U.S. patent application number 09/893223 was filed with the patent office on 2001-12-13 for apparatus and method for cleaning and restoring floor surfaces.
This patent application is currently assigned to Ecolab Inc.. Invention is credited to Kelton, Shane M., Klos, Terry J., Outlaw, Tina O..
Application Number | 20010051493 09/893223 |
Document ID | / |
Family ID | 26694270 |
Filed Date | 2001-12-13 |
United States Patent
Application |
20010051493 |
Kind Code |
A1 |
Kelton, Shane M. ; et
al. |
December 13, 2001 |
Apparatus and method for cleaning and restoring floor surfaces
Abstract
A cleaning and restoration system 10 for floors 11 and other
hard surfaces is disclosed. The system 10 has an cleaning head 12
which can be moved across a floor 11 or other hard surface. The
cleaning head 12 impinges particulate media upon the floor 11 to
remove soils and provide a slip-resistant surface. The media is
entrained into the air by a pressure tank 17 which includes a
classifier 18 for reclaiming a portion of the media for reuse. The
pressure tank 17 has a series of dispersion bars 68 for separating
the heavy particles to be re-used. The dust, soils, and other
undesirable materials are filtered in a dust collector 57 having a
cyclonic filter 71. A compressor 20, a vacuum/blower 22, and other
components of the system are mounted on a truck 19. A method for
utilizing the restoration system 10 is also disclosed.
Inventors: |
Kelton, Shane M.; (May,
TX) ; Outlaw, Tina O.; (Inver Grove Heights, MN)
; Klos, Terry J.; (Victoria, MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Ecolab Inc.
St. Paul
MN
|
Family ID: |
26694270 |
Appl. No.: |
09/893223 |
Filed: |
June 27, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09893223 |
Jun 27, 2001 |
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09021106 |
Feb 10, 1998 |
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6254462 |
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09021106 |
Feb 10, 1998 |
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08382906 |
Feb 3, 1995 |
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5716260 |
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Current U.S.
Class: |
451/36 ; 451/38;
451/39; 451/87; 451/92 |
Current CPC
Class: |
Y02P 70/10 20151101;
B24C 9/006 20130101; B24C 3/065 20130101; Y02P 70/179 20151101 |
Class at
Publication: |
451/36 ; 451/38;
451/39; 451/87; 451/92 |
International
Class: |
B24C 001/00; B24C
003/06 |
Claims
What is claimed is:
1. A system for cleaning a surface and/or restoring the slip
resistance of a surface, the surface having soils and surface
particles, the system comprising: a) compressor means for supplying
an air stream, said compressor means being adjustable to a desired
level of air pressure, said compressor means being in fluid
communication with an air supply conduit; b) moisture reduction
means in association with the air stream; c) entrainment means for
entraining media particulates into the air stream, said entrainment
means being adjustable so that the amount of media particulates
entrained can be varied; d) media chamber means for storing the
media particulates before entrainment in the air stream; e)
restoration means for impinging the media particulates upon the
surface to remove soils and surface particles, said restoration
means being movable across the surface in any direction, said
restoration means being in fluid communication with an exhaust
conduit, wherein said restoration means comprises: i) a support
frame including a plurality of wheels; ii) a nozzle having a
longitudinal bore, one end of which is proximate the surface; and
iii) an exhaust chamber in fluid communication with said bore and
with said exhaust conduit; f) vacuum means in fluid communication
with said exhaust conduit for the evacuation of substantially all
of the soils and surface particles from the surface, wherein said
vacuum means automatically adjusts to said level of said air stream
of said compressor; g) classifier means for separating a portion of
the media particulates from the soils and surface particles, said
classifier means being in fluid communication with said exhaust
conduit; h) automatic transfer means for transferring heavy media
particulates from said classifier means to said media chamber
means; and i) filter means for filtering the soils and surface
particles, said filter means being in fluid communication with said
classifier means, wherein said system etches the surface and
increases the coefficient of friction of the surface.
2. The system of claim 1, wherein said transfer means includes a
valve which automatically opens when said cleaning system is
inactivated so as to permit the particulates to enter said media
chamber means by gravity, wherein said classifier means is
positioned above said media chamber means.
3. The system of claim 1, further comprising a truck having a power
takeoff shaft, wherein said compressor means is powered by said
truck takeoff shaft.
4. The system of claim 3, wherein said filter means comprises a
dust collector.
5. The system of claim 4, wherein said dust collector includes
pulse jet cleaning means.
6. The system of claim 1, further comprising a drying chamber which
contains a desiccant means, at least a portion of said air stream
being in fluid communication with said drying chamber.
7. The system of claim 3, wherein said vacuum means is powered by
said truck takeoff shaft.
8. The system of claim 1, wherein the media particulates are
selected according to the material from which the surface is
made.
9. The system of claim 1, wherein the media particulates comprise
garnet.
10. The system of claim 1, wherein the media particulates are
approximately 0.1 to 0.8 mm in size.
11. The system of claim 1, wherein the surface is a floor.
12. The system of claim 1, wherein said classifier means includes a
plurality of dispersion bars.
13. The system of claim 12, wherein a longitudinal axis of said
inlet conduit of said classifier is approximately 120 degrees from
a longitudinal axis of said exhaust conduit.
14. The system of claim 12, wherein a terminal end of said inlet
conduit of said classifier includes a deflection plate.
15. The system of claim 1, wherein said abrasion means includes a
control panel for controlling operation of said system.
16. The system of claim 15, wherein said control panel includes
adjustment means for varying the amount of particulates entrained
in said air stream.
17. The system of claim 15, wherein said control panel includes
particulate transfer means for automatically transferring the media
particulates from a media hopper to said media chamber means.
18. A system of cleaning a floor and restoring the slip resistance
of a floor by means of media particulates, the floor being made of
relatively soft and hard components, the floor having soils and
surface particles thereon, the system comprising: a) a compressor
for supplying an adjustable air supply to an air conduit; b) a
pressure tank for containing a media storage means and for
entraining an effective amount of the media particulates into the
air supply, said media particulates being made of garnet, wherein
said media particulates impinge upon the floor to dislodge the
soils and surface particles and to remove soft components of the
tile; c) moisture reduction means associated with said pressure
tank, said moisture reduction means including a deliquescent; d) a
portable cleaning head movable on the floor in any direction, said
cleaning head including: i) a support frame including a plurality
of wheels, said support frame including a handle; ii) a nozzle
which is in fluid communication with said air conduit; iii) a wear
tube releasably attached to a lower end of said nozzle; iv) an
exhaust chamber proximate said nozzle, said exhaust chamber being
in fluid communication with an exhaust conduit; e) vacuum means in
fluid communication with said exhaust conduit for the evacuation of
substantially all of the soils and surface particles from the
floor; f) classifier means for separating the media particulates
from the soils and surface particles, said classifier means being
located above said pressure tank, said classifier means including
an inlet conduit having a plurality of dispersion bars; and g) dust
collector means for filtering soils and surface particles, said
dust collector means being in fluid communication with said
classifier means.
19. The system of claim 18, further comprising a truck having a
power takeoff shaft, wherein said compressor means is powered by
said truck takeoff shaft.
20. The system of claim 18, where said dust collector includes
pulse jet cleaning means.
