Cleaning and fluid application assembly for rotary scrubber

Abstract

A rotary scrubber system having an improved driver disk adapted to facilitate downward dispersion of a cleaning or treatment solution to the interior of an underlying brush or textile pad structure. The driver disk has an annular construction with a raised central hub extending upwardly from a first side. A raised fluid containment wall is disposed in spaced-apart surrounding outboard relation to the central hub. A depressed annular fluid receiving zone is disposed between the central hub and the fluid containment wall. The fluid receiving zone is adapted to receive a flow of cleaning or treatment fluid. A plurality of drain openings is disposed within the fluid receiving zone. The drain openings are in fluid communication with hollow nipples extending downwardly away from a second side of the driver disk facing away from the first side. The hollow nipples include interior channels adapted to transfer fluid away from said drain openings. A fibrous felt connector pad may be mounted across the second side of the driver disk with openings adapted to receive the hollow nipples in mating relationship.

Description

CLEANING AND FLUID APPLICATION ASSEMBLY FOR ROTARY SCRUBBERCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This nonprovisional application claims the benefit of prior US provisional application No. 63 / 743,785 filed on 10 January 2025. 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. More particularly, this disclosure relates to a rotary scrubber including an improved system for supporting and delivering fluid to a cleaning pad structure for use in cleaning floors and other surfaces in environments such as hospitals, hotels, and the like.BACKGROUND

[0003] Auto scrubber systems using rotational movement of cleaning pads and brushes 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 textiles. The bonding resin contains aggregate in different amounts designated by the color of the pad.

[0004] In current rotary scrubbers cleaning solution is typically introduced from an internal reservoir tank to an upper surface of a driver disk above the pad or brushes and offset from the axis of rotation. As the driver disk rotates, the cleaning solution moves radially outwardly along the upper surface to a groove which directs the captured solution downwardly to the underlying pad or bristles. However, the rotation may expel a significant portion of the solution outwardly away from the cleaning surface to positions beyond the scrubber cleaning and vacuum zone.Some portion of the cleaning solution may thus be wasted and may have to be manually removed by a secondary mopping operation to avoid a slipping hazard.

[0005] In view of the above, a rotary scrubbing system providing reduced abrasion and having improved fluid delivery which may be used with existing equipment would represent a meaningful improvement over the current art.SUMMARY

[0006] The present disclosure provides advantages and / or alternatives over the prior art by providing a rotary scrubber system having an improved driver disk adapted to facilitate downward dispersion of a cleaning solution to the interior of an underlying brush or textile pad structure. The present disclosure also provides a pad assembly having an easily removable / replaceable surface cleaning textile material incorporating low denier microfiber constituents in a hook and loop type engagement with a supporting nonwoven fiber connector pad. Microfiber has more surface area and thus fluid transfer is more efficient thereby reducing splashing as compared to brushes or resin bonded coarse denier pads. The surface cleaning textile material contacts the floor during use while the underlying connector pad provides structural integrity and connects to the driver disk. 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 singing or other heat activation of fibers at the connector pad surface. In this regard, the peel strength between thesurface cleaning textile material and connector pad may be relatively low to facilitate removal and replacement of the surface cleaning textile material. However, the friction in pure shear is extremely high thereby securing the surface cleaning textile material in a fixed relative position during use. In one embodiment, the fiber connector pad may include a plurality of apertures extending at least partially through the thickness dimension adapted to receive and contain cleaning fluid directed downwardly from the driver disk thereby enhancing absorption and reducing the propensity for waste.In accordance with one exemplary aspect, the present disclosure provides a rotary scrubber adapted to deliver a cleaning or treatment fluid to cleaning pads and having at least one drive motor adapted to impart rotation or orbital movement to the cleaning pads to clean a flooring surface. The rotary scrubber includes at least one driver disk operatively engaging the drive motor. The driver disk may have an annular construction with a raised central hub extending upwardly from a first side. A raised fluid containment wall is disposed in spaced-apart surrounding outboard relation to the central hub. A depressed annular fluid receiving zone is disposed between the central hub and the fluid containment wall. The fluid receiving zone is adapted to receive a flow of cleaning or treatment fluid. A raised perimeter wall is disposed in spaced-apart surrounding outboard relation to the fluid containment wall with a plurality of support ribs extending radially between the fluid containment wall and the raised perimeter wall. The height of the fluid containment wall may be lower than the central hub and the perimeter wall may be lower than the fluid containment wall. A plurality of drain openings is disposed within the fluid receiving zone. The drain openings are in fluid communication with aligned hollow nipples extending downwardly away from a second side of the driver disk facing away from the first side. The hollow nipples include interior channels adapted to transfer fluid away from said drain openings. An annular fibrous felt connector pad may be mounted across the second side of the driver disk with openings adapted to receive the hollow nipples in mating relationship. A removeable surface cleaning textile layer incorporating a plurality of microfiber yarns adapted to contact a floor surface being cleaned may be disposed in juxtaposed relation to the connector pad.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] 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:

