not shown) typically found on auto scrubber driver pads at the interior of driver disk 16 as will be well known to those of skill in the art. That is, in the illustrated exemplary construction, the singed face of connector pad 32 defines a hooking surface for attachment to surface cleaning textile 30 in a first hook and loop connection, while the opposing face defines a type of loop structure for attachment to hooking elements for operative connection to the driver disk in a second hook and loop connection.

[0022] Surprisingly, it has been found that the layered composite 20 including microfiber cleaning textile 30 in combination with the nodule surface fibrous connector pad 32 maintains an adequate connection between the layers for use in a rotary scrubber without the need for additional adhesive. In this regard, the microfiber yam constituents in the cleaning textile form a high surface area engaging the nodules in a modified hook and loop connection. At the same time, the combination of scrubbing bands 34 formed by heat bonded fiber and microfiber bands 36 across the cleaning textile 30 provide excellent cleaning without excessive abrasion. The present disclosure thus provides a significant benefit over prior constructions due to performance and ease of replacement.

[0023] Of course, variations and modifications of the foregoing are within the scope of the present disclosure. Thus, it is to be understood that the disclosure herein extends to all alternative combinations of two or more of the individualfeatures mentioned or evident from the text and / or drawings. All of these different combinations constitute various alternative aspects of the disclosure. The embodiments described herein explain the best modes for practicing the disclosure and will enable others skilled in the art to utilize the disclosure. The claims are to be construed to include alternative embodiments and equivalents to the extent permitted by the prior art.

[0024] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e. , meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure, and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

[0025] Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the disclosure to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof isencompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

What is claimed is:1 . A layered composite adapted for use in a rotary scrubber in place of brushes or abrasive pads during a floor cleaning operation, the layered composite comprising: a fibrous felt connector pad comprising a first plurality of polymer fibers including a constituent characterized by a first melting point and at least a second plurality of polymer fibers characterized by a melting point higher than the first melting point, the connector pad including at least a first face comprising a plurality of irregular surface nodules comprising heat softened and resolidified portions of said first plurality of polymer fibers, the connector pad further including at least a second face projecting away from the first face; and a removable cleaning textile layer adapted to contact a floor surface being cleaned, the cleaning textile layer being disposed in juxtaposed relation to said surface nodules, the cleaning textile layer comprising a plurality of microfiber yams adapted to engage said surface nodules in a self-supporting hook and loop connection, wherein said connection has a shear strength greater than its peel strength.

2. The layered composite as recited in Claim 1 , wherein the second plurality of polymer fibers are characterized by a higher denier than the first plurality of polymer fibers.

3. The layered composite as recited in Claim 1 , wherein the fibrous felt connector pad comprises a plurality of bicomponent polyester fibers, thebicomponent polyester fibers having a core of PET polyester characterized by a first melting point and a sheath of PET polyester with a second melting point lower than the first melting point.

4. The layered composite as recited in Claim 1 , wherein the second plurality of polymer fibers comprise non-bicomponent PET polyester.

5. The layered composite as recited in Claim 1 , wherein said first face is flame singed.

6. The layered composite as recited in Claim 1 , wherein the second face comprises a plurality of surface loops.

7. The layered composite as recited in Claim 1 , wherein the second face comprises a plurality of surface loops, of non-bicomponent polyester fiber.

8. The layered composite as recited in Claim 1 , wherein said microfiber yarns are polyester.

9. The layered composite as recited in Claim 1 , wherein the cleaning textile layer further comprises a plurality of heat fused non-microfiber yams.

10. The layered composite as recited in Claim 9, wherein said plurality of heat fused non-microfiber yams are polypropylene yams.11 . The layered composite as recited in Claim 10, wherein the microfiber yarns and non-microfiber yarns are arranged in a striped pattern across the cleaning textile layer.

12. A layered composite adapted for use in a rotary scrubber in place of brushes or abrasive pads during a floor cleaning operation, the layered composite comprising: an annular fibrous felt connector pad comprising a plurality of bicomponent polyester fibers, the bicomponent polyester fibers having a core of polyester characterized by a first melting point and a sheath of polyester with a second melting point lower than the first melting point, the connector pad further comprising a plurality of non-bicomponent polyester fibers characterizing by a melting point higher than the sheath of the bicomponent fibers, the non-bicomponent polyester fibers having a liner density larger than the bicomponent fibers, the connector pad including at least a first face comprising a plurality of irregular surface nodules comprising melted and resolidified polyester, the connector pad further including at least a second face projecting away from the first face, the second face comprising a plurality of surface loops of non-bicomponent polyester; and a removable cleaning textile layer adapted to contact a floor surface being cleaned, the cleaning textile layer being disposed in juxtaposed relation to said surface nodules, the cleaning textile layer comprising a plurality of microfiber polyester yams adapted to engage said surface nodules in a self-supporting hook and loop connection without adhesive assistance, wherein said connection has a shear strength greater than its peel strength the cleaning textile layer further comprising a plurality of heat fused non-microfiber polypropylene yarns wherein themicrofiber yarns and non-microfiber yams are arranged in a striped pattern across the cleaning textile layer.

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