21. The system of claim 18, wherein said dust collector includes a
cyclonic filter.
22. The system of claim 19, wherein said vacuum is powered by said
truck takeoff shaft.
23. The system of claim 18, wherein the media particulates are
approximately 0.1 to 0.8 mm in size.
24. The system of claim 18, wherein an axis of said inlet conduit
of said classifier is approximately 120 degrees from an axis of
said exhaust conduit.
25. The system of claim 18, wherein one end of said inlet conduit
of said classifier includes a deflection plate.
26. The system of claim 18, further comprising an automatic media
transfer means for transporting the media from a storage hopper to
said pressure tank.
27. The system of claim 18, further comprising a classifier
transfer means for transferring the heavy particulates from said
classifier means to said media storage means of said pressure tank,
said classifier transfer means comprising a plunger valve means
within said pressure tank, having an upper, closed position and a
lower, open position, said plunger valve means permitting transfer
of the media particulates by gravity when in said open
position.
28. The system of claim 27, wherein said classifier transfer means
is electrically interconnected to a switch on said cleaning head,
such that said classifier transfer means automatically permits
transfer of media particulates when said cleaning head is switched
to an "off" position.
29. A method of cleaning and restoring a hard surface, comprising
the steps of: a) positioning a vehicle proximate a site of the hard
surface, said vehicle containing the components of a restoration
system, including a vacuum means, a compressor, a pressure tank for
containing particulate media, a classifier and a dust collector; b)
removing a cleaning machine from the vehicle and positioning said
machine upon the surface, said machine being operatively connected
to an air supply conduit and to an exhaust conduit; c) turning on
said cleaning machine; d) entraining the particulate media into an
air stream from a compressor; e) adjusting the amount of said
particulate media which is entrained into said air stream; and f)
making repeated passes of said cleaning machine over the surface,
wherein soils and surface particles are removed by impingement of
the particulate media on the hard surface.
30. The method of claim 29, further comprising the step of
transferring the particulate media from said classifier to said
pressure tank.
31. The method of claim 29, further comprising the step of engaging
the power takeoff shaft of the vehicle so as to power said vacuum
means and said compressor.
32. The method of claim 29, further comprising the step of
adjusting the pressure under which the media is impinged on the
hard surface.
33. The method of claim 29, further comprising the step of
recycling a portion of the particulate media.
34. The method of claim 33, further comprising the step of
adjusting the proportion of particulate media which is to be
recycled.
35. The method of claim 29, further comprising the step of
automatically transferring the particulate media from a truck bed
storage tank to a storage reservoir in said pressure tank.
36. A tile floor surface having a surface composition comprising
about 50-66 wt % silicon and about 17-25 wt % aluminum.
37. A tile floor surface which, after treatment with the
restoration system of claim 29, has a surface composition
comprising about 50-66 wt % silicon and about 17-25% aluminum.
38. The tile floor surface of claim 36, wherein the tile is quarry
tile.
39. The tile floor surface of claim 38 which has a coefficient of
friction of about 0.8-1.0 when clean and dry.
40. The tile floor surface of claim 38 which has a coefficient of
friction of about 0.9-1.0 when clean and dry.
41. The tile floor surface of claim 38 which has a coefficient of
friction of about 0.5-0.6 when wet.
42. The tile floor surface of claim 38 which has a coefficient of
friction of about 0.3-0.5 when soiled and wet.
43. A tile floor surface wherein after treatment with the
restoration system of claim 29 the elemental composition of the
tile surface is substantially the same as the elemental composition
of the core of the tile.
44. A tile floor surface which, after treatment with the
restoration system of claim 29, has a coefficient of friction at
least as high as a coefficient of friction of a new tile floor
surface.
Description
[0001] This patent application is a continuation-in-part of U.S.
Ser. No. 08/382,906, filed Feb. 3, 1995, now U.S. Pat. No.
5,716,260.
FIELD OF THE INVENTION
[0002] This invention relates generally to systems for cleaning and
restoring hard surfaces such as floors. The invention is
particularly useful for maintaining a clean and slip-resistant
surface on quarry tile floors.
BACKGROUND OF THE INVENTION
[0003] Extruded clay or ceramic tile, sometimes called quarry tile,
is used in restaurant kitchens. Quarry tile is popular in
restaurants and other kitchen areas because it is relatively
inexpensive, durable, and has relatively low porosity. Quarry tile
is made from natural clays with the composition being approximately
50% hard particles (silicon) and 50% soft particles (clay
components). When he clay tile is fired, it develops a pervious
glaze-like coating which encapsulates pores under the surface.
Because of the pervious nature of the surface, these pores collect
and entrap various soils that are extremely difficult to clean
thoroughly.
[0004] The surface of the tile is subject to wear, polishing and
soil build-up which can result in a slippery floor condition.
Slippery floors result in accidents and injuries from slipping and
falling. These accidents can cause a serious injury to the
restaurant worker, and they result in significant costs for the
restaurant owner.
[0005] One of every twenty workplace injuries in the United States
occurs in a restaurant. The U.S. Food Service Industry spends
approximately four hundred million dollars per year on slips and
falls. Approximately half of that amount is spent on re-training
and time lost, and the other half is spent on medical, worker's
compensation, and overtime expenses. Many other accidents occur in
hotels, homes, places of business, hospitals, and around swimming
pools, due to slipping on wet surfaces of ceramic tile, glazed
porcelain and smooth concrete.
[0006] During the manufacturing process of quarry tile, a natural
surface roughness is created consisting of hard, microscopic peaks
of silica and inert clays. The surface texture or roughness coupled
with the surface porosity provides the tile with an optimum static
coefficient of friction (traction). New quarry tile tends to be
slip-resistant, and some tiles feature anti-slip properties such as
added grit, grid patterns or a rougher surface texture. However,
even the anti-slip tiles become worn, soiled, and slippery over
time. After a short time, the quarry tile is subjected to abrasion
and surface wear due to foot traffic, soils and daily surface
cleaning. The original hard microscopic peaks become polished or
worn down, leading to flat surface areas. These worn areas result
in a lower static coefficient of friction and create a potentially
slippery floor surface. In addition, frying, grilling and sauteing
create airborne grease, which causes a potentially hazardous film
to develop on kitchen floors. The grease gets carried by shoes to
other parts of the restaurant. This layer of grease can be enough
to cause an accident. If poorly cleaned, a quarry tile floor can
become saturated with grease, and may continue to stay slippery
despite routine cleaning.
[0007] To address this slipperiness problem, several techniques
have been utilized. One technique is the application of an acid
etchant to the surface of the floor. An example of this process is
the Gillice patent, U.S. Pat. No. 3,847,688. The acid etch system
works by dissolving silicon and creating microscopic pores in the
tile. While the acid etchant reduces floor slipperiness on a
temporary basis, it is not effective over the long-term. After use
of the acid etch technique, the microscopic pores become filled
with grease and other types of soil, thereby resulting in a
slippery floor condition. Additionally, the acid etch process
destroys the hard components of the clay tiles (the silicon),
leaving softer components of the floor at the surface. These softer
components are easily worn away, which can result in a worn and/or
uneven floor surface. In effect, the acid etch technique destroys
the tile. In addition, the acid poses a potential safety hazard if
it is not utilized properly. For a variety of reasons, some
manufacturers of tile do not recommend the use of any acid cleaning
on their ceramic tile products.