[0008] FIG. 1 illustrates an exemplary conventional rotary scrubber as will be well known to those of skill in the art;

[0009] 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 exemplary constructions consistent with the present disclosure;

[0010] FIG. 3 is an edge view of an exemplary pad assembly showing a surface cleaning textile material in place facing downward across a connector pad;

[0011] FIG. 4 is an elevation plan view of an exemplary driver disk consistent with the present disclosure;

[0012] FIG. 5 is a perspective view of the upper face of the exemplary driver disk of FIG. 4 supporting a pad assembly of FIG. 3;

[0013] FIG. 6 is a perspective view of the lower face of the exemplary driver disk of FIG. 4 and mating connector pad;

[0014] FIG. 7 is a side view of the exemplary driver disk of FIG. 4 coupled with the exemplary pad assembly of FIG. 3; and

[0015] FIG. 8 is a sectional view taken generally along line 8-8 of FIG. 7.

[0016] 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)

[0017] 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 prior art rotary scrubber incorporating a pair of drive motors 12 operatively engaging rotary disk brushes 14 via an intermediate rotating driver disk 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.

[0018] Referring to FIG. 2, an exemplary embodiment of a rotary scrubber 10 consistent with the present disclosure substitutes brushes 14 (or abrasive pads) with a layered composite 20 (FIG. 3) operatively engaging an improved driver disk 16 as will be described further hereafter mated to drive motors 12. By way of example only, and not limitation, layered composite 20 may be a two-layered structure incorporating a surface 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 surface cleaning textile 30 and connector pad 32 are preferably substantially coextensive with one another to permit full coverage without substantial overhang. By way of example only, both surface cleaning textile 30 and 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 usedif desired. As will be appreciated, such polygonal geometries may be useful in reducing waste when cutting from larger sheets of material.

[0019] In accordance with one potentially preferred practice, engagement between the surface cleaning textile 30 and connector pad 32 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.

[0020] In accordance with one exemplary practice, surface cleaning textile 30 may be a terry warp knit formed by using an alternating pattern of (i) relatively high denier yam and (ii) multifilament microfiber yarn characterized by a denier per filament level of less than 1 to form a striped pattern as shown in FIG. 3. 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 pattern to 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 between microfiber bands. Of course, different yams and / or patterns may be used as desired.

[0021] As illustrated, connector pad 32 acts as an intermediate connector between driver disk 16 and surface cleaning textile 30. Connector pad 32 drives the surface cleaning textile 30 and provides the fluid absorbing backing for easy change out. In accordance with one exemplary construction, connector pad 32 may incorporate a modified hook connection surface on one face which engages yam 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 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 about50% 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.

[0022] 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 of heat softened and resolidified fiber 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 localized heating 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 a modified hook surface to establish a hook and loop attachment with much greater attachment to surface cleaning textile 30 in the shear direction (x direction) vs peel (z direction). This attachment enhances grip during cleaning while permitting the user to easily disengage the pad from surface cleaning textile 30 for changeout.