[0008] Other solutions to the slipperiness problem have been to lay
non-slip mats upon the floor, and to apply abrasive strips to the
floor. However, these mats and strips become worn rather quickly,
and they hinder the daily routine cleaning of the floor. The mats
sometimes come loose and slide, and they significantly alter the
appearance of the floor surface. It is also is difficult to clean
and sanitize the mats.
[0009] Another attempt at solving the slipperiness problem is a
diamond etch technique. With the diamond etch system, a diamond
cutter may be utilized to create concentric circles in the floor.
The circles are approximately 1/8 to 1/4 inch in depth, which
unfortunately create circular cracks for soil buildup. These
circles, along with the tile's grout areas, are especially
difficult to clean. It is also possible to apply a slip resistant
coating to floors. These coatings can be difficult to apply, and
soil can adhere to the coating.
[0010] Although sandblasting systems are known in the prior art,
the typical sandblasting systems can ruin some floors and produce
too much dust for indoor use. For example, the Ricklefs patent
(U.S. Pat. No. 3,925,935) discloses a system for abrading the
surface of a porcelain bathtub to render it slip resistant. With
this system, the bottom of the tub is covered with a stencil, a
cover is draped over the tub, and a stream of abrasive granules is
applied to the bottom of the tub at the stencil. However, there is
no teaching or disclosure in the Ricklefs patent regarding the
utilization of a system for cleaning and restoring floor
surfaces.
[0011] Another attempt found in the prior art is described in the
Mead patent, U.S. Pat. No. 2,770,924. This patent discloses a
blasting device for cleaning and treating surfaces such as wood,
glass, metal, cement, or a synthetic. In addition, British Patent
No. 2193454A describes a system for projecting glass beads, grit or
sand onto a surface to be cleaned. With this system, the compressor
and the storage container for the grit are mounted upon a
truck.
[0012] The present invention addresses the problems associated with
currently available cleaning techniques.
SUMMARY OF THE INVENTION
[0013] The invention is a closed mechanical system for moving a
fluidized stream of particles through a carrying medium (air, for
example) onto the target surface, such as a floor. The stream of
particles impacts the hard surface, so as to physically remove
soils and surface materials. The particles are instantly vacuumed
and recovered from the point of impact.
[0014] The system for cleaning and restoring the slip resistance of
a floor comprises several elements: a compressor for supplying an
air stream through an air supply conduit; moisture reduction means
for removing excess moisture from the air stream; entrainment means
for entraining particulate media into the air stream; a media
chamber for storing the particulates before entrainment; abrasion
means for impinging the particulates upon the floor for removal of
soils and surface particles; a vacuum means which evacuates soils
and surface particles from the floor; a classifier for separating
the reusable particulate media from the soils; and a filter means
for filtering and collecting the soils for disposal. In the
preferred embodiment, the system has two unique media transfer
systems: 1) for automatically transferring the reclaimed
particulate media from the classifier and into a pressure tank for
re-use, and 2) for automatically transferring virgin media from a
storage hopper to the pressure tank.
[0015] Another aspect of the invention is a method for leaning and
restoring a hard surface. This method includes the steps of:
positioning a vehicle proximate the site of the hard surface to be
restored, with the vehicle containing a compressor, a
vacuum/blower, a pressure tank containing particulate media, and a
dust collector; entraining the particulate media into the air
stream; adjusting the amount of particulate media to be entrained;
and passing the cleaning head over the surface to be treated. The
inventive method also includes the steps of adjusting the pressure
at which the media is applied, and adjusting the amount of
particulate media which is designated for re-use.
[0016] A final aspect of the present invention is a tile floor
surface which has been treated with the restoration system of the
present invention. The tile floor surface has a certain preferred
chemical composition, and a preferred coefficient of friction.
[0017] A primary advantage of the present invention is that it
restores the traction of the tile to a condition that is equal to
or better than new tile, as measured by the coefficient of
friction. By increasing the coefficient of friction and reducing
floor slipperiness, dangerous and costly accidents can be avoided.
The present invention results in a relatively non-slippery floor
surface, even when the floor becomes soiled or wet. The slip
resistance is achieved primarily by the mechanical removal of more
of the softer components of the tile, while leaving a substantial
amount of the hard components of the tile in place. This type of
mechanical action preserves the overall integrity of the tile,
unlike acid etch treatments.
[0018] Another advantage of the present invention is that it
provides a deep and thorough cleaning of the floor tile. Despite
daily cleansing of the floor, soil and grease often build up over
time. The present invention effectively impacts, loosens, and
removes the soil buildup, thereby resulting in a sanitary,
attractive floor surface.
[0019] Yet another advantage of the present invention is that it
may be utilized on a wide variety of surfaces, and it may be
utilized either indoors or outdoors. For example, the present
invention may be utilized on concrete (pool decks, buildings,
roadways, walkways, etc.); stainless steel (hood and ducts, etc.);
asphalt (driveways, roads, etc.); and other surfaces and
applications. Because the invention incorporates a closed
mechanical system in which the fluidized stream of particles is
contained, the invention may be utilized both indoors and
outdoors.
[0020] A further advantage of the present invention is that the
floor maintains its slip resistance over the long term, assuming
that normal floor maintenance is performed. Specifically, a tile
floor may be able to maintain its slip resistance for one to three
years after use of the present invention. After treatment of the
floor with the inventive system, routine cleaning with a deck brush
is more effective at removing grease and other soils. The
restoration system can also decrease the drying time of the floor
surface by restoring the floor's natural porosity.
[0021] The present invention is also advantageous because it is
relatively easy to use. The equipment is relatively compact,
lightweight and portable, so that it can be easily moved from
location to location. All components of the system can be mounted
on a truck, trailer or other portable vehicle; or the system can be
maintained as a permanent installation near the desired place of
use. The machine's cleaning head covers a relatively wide path, and
the treatment can be applied uniformly over the floor's surface.
Additionally, the present invention effectively filters dust
through use of a unique filtering and vacuum system. The design of
the present invention provides for the effective flow of the media
without problems due to clogging and excess moisture.
[0022] Yet another advantage of the present invention is that the
optimum media can be selected for use, depending upon the type of
floor surface, the type of soil, the amount of cleaning and/or
traction to be achieved, and other particular conditions of the
situation. Additionally, the proper particle size, pressure and
flow rate of the media may be selected and adjusted to achieve the
best results.
[0023] Another advantage of the present invention is that the media
flow is greatly improved by the drying chamber of the present
invention. This reduces problems with clogging, which means that
the system has less "down" time.
[0024] For a better understanding of the invention and the
advantages obtained by its use, reference should be made to the
drawings and the accompanying descriptive matter, in which there is
illustrated and described a preferred embodiment of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of the floor restoration system
of the present invention.
[0026] FIG. 2 is a schematic view of the system's flow lines.
[0027] FIG. 3 is a side, schematic view of the system's cleaning
head.
[0028] FIG. 4 is a side elevational, schematic view of the
combination classifier and pressure tank of the floor restoration
system.
[0029] FIGS. 5A and 5B are side, schematic views of the dust
collector.
[0030] FIG. 6 is a perspective view of untreated floor tile and
floor tile which has been treated with the restoration system of
the present invention.
[0031] FIG. 7 is a side, schematic view of the media hopper.
[0032] FIG. 8 is a side elevational view of the dispersion bars of
the present invention.
[0033] FIG. 9 is a top plan view of the dispersion bars illustrated
in FIG. 8.
[0034] FIG. 10 is a top plan view of the truck and system
components.
[0035] FIG. 11 is a front elevational view of the media metering
assembly.
[0036] FIG. 12 is an enlarged, cutaway view of a portion of the
media metering assembly shown in FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] FIG. 1 illustrates the cleaning and restoration system 10 of
the present invention. The system 10 includes a cleaning head 12
which is movable across the surface 11 to be treated. FIG. 1 shows
the cleaning head 12 removed from the truck 19. The cleaning head
12 impinges a high-velocity fluidized stream of abrasive particles
(not shown) against the surface 11 to be abraded. The system 10
includes a blast tank 58, which is divided into two chambers: a
pressure tank 17 and a classifier 18. In the classifier 18, the
material which is returned from the floor is separated into dust
(which is disposed of) and clean media (which is reused).
[0038] The system 10 is designed so that all of its components can
be mounted within a truck 19 or other type of vehicle for
portability, as shown in FIG. 10. Alternatively, the system
components may be stationary, so that the surfaces to be treated
(e.g. pots or storage tanks) would be brought to the site of the
restoration apparatus. FIG. 10 shows a preferred embodiment of the
system, with each of the components being positioned in the trailer
of the truck 19. With this truck-mounted system 10, the media is
automatically transferred into the blast tank 58, and the blast
tank 58 remains on the truck 19 during operation. The truck bed has
a rear door 74 and a pair of side doors 73 for access to various
components of the system.
[0039] As an alternative, the blast tank 58 could be removable from
the truck 19, and mounted on a cart (not shown). With this mobile
embodiment, the media is poured into an opening in the blast tank
58 manually.
[0040] FIG. 2 schematically illustrates the various components of
the system 10. As shown in FIG. 2, compressed air is provided by a
compressor 20 mounted upon the truck 19. The air compressor 20 is
preferably mounted beneath the truck's bed; however, the compressor
20 could be mounted at other locations on the truck or could be
entirely separate from the truck. The compressor 20 is a source of
compressed air, which develops approximately 125 psig air. The
compressor 20 is adjustable to the desired level of air pressure.
It is necessary for the air pressure at the cleaning head 12 to be
approximately 60 psi.
[0041] A vacuum/blower 22 creates suction to facilitate the floor
cleaning process. The vacuum/blower 22 facilitates withdrawal and
recovery from the floor 11 of the spent abrasive particles, dust,
soil and floor particles. The vacuum/blower 22 is preferably
mounted on the truck bed 19. The vacuum/blower 22 is of the
positive displacement type, and is in fluid communication with the
cleaning head 12. The vacuum/blower 22 is a type of vacuum pump
which provides a relatively high flow rate. In the preferred
embodiment, the vacuum/blower 22 is belt driven by the
power-takeoff shaft of the truck 19.
[0042] The compressor 20 and the vacuum/blower 22 are both driven
by the same power-takeoff shaft of the truck, so that increased air
pressure provided by the compressor 20 automatically results in an
increased vacuum in the vacuum/blower 22. This synchronization of
the compressor and vacuum could also be accomplished by using
separate power sources and an electronic control system.
Alternatively, the compressed air may be provided by a compressor
at the work site, coupled with an appropriate synchronization
system for the vacuum and the pressurized air. For example, some
hotels have an internal supply of compressed air for their laundry
facilities. Depending upon the type of floor surface 11, the type
of media, and the amount of soil, the air pressure may be adjusted
in the 30-80 psig range.
[0043] The arrow 120 in FIG. 2 illustrates the air coming into the
compressor 20. An air conduit 28 extends between the compressor 20
and the blast tank 58. A media hose 21 extends between the blast
tank 58 and the cleaning head 12. The media hose 21 is wound on a
reel 27 on the truck, and the media hose 21 is approximately one
inch in diameter.
[0044] An exhaust hose 23, containing a media and dust mixture,
extends between the cleaning head 12 and the classifier 18. A
second exhaust hose 56, containing dust and media which cannot be
recycled, extends between the classifier 18 and the dust collector
57. A third exhaust hose 79 extends between the dust collector 57
and the vacuum/blower 22. The exhaust hoses 23, 56 and 79 are
flexible hoses of approximately four inches in diameter. The hose
23 is mounted upon a reel 87 on the truck 19.
[0045] The vacuum/blower 22 is associated with a silencer 25 and a
muffler 24 for the reduction of noise. The silencer 25 reduces the
noise level of the blower exhaust, and the muffler 24 further
serves to reduce the noise of the silencer exhaust. In addition,
the walls of the truck preferably have noise reduction panels.
[0046] The air is delivered through conduit 28 from the compressor
20 to a water separator 26. The water separator 26 removes moisture
from the compressed air. A hose (not shown) extends below the water
separator 26 to the ground beneath the truck 19 to allow drainage
of water from the water separator 26. The system also features an
aftercooler 85 to remove moisture in the air inlet line 28
extending from the air compressor 20. The system may also have a
coalescing filter to remove molecules of oil and water from the
compressed air. A moisture reduction means (such as an aftercooler
with a water separator and/or coalescing filter) is desirable,
because the dry air helps to maintain the fineness and separation
of the abrasive particles in the fluid stream. This minimizes
problems with sticking and clogging in the system.
The Pressure Tank
[0047] At the blast tank 58, the media is pressurized and forced
out of the pressure tank 17 to the cleaning head 12. A pressure
equalizer valve 33 ensures that an equal pressure is maintained
between the pressure in the blast tank's drying chamber 164 and the
pressure in the classifier 18. As shown in FIG. 4, the air from the
inlet line 28 passes into the pressure tank 17 through the tank's
side wall. The air inlet line 28 has an inlet valve (not shown).
The pressure tank inlet line 160 splits into an upwardly directed
line 161 and a downwardly directed line 162, as shown in FIG. 4.
The particulate matter 163 is stored in the media chamber 13 of the
blast tank 58 until it is used. The lower portion of the pressure
tank 18 is a compressed air drying chamber 164 which contains a
deliquescent or desiccant 165. In the preferred embodiment, the
deliquescent 165 is a commercially available pellet product
manufactured by Van Air Systems Inc. of Lake City, Pa. The
deliquescent 165 removes droplets of water from the compressed air.
The desiccant tablets 165 surround an air manifold 166. The air
passes through apertures in the manifold 166, as depicted by the
arrows in FIG. 4. A free water drain 31, having a valve 32, extends
downwardly for drainage of moisture from the blast tank 58.
[0048] An air outlet line 8 extends from the compressed air drying
chamber 164 to the media aspiration vessel 19. In the pressure
vessel 19, the media is entrained into the compressed dry air and
becomes fluidized in the air. The dry air flows horizontally
through the exit conduit 8, then flows upwardly through a media
flow regulator 30, which regulates the amount of media delivered to
the cleaning head 12. The media/air mixture then passes through the
flexible conduit 21 to the cleaning head 12.