[0023] Referring now to FIGS. 4-7, an exemplary improved driver disk 16 for use with rotary scrubber 10 is illustrated. As best seen through reference to FIGS. 4 and 5, the upper face of driver disk 40 facing away from the surface being cleaned incorporates a central hub 42 having a plurality of interior lugs 44 adapted to operatively engage a rotating drive element from drive motors 12. A raised fluid containment wall 46 is positioned radially outwardly from central hub 42 to define a fluid receiving zone 48 adapted to receive cleaning fluid during rotation.

[0024] In the illustrated exemplary construction, a plurality of drain openings 50 are arranged about the outer perimeter of the fluid receiving zone to collect applied cleaning fluid and direct it downwardly. In this regard, it will be readily appreciatedthat rotation will cause fluid within receiving zone 48 to move outwardly until being obstructed by containment wall 46. The fluid will then move along the containment wall until encountering a drain opening 50 and will then exit downwardly through that drain opening. A plurality of support ribs 52 extend radially away from fluid containment wall 46 to a raised perimeter wall 54.

[0025] Referring now to FIG. 6, the underside of an exemplary driver disk 16 consistent with the present disclosure is shown. As illustrated, the underside is adapted to receive an annular connector pad 32 as previously described. By way of example only, and not limitation, connector pad 32 may be attached by use of low-profile hook material disposed at positions across the underside of driver disk to establish a hook and loop connection with the fiber of connector pad 32. Of course, any other attachment mechanism such as light adhesive bonding or pressure fitting within depressions across the underside may likewise be used. As shown, a plurality of hollow nipples 70 aligned in fluid communication with drain openings 50 extend downwardly. During operation, the nipples 70 convey cleaning fluid into the seated connector pad 32. Nipples 70 may have a generally square, rectangular or other quadrilateral perimeter with a hollow interior along their length defining a channel for fluid movement. However, other polygonal or nonpolygonal geometries may be used including pentagonal, hexagonal, round, oval and the like as maybe desired. As illustrated, nipples 70 may include flexible ledges extending laterally away at the distal outlet ends of the nipples. If present, such ledges may extend from opposing sides as shown or from the entire perimeter of the nipple. Connector pad 32 may include optional aligned openings to receive nipples 70 in mating relation to facilitate fluid absorption at the interior. Such openings within the connector pad may extend partially or completely through the pad thickness dimension.

[0026] As will be appreciated, as cleaning fluid is discharged from nipples 70, both the fluid and the underlying connector pad 32 will be rotating at substantially the same rate. Thus, any propensity for the applied fluid to be thrown outwardly rather than being absorbed will be reduced. The cleaning fluid absorbed within connector pad 32 can then be transferred efficiently to the surface cleaning textile 30 for application to the floor with minimal waste.

[0027] While the use of a layered composite 20 incorporating a connector pad as described may be desirable for many applications, alternative attachable cleaning pad structures may likewise be used. One structure that may be particularly useful for cleanrooms and other critical environments is a fully disposable multi-layer composite structure having an upper surface layer of structural polymer film of suitable polymer such as nylon, polyester, polypropylene or the like in attached laminar relation to an underlying sandwich structure of open cell foam between layers of circular knit microfiber cleanroom wipe material. The polymer film defining the upper surface may preferably have a thickness in the range of 3 mils to 20 mils and most preferably about 7 mils. However, thicker and thinner layers may likewise be used. In such a construction, the polymer film may include cut-outs aligned with nipples 70 with dimensions such that distal ends of nipples 70 may be pushed through the cut-outs pushing the underlying material away and causing flexible ledges at the distal ends to snap behind the underside of the film in a snap-fit connection.

[0028] 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 individual features 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.

[0029] 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 ofvalues 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.