[0049] As illustrated in FIGS. 11 and 12, the media flow regulator
30 has a conical orifice metering assembly 67 or media metering
valve to control the amount of media which enters the air stream.
Preferably, the media metering valve 67 is a needle valve. The
compressed air flows upwardly through the nozzle 63 of the needle
valve. The media is entrained into the air jet, as illustrated by
the arrows 64 of FIG. 12. The amount of the media entrained is
adjustable by raising or lowering the valve seat 62 relative to the
fixed nozzle 63, in order to open or close the gap through which
the media flows. The needle valve seat 62 is attached to a vertical
pipe 64, which can be raised or lowered by a motor 70, which is
operable via gears 65 and a threaded connector 66. Alternatively,
the metering assembly 67 may be controlled by a knob (not shown)
which would allow for manual adjustment of the amount of media
entrained. In addition, other types of media metering assemblies
could be devised.
Media Transfer from the Classifier
[0050] The pressure tank's media chamber 13 is periodically
replenished by the transfer of media 163 from the classifier 18.
The transfer process is controlled by the position of a plunger
valve 82. The plunger valve 82 is closed during normal operation.
That is, the plunger 82 is in its upper position, such that the
plunger head 35 abuts against its valve seat, as shown in FIG. 4.
The plunger valve 82 is preferably a plug valve, which is operated
by spring cams (not shown) which plug and unplug the opening by
axial motion. When the plunger valve 82 descends, the media 163 in
the classifier 18 falls by gravity into the media chamber 13.
Whenever the cleaning head 12 is turned off, the plunger 82 falls
automatically to its lower position. During operation of the
cleaning system, the plunger 82 is held up in its upper position by
the air flow from the conduit 161.
[0051] A vibrator (not shown) is preferably mounted on the outer
wall of the blast tank 58. The vibrator prevents clogging and
facilitates the flow of the media. The pressure tank 17 has one or
more access doors (not shown) for the purpose of cleaning the
pressure tank 17 when necessary. In the preferred embodiment, the
entire top portion of the blast tank 58 is hingedly attached to the
rest of the structure. When media needs to be added to the pressure
tank 17 manually, or when the pressure tank 17 or classifier 18
need to be cleaned, then the top of the blast tank 58 can be easily
opened. The pressure tank 17 may have a glass sight plug (not
shown) which enables the operator to observe the media 163 within
the pressure tank 17 and/or classifier 18.
The Cleaning Head
[0052] The cleaning head 12 is illustrated in detail in FIG. 3. The
cleaning head 12 is an abrasion means by which the particulate
matter is impinged upon the floor 11 to clean the floor and
increase its slip resistance. The cleaning head 12 has a set of
swivel wheels 37 to facilitate maneuverability and to allow the
cleaning head 12 to move in any direction, including forward and
backward. A support frame 38 carries the elements of the cleaning
head 12. The height of the main body 93 of the cleaning head 12 is
approximately ten inches from the floor, which allows the cleaning
head 12 to move freely beneath sinks and tables.
[0053] The frame 38 has a handle member 39 with a height adjustment
mechanism 40. At its bottom end, the cleaning head 12 has an
annular floor brush 41. Preferably, the floor brush 41 is
approximately six inches in diameter. In the preferred embodiment,
the cleaning head 12 treats approximately a six inch path of floor
with each pass. Typical floor tiles have a width of approximately
six to seven inches, so the cleaning head 12 covers the entire tile
in approximately a single pass. With the cleaning head's design,
the edges of the treated area are "feathered," so that there is
less treatment on the edges and the edges do not become subjected
to excessive etching, which can cause shadows on the floor. The
annular brush 41 makes firm contact with the floor 11 to be
abraded, confines the spent particles, and facilitates evacuation
of the particles from the floor 11.
[0054] The media hose 21 from the blast tank 58 attaches to port 44
on the cleaning head 12 by means of a suitable connector 45. The
air/media inlet line 44 is in fluid communication with a vertical
bazooka nozzle 48. Preferably, the nozzle 48 has an upper,
converging bore portion 47 and a lower, diverging bore portion 46.
The nozzle 48 is preferably screwed into position on the cleaning
head 12. When the air passes through the converging portion 47 of
the bore, it is discharged at increased velocity, thereby allowing
the particle stream to be directed toward the floor surface 11 at
high velocity. Although the present invention contemplates the use
of a human operator to direct the cleaning head 12, it would be
possible to have the position of the cleaning unit 12 controlled by
laser coordinates, so that no operator would be needed.
[0055] In the preferred embodiment, the cleaning head 12 has a
cylindrical wear tube 122. The wear tube 122 is referably made of
steel, but could be made of a high-strength polymer, carbide, or
stainless steel. The tube 122 preferably has removable attachment
means, such as screw threads. Alternatively, the wear tube 122
could be connected by means of welding, a clamp, or a
quick-connection mechanism.
[0056] The fluidized particles impinge the surface 11 to be abraded
at high velocity. This abrasion effectively removes soil, grease,
wax buildup, surface materials and a microscopic layer from the
floor surface 11. (These materials are referred to as "soils"
below). The spent media particles and soils are then evacuated from
the floor 11 into a channel 60, which carries away the media and
dust mixture. The exhaust channel 60 has an outlet port 50 which is
interconnected to the exhaust hose 23, which extends to the
classifier 17.
[0057] On the handle 39 of the cleaning head 12 is a control panel
51. The control panel 51 has a switch for turning on and off the
media blast. The control panel has another switch for turning the
transfer system on and off, i.e., to transfer media from the media
reservoir 81 to the pressure tank reservoir 13, as will be
described below. The cleaning head 12 also has controls for the
hose reels 27, 87 for the air supply hose 21 and exhaust hose 23.
Preferably, the control panel allows the operator to adjust the
amount of media which is entrained into the air, i.e., the
operation of the metering assembly motor 70 is controlled by the
operator from the cleaning head 12. The controls on the cleaning
head 12 are powered by a twelve volt battery, preferably by the
truck battery, via cord 52. However, it is possible to power the
controls with an alternative power source.
The Classifier
[0058] In the preferred embodiment, the classifier 18 forms the
upper portion of the blast tank 58, so that the classifier 18 and
pressure tank 17 are combined in a single structure, rather than
two separate tanks. The classifier 18 separates the heavy media
particulates from the lightweight, small particulate media and from
the soils. The heavy particulates are suitable for reuse, and the
other materials are disposed of. Alternatively, the system 10 could
have no classifier. That is, none of the media would be recycled;
all of the media would simply be disposed of after one cycle. In
our experience, approximately two-thirds of the media is recovered
after the initial feed.
[0059] During operation of the system, the plunger 82 prevents
particulate media 163 from dropping by gravity to the bottom of the
media storage chamber 13. The bottom portion 54 of the classifier
17 is a trough-shaped chamber 54 having sloped walls, which is
where the reclaimed media accumulates until it is transferred to
the pressure tank 17.
[0060] The classifier 17 has a port 53 which attaches to the
exhaust hose 23 extending from the cleaning head 12. The exhaust
hose 23 terminates in a channel 84 at the upper portion of the
classifier 18. The channel 84 has a series of dispersion bars 68.
In the preferred embodiment, there are a total of four rows of
dispersion bars 68, as illustrated in FIG. 9. The dispersion bars
68 are preferably angled somewhat from vertical and the dispersion
bars are of varying height, as illustrated in FIG. 8. The bottom
floor of the channel 84 is substantially horizontal, whereas the
top wall of the channel 84 slopes downwardly, as illustrated in
FIG. 4.
[0061] At the terminal end of channel 84 is a sloped backup plate
61. In the preferred embodiment, the backup plate 61 is angled at
approximately 120.degree. from horizontal. The media and soils flow
horizontally through the channel 84 and strike the backup plate 61.
The heavier material then drops into the classifier chamber 54. The
dust, soils and lighter media particles are pulled around plate 61
and through exit section 62 and exit port 55, then out of the
classifier 17 to the dust collector 57. A conduit 56 extends
between the classifier 17 and the dust collector 57.
[0062] The dispersion bars 68 break up the single flow stream into
many small streams. These streams must then move through an abrupt
120.degree. angle in order to continue movement toward the suction
source. The lighter particles turn to follow the suction, and the
larger, heavier particles (which are unable to make the abrupt
change of direction) are deflected off the backup plate 61 and into
the bottom of the classifier 18.
[0063] In the preferred embodiment, the classifier 18 has one or
more fresh air bleed pipes (not shown). With this design, fresh air
is bled into the collecting media 163 in the bottom of the
classifier 18, which serves to "fluff up" any dust at the bottom of
the classifier 18, thereby allowing the dust and lighter particles
to be entrained into the air and drawn back to the dust collector
57.
[0064] As the air and recyclable media moves downward in the
classifier 18, the classifier 18 directs the media along its
outside walls, as shown by the arrow 69 in FIG. 4. As such, the
classifier 18 acts like a cyclone separator to separate the heavy
media particles which are suitable for re-use from the dust and
lighter particles which must be disposed of. The cyclone action at
the top of the classifier 18 is caused by the sharp turn in the air
flow proximate the backup plate 61.
[0065] It is possible to adjust the amount of particulate media
which is recovered for re-use by varying the position of certain
components of the classifier 18, such as the position of the backup
plate 61. This adjustment may be desired for different types of
media and different types of surfaces to be treated. In the
preferred embodiment, the vertical and horizontal position of the
backup plate 61 can be varied by means of a screw arrangement (not
shown). However, in the preferred embodiment, the backup plate 61
and other classifier components are in a permanently fixed
position.
[0066] A screen (not shown) of approximately six inches in
diameter, with three sixteenth inch perforations, extends across
the upper portion of the classifier 18. This screen removes larger
objects such as cigarette butts and chunks of glass from the media
stream.
The Dust Collector
[0067] The dust collector or filter means 57 is illustrated in
FIGS. 2, 5A and 5B. The fluidized materials first pass through a
cyclonic pre-filter 71, after which the fluidized materials pass
through a pair of air filter elements 72. The cyclonic pre-filter
71 is a metal conduit formed in a circular shape. The cyclonic
pre-filter 71 may be positioned at one end of the dust collector
cabinet, or in an upper portion of the dust collector cabinet.
Preferably the outside diameter of the cyclonic pre-filter 71 is
approximately fourteen inches, with the inside diameter of the
pre-filter's conduit being approximately 41/2 inches. The
horizontal portion 49 of the cyclonic pre-filter is approximately
twenty-two inches in length and four inches in diameter. The
purpose of the cyclonic pre-filter 71 is to remove relatively large
objects and heavy media particles from the air stream, so that
these items do not blast holes in the cellulose air filter elements
72. The cyclonic pre-filter 71 also removes a substantial amount of
dust, which then falls to the bottom of the dust collector 57 by
gravity.
[0068] After the soils, surface materials, and lightweight
particulate matter pass through the cyclonic pre-filter 71, the
soils are passed through a pair of filters 72. The soils are
deposited on the outside surface of the filters 72, or the
materials accumulate at the bottom of the dust collector, as
illustrated in FIG. 5B. The dust collector 57 has a vacuum rating
of ten inches of mercury (column).
[0069] The dust collector's filters are cylindrical in shape, and
made of pleated paper material. The filter elements may have
several components, such as a coalescer element for oil removal, an
interceptor element for particulate removal, and an absorber
element for odor remover.
[0070] The filters 72 have an air flow rating of approximately 1200
cubic feet per minute, and a dust capacity of approximately 9500
grams. The filters 72 are made of a heavy-duty cellulose material.
Both the height and outside diameter of each filter 72 is
approximately fourteen inches, and the inside diameter is
approximately nine and one-half inches. Each filter 72 is held in
place by a top plate 29.
[0071] There are one or more access doors (not shown) in a wall of
the dust collector 57 to facilitate replacement of the filters 72,
and preferably there is also an access door 73 in the side wall of
the truck 19 proximate the dust collector 57.
[0072] The upper portion of the dust collector 57 has two air
directors 88, which permit pulses of air to be delivered through
the filters 72 for cleaning. One air director 88 is positioned
above each filter cartridge 72. The air directors 88 (also known as
back pulse check valves) deliver air downwardly through the center
of each filter 72 in intervals so as to remove accumulated soils
from the filters 72. This provides an automatic, pulse jet cleaning
mechanism for the dust collector 57. A slight interruption in the
vacuum, operated by an appropriate control circuit, causes pulses
of air to pass through the filters 72. The blasts of air emanate
from the dust collector's pulse jet tank (not shown). Preferably,
only one air filter 72 is pulsed at a time.
[0073] Near the upper end of the dust collector 57 is a port 97
which receives exhaust line 79, which is preferably four inches in
diameter. The conduit 79 extends to the vacuum pump 22. The exit
port 97 has a vacuum relief valve (not shown).
[0074] In the preferred embodiment, the bottom portion of the dust
collector has side walls which converge to form a trough at the
bottom of the dust collector. Proximate the bottom of the dust
collector is an auger 96 which carries the soils to the outlet pipe
73. A pipe 73 directs the soils 74 out of the dust collector 57 for
emptying. The soils are expelled through the pipe by a flapper
valve 118. The operator attaches a hose to the outlet pipe 73, and
the soils then empty into a bucket or bag for disposal. The bottom
portion of the dust collector 57 has a vibrator (not shown) to
facilitate movement of the soils. The dust collector 57 also has a
pressure relief valve (not shown).
[0075] An alternative to the auger 96 is an air sluice (not shown),
which injects air into the dust collector 57 to expel the soils.
The air sluice is in fluid communication with air tubing which
carries air toward the discharge chute. A manual air switch (not
shown) controls this air injection mechanism.
Effect of Floor Treatment
[0076] As illustrated in FIG. 6, the restoration process of the
present invention removes the top layer 76 and exposes the floor's
pores to the surface 70. The schematic view of FIG. 6 is
exaggerated for clarity; the present invention removes
approximately two to three thousandths of an inch from the floor
11. The floor's pores are shallowed, which makes cleaning and
drying more efficient and effective. The soils, grease, excess
cleaning material, dust, etc., designated in FIG. 6 as 69, are also
removed. The right side of FIG. 6 illustrates the composition of
the floor 11 after the restoration process of the present
invention. The surface 70 of the floor has small peaks and valleys
which are free from soil. The floor surface 70 provides excellent
slip resistance. Besides providing a clean and slip-resistant floor
surface, the present invention may also be used to etch a floor
surface to provide a bonding tooth for a subsequent surface
coating. When used in this patent application, the terms "etching"
and "abrasion" do not imply any damage or visible design on the
floor's surface; rather, these terms are used to describe the
removal of the soils, etc., as described above.