[0030] 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 is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims

What is claimed is:

1. A rotary scrubber adapted to deliver a cleaning or treatment fluid to a cleaning pad and having at least one drive motor adapted to impart rotation to the cleaning pad to clean a flooring surface, the rotary scrubber comprising:at least one driver disk operatively engaging at least one drive motor, said at least one driver disk comprising a raised central hub extending upwardly from a first side of said at least one driver disk, a raised fluid containment wall disposed in spaced-apart surrounding outboard relation to the central hub, a depressed annular fluid receiving zone disposed between the central hub and the fluid containment wall, the fluid receiving zone adapted to receive a flow of cleaning or treatment fluid, a plurality of drain openings disposed within the fluid receiving zone, said drain openings being in fluid communication with hollow nipples extending downwardly away from a second side of said at least one driver disk facing away from the first side, said hollow nipples comprising interior channels adapted to transfer fluid away from said drain openings.

2. The rotary scrubber as recited in Claim 1 , comprising a pair of drive motors.

3. The rotary scrubber as recited in Claim 1 , wherein said at least one driver disk is annular.

4. The rotary scrubber as recited in Claim 1 , wherein a plurality of lugs are disposed at the interior of the central hub.

5. The rotary scrubber as recited in Claim 1 , further comprising a raised perimeter wall disposed in spaced-apart surrounding outboard relation to the fluid containment wall.

6. The rotary scrubber as recited in Claim 5, further comprising a plurality of support ribs extending radially between the fluid containment wall and the raised perimeter wall.

7. The rotary scrubber as recited in Claim 1 , wherein at least a portion of said plurality of drain openings are disposed at an intersection between the fluid receiving zone and the fluid containment wall.

8. The rotary scrubber as recited in Claim 1 , wherein the hollow nipples are aligned with the drain openings.

9. The rotary scrubber as recited in Claim 8, wherein the hollow nipples have a quadrilateral outer perimeter.

10. The rotary scrubber as recited in Claim 8, wherein one or more of said hollow nipples comprises a plurality of flexible ledges projecting laterally away from distal ends of said hollow nipples.

11. The rotary scrubber as recited in Claim 1 , further comprising an annular fibrous felt connector pad mounted across the second side of said at least one driver disk, said connector pad including openings adapted to receive hollow nipples in mating relationship, and a removeable surface cleaning textile layer adapted to contact a floor surface being cleaned, the cleaning textile layer being disposed in juxtaposed relation to said connector pad and comprising a plurality of microfiber yams.

12. A rotary scrubber adapted to deliver a cleaning or treatment fluid to cleaning pads and having a pair of drive motors adapted to impart rotation to the cleaning pads to clean a flooring surface, the rotary scrubber comprising:at least one driver disk operatively engaging at least one drive motor, said at least one driver disk having an annular construction comprising a raised central hub extending upwardly from a first side of said at least one driver disk, a raised fluid containment wall disposed in spaced-apart surrounding outboard relation to the central hub, a depressed annular fluid receiving zone disposed between the central hub and the fluid containment wall, the fluid receiving zone adapted to receive a flow of cleaning or treatment fluid, a raised perimeter wall disposed in spaced-apart surrounding outboard relation to the fluid containment wall, a plurality of support ribsextending radially between the fluid containment wall and the raised perimeter wall, a plurality of drain openings disposed within the fluid receiving zone at an intersection between the fluid receiving zone and the fluid containment wall, said drain openings being in fluid communication with aligned hollow nipples extending downwardly away from a second side of said at least one driver disk facing away from the first side, said hollow nipples comprising interior channels adapted to transfer fluid away from said drain openings;an annular fibrous felt connector pad mounted across the second side of said at least one driver disk, said connector pad including openings adapted to receive said hollow nipples in mating relationship; anda removeable surface cleaning textile layer adapted to contact a floor surface being cleaned, the cleaning textile layer being disposed in juxtaposed relation to said connector pad and comprising a plurality of microfiber yams.

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