[0077] The preferred media consists of garnet particles, which is
an aluminosilicate mineral. The preferred size range of the garnet
particles is 0.1 to 0.8 mm. Alternative types of suitable media
include silicon carbide, silica sand, and any other suitable
homogeneous, inert minerals. Somewhat softer suitable types of
media include walnut shells, corn cobs, baking soda, glass beads,
plastic beads, and copper slags. The size and hardness of the media
is selected to match the hardness of the surface to be treated and
the goal of the treatment. For example, if the goal is to clean the
floor, then a relatively soft grit would be selected. If the goal
is to significantly increase the floor's coefficient of friction,
then a relatively small, hard type of media would be selected. If
the surface being treated is thin (such as a pan) or soft (such as
asphalt) then a relatively soft media material would be used.
Media Storage and Transfer System
[0078] As shown in FIGS. 7, 2 and 10, the truck 19 has media
storage means, i.e., a bulk media hopper 80. The truck also has a
smaller, reserve media hopper 81 which is equal in capacity to the
volume of the pressure tank's media chamber 13. When the cleaning
process is not operating, the operator may flip a switch on the
cleaning head's central panel in order to transfer media from the
reserve hopper 81 to the pressure tank's media tank 13. The media
is drawn into the blast tank 58 by means of a vacuum. It takes
approximately 40 seconds for the media to pass from the reserve
hopper 81 to the pressure tank 17. Alternatively, the system could
pulse media on a continuous basis from the reserve hopper 81 to the
pressure tank 17. The bulk of the media is held in the large hopper
80 until the transfer switch is turned off. When the transfer
switch is turned off, the reserve hopper 81 is allowed to fill.
[0079] Preferably, the operator adds media through a door 82 in the
floor of the trailer, which is above the large holding tank 80. The
chamber 80 has sufficient capacity to permit the system to run for
a substantial period of time. It takes approximately ten minutes to
transfer the media into the bulk hopper 80.
[0080] In the preferred embodiment, the initial charge of media in
the pressure tank chamber 13 is approximately 200 pounds. Depending
upon the size of the area 11 to be cleaned, additional media may
need to be added to the pressure tank 17 during the cleaning
operation in order to compensate for the media that is not recycled
and recovered.
[0081] A pinch valve 89 in the conduit 90 (between the reserve
media tank 81 and the pressure tank 17) remains closed during
operation of the cleaning system 10 in order to prevent vacuum
loss. The pinch valve 89 is opened during transfer of media from
the reserve hopper 81 to the pressure tank 17. In the event that
the pressure tank 17 is not permanently mounted to the truck, and
is instead mobile on a cart, then the media transfer mechanism
described above would not be used. Instead, the top of the pressure
tank 17 would be opened in order to allow the media to be filled
manually.
[0082] As shown in FIG. 7, the reserve tank 81 is located directly
below the main media hopper 80, so that the media can fall through
the grate 93 by gravity. After the reserve tank 81 is filled, the
grate 93 is closed, and the grate 93 remains closed during transfer
of media from the reserve hopper 81 to the pressure tank 17.
[0083] The restoration process of the present invention is only one
step in an ongoing floor maintenance program. Preferably, the
quarry tile floor is restored with the invention's system every one
to three years. Routine daily cleaning with proper floor cleaning
procedures and chemicals (the preferred routine being to sweep,
apply detergent, deck brush, and rinse) are required to maintain
the optimum coefficient of friction.
[0084] Although the present invention has been described for
restoration of a floor, specifically a quarry tile floor, the
present invention could be used for many other types of surfaces.
For example, the present invention may be utilized on concrete
(pool decks, buildings, roadways, walkways, etc.); stainless steel
(storage tanks, hood and ducts, etc.); asphalt (driveways, roads,
etc.); and other surfaces and applications. The system may be used
to remove rust, provide a thorough cleaning, and/or increase the
surface's coefficient of friction. Because the invention is a
closed system which contains the stream of particles, the invention
may be utilized both indoors and outdoors.
Operation of the Invention
[0085] The operation of the cleaning and restoration system will
now be described. The truck 19 is positioned close to the work
site. The cleaning head 12 is positioned upon the surface 11 to be
treated. The blast tank's pressure valve is opened, and the drain
valve 32 on the pressure tank 17 is also opened.
[0086] The pressure tank 17 is loaded with the particulate media
from the storage tanks 80, 81. An appropriate type and size of
media is selected, depending upon the type of surface being treated
and the goal of the treatment. For floor areas under approximately
1,000 square feet, approximately 200 pounds of media should be
charged in the pressure tank 17. The vibrator 37 on the blast tank
58 is engaged.
[0087] The exhaust conduit 23 from the cleaning head 12 to the
classifier 18 is connected. The dust collector 57 and aftercooler
85 require a 110 volt power source. This electrical connection is
made from the job site's "house" outlet with an extension cord.
[0088] Before the system 10 is activated, the rear and side doors
of the truck trailer are closed to reduce noise. The truck 19 is
started, with the emergency brake on and the truck out of gear. A
power cord 52 extending between the cleaning head's control panel
and the truck 19 is attached so that the truck's battery can power
the switches on the cleaning head 12. To start the system, the
truck's engine is started and the operator turns the key switch to
the "start" position. The vacuum/blower 22 is started by engaging
the PTO clutch via a belt and activating a vacuum/blower knob in
the truck's cab. The compressor 20 is also started by engaging the
PTO and activating a compressor knob (not shown) in the truck's
cab.
[0089] The media metering system 30 for the pressure tank 17 is
adjusted to regulate the amount of abrasive particles which are
entrained in the air stream and delivered to the cleaning unit 12.
The needle valve's setting may need to be adjusted throughout the
cleaning process of the floor 11, because the withdrawal of grease,
debris and moisture from the floor 11 may affect the flow rate of
the particulate media. Additionally, the air pressure may need to
be increased or decreased in the 40-60 psig range.
[0090] The blasting action is turned on with the "on/off" switch on
the cleaning head's control panel. This activates the vacuum
recovery system and begins movement of the particulate media to the
floor area 11. The cleaning head 12 is moved slowly back and forth
across the floor surface 11 to give the level of cleansing and
restoration desired. The treated floor 11 will have a slightly dull
appearance free of grease, oils and debris. The treated floor 11
will exhibit an increased coefficient of friction. The cleaning
head 12 should not be allowed to remain in one area too long or
move too slowly, because excessive erosion of the floor 11 may
occur. As the media is transferred from the pressure tank 17 and
vacuumed up, portions of the media are accumulated in the
classifier tank 54 from which it can be reused.
[0091] If a large floor area 11 is being treated, for example in
excess of 1500 square feet, the operator may need to add additional
particulate media to the pressure tank 17, due to the loss of some
particulate media in the vacuum recovery system. After about three
transfer sequences, there may be an insignificant amount of
recyclable media remaining. Large floor areas may also require
draining of the particulate media and the substitution of new media
if the media becomes heavily laden with grease, oil and/or
moisture.
[0092] In order to shut down the system, the blast switch on the
cleaning head 12 is turned to its "off" position. To stop the
vacuum/blower 22 and compressor 20, the PTO clutch is disengaged.
The vacuum pump 22 is disengaged by pushing in the clutch and
depressing the vacuum pump engagement knob (not shown). The clutch
is released, and the compressor 20 is allowed to continue running
long enough to clean the dust collector filters 72. The air
directors 82 are activated to clean the filter elements 72. The
chute cover (not shown) of the dust collector 57 is opened, and a
dust bag is placed over the end of the chute 118. The dust
collector is emptied with the auger 96, and the cleaning head 12
and cart 15 are returned to the truck 19.
[0093] Any loose media upon the floor 11 is swept up and disposed
of. The treated floor 11 is then rinsed to remove any residual dust
or material left on the floor. The classifier 18 is drained by
transferring media into the pressure tank 17. The pressure tank 17
and dust collector are then drained of media and soils, which are
disposed of.
Experimental Section
[0094] X-ray microanalysis tests were conducted to determine the
elements present in quarry tile. A new, untreated quarry tile was
tested, as well as quarry tile treated by an acid etch process and
a quarry tile treated with the cleaning and restoration process of
the present invention. The first three columns show the composition
of the tile's surface, whereas the right-hand column shows the
composition of the core of a new, untreated tile. The type of
quarry tile tested is sold by the American Olean Co. under the
trademark Canyon Red.TM.. The acid etch product was of the type
manufactured by the Economics in Technology/Carroll Co. of Costa
Mesa, Calif. under the Ultra Traxion.TM. trademark. The below
figures show the percent by weight of each element. The figures
have been rounded off, resulting in slight variations from 100
percent. The elemental analysis results are shown in Table I.
1TABLE I ELEMENTAL ANALYSIS Untreated Acid Etched Restored Element
Tile Tile Tile Core Silicon 51 39 51 51 Aluminum 32 29 22 23 Sodium
6 -- 2 2 Potassium 5 3 6 7 Manganese 4 3 3 2 Calcium 2 4 2 2 Iron 1
20 12 12 Titanium -- 2 1 1 101 100 99 100 (The above percentages do
not include oxygen).
[0095] These data show that the acid etch treatment significantly
reduces the amount of hard particles (silicon) in the quarry tile,
by reducing them from 51% to 39% of the tiles composition. In
contrast, the restoration system of the present invention maintains
the amount of hard particles at about 50%, thereby maintaining the
integrity and durability of the tile surface. The tile treated with
the restoration system exhibited an elemental composition
substantially the same as the core of new, untreated quarry tile.
Therefore, the restoration system does not appear to reduce the
life expectancy of the tile.
[0096] We have found that the aluminum content of the surface of
untreated tile floors ranges from about 19 wt % to about 32 wt %
while the tile core has an aluminum content of about 17 wt % to
about 25 wt %. The silicon content of the tile floors ranges from
about 50 to about 59 wt % at the surface of an untreated tile floor
to about 51 to about 66 wt % at the core.
[0097] The coefficient of friction (COF) measures how well a shoe
resists slipping on a floor. A high number is slip resistant; a low
number is slippery. Although there is no current ANSI (American
National Standard Institute) requirement, a minimum coefficient of
friction of 0.50 (wet and dry) is a recognized industry standard
for a slip resistant flooring surface. The Ceramic Tile Institute
and the National Bureau of Standards consider coefficient of
friction values in excess of 0.60 as safe values, from 0.50 to 0.60
as marginally or conditionally safe, and values below 0.50 as
slippery. New tile typically has a COF of 0.8-0.9 when clean and
dry; 0.4-0.5 when wet; and 0.2-0.3 when soiled and wet. Old tile
typically has a COF of 0.5-0.6 when clean and dry; 0.2-0.3 when
wet; and 0.1 when soiled and wet.
[0098] Experiments where conducted to measure the slip resistance
or coefficient of friction (COF) of tile floors. The COF was
measured by using a Brungraber Mark II.TM. slip tester machine.
Measurements were taken of new quarry tile, old untreated quarry
tile, and old quarry tile which had been treated with the abrasion
system of the present invention. The "new" tile was in use in a
restaurant setting, but had been installed only months before the
testing. Measurements were taken under the following floor
conditions: 1) clean and dry, 2) wet, and 3) soiled and wet. The
COF measurements are summarized in Table II.
2TABLE II COEFFICIENT OF FRICTION Old, Untreated Old, Treated New
Tile Tile Tile Clean/Dry 0.3-0.9 0.4-0.6 0.8-0.9 Wet 0.4-0.5
0.2-0.3 0.5-0.6 Soiled/Wet 0.2-0.3 0.1 0.3-0.4
[0099] These data show that the present invention produces a floor
surface that is comparable to new quarry tile when the floor is
clean and dry. When the floor is wet, or soiled and wet, the system
of the present invention actually increases the COF and traction of
the floor as compared to a new tile.
[0100] As noted above, it is possible to use different types and
sizes of media in order to achieve the desired floor surface which
is cleaner and/or has increased traction. Experiments were
conducted to measure the coefficient of friction of quarry tile
floors with respect to the effect of varying air pressures and
varying sizes of the media. Measurements were taken of brand new,
unused, dry tile which had been treated with the restoration system
of the present invention, as well as brand new tile which had been
subjected to a coating of oil and water after treatment by the
restoration system. These respective COF measurements are
summarized in Tables III and IV respectively. The type of media
utilized for these experiments was garnet.
3TABLE III EFFECT OF GRIT SIZE AND PRESSURE ON COEFFICIENT OF
FRICTION (DRY FLOOR) Pressure (psi) 40 50 60 70 Grit 0.5-0.65 0.92
0.94 0.95 0.94 Size 0.32-0.38 0.93 0.95 1 1 (mm) 0.18-0.24 0.96
0.95 0.96 1.01
[0101]
4TABLE IV EFFECT OF GRIT SIZE AND PRESSURE ON COEFFICIENT OF
FRICTION (WET AND OILY FLOOR) Pressure (psi) 40 50 60 70 Grit
0.5-0.65 0.27 0.32 0.37 0.31 Size 0.32-0.38 0.37 0.41 0.45 0.46
(mm) 0.18-0.24 0.34 0.37 0.43 0.46
[0102] It is possible to modify the system to take additional
precautions with respect to noise, such as inserting foam inside
the truck's fender wells, or adding noise reduction skirting.
[0103] These data show that, generally, increased air pressure
results in an increased coefficient of friction and a smaller-sized
media also increases the coefficient of friction and traction of
the floor.
[0104] It is to be understood that numerous and various
modifications can be readily devised in accordance with the
principles of the present invention by those skilled in the art
without departing from the spirit and scope of the present
invention. For example, in order to allow the system to operate on
higher level floors than the ground floor of a building, the system
could be modified so that the pressure tank and dust collector are
mobile. Another modification would be to use an electric motor to
run the system, rather than the PTO of the truck. The remote system
could also be propane powered instead of electrically powered.
Therefore, it is not desired to restrict the invention to the
particular constructions illustrated and described, but to cover
all modifications that can fall within the scope of the appended
claims.
* * * * *