U.S. patent application number 13/879963 was filed with the patent office on 2013-08-22 for carpet cleaning system and method.
This patent application is currently assigned to DIVERSEY, INC.. The applicant listed for this patent is Ronald Jones, Ryan E. Kron, Michael J. Williams. Invention is credited to Ronald Jones, Ryan E. Kron, Michael J. Williams.
Application Number | 20130213438 13/879963 |
Document ID | / |
Family ID | 45975837 |
Filed Date | 2013-08-22 |
United States Patent
Application |
20130213438 |
Kind Code |
A1 |
Kron; Ryan E. ; et
al. |
August 22, 2013 |
CARPET CLEANING SYSTEM AND METHOD
Abstract
A carpet cleaning system including a cleaning agent that is one
of dilutable with and dissolvable in water to generate a cleaning
solution. The cleaning system includes a brush disc that has a
substantially bowl-shaped glide plate, and bristles disposed in a
bristle region. The cleaning system further includes a carpet
cleaning apparatus that has a reservoir for containing the cleaning
solution, a motor, an aeration device, a power source, and a
control system. The motor rotatably actuates the brush disc. The
aeration device is fluidly coupled to the reservoir for aerating
the cleaning solution to generate foam. The aeration device
dispenses foam into at least one of the opening of the glide plate
and the bristle region at a rate equivalent to between about 0.028
gallons per minute and about 0.042 gallons per minute.
Inventors: |
Kron; Ryan E.; (Racine,
WI) ; Williams; Michael J.; (Pasadena, MD) ;
Jones; Ronald; (Summerville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kron; Ryan E.
Williams; Michael J.
Jones; Ronald |
Racine
Pasadena
Summerville |
WI
MD
SC |
US
US
US |
|
|
Assignee: |
DIVERSEY, INC.
Sturtevant
WI
|
Family ID: |
45975837 |
Appl. No.: |
13/879963 |
Filed: |
October 18, 2011 |
PCT Filed: |
October 18, 2011 |
PCT NO: |
PCT/US2011/056742 |
371 Date: |
May 8, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61394613 |
Oct 19, 2010 |
|
|
|
Current U.S.
Class: |
134/6 ;
15/21.1 |
Current CPC
Class: |
A47L 11/34 20130101;
A47L 11/4088 20130101; A47L 11/283 20130101; A47L 11/4038 20130101;
A46B 13/008 20130101; A47L 11/4083 20130101 |
Class at
Publication: |
134/6 ;
15/21.1 |
International
Class: |
A47L 11/283 20060101
A47L011/283 |
Claims
1. A carpet cleaning system comprising: a cleaning agent being at
least one of dilutable with and dissolvable in water to generate a
cleaning solution; a brush disc including a substantially
bowl-shaped glide plate located adjacent a center of the brush
disc, the glide plate having a bottom wall and a walled periphery
extending upward from the bottom wall to define an upward-facing
opening opposite the bottom wall, the brush disc further including
bristles disposed in a bristle region located radially outward from
the glide plate; and a carpet cleaning apparatus including: a
reservoir for containing the cleaning solution, a motor for
rotatably actuating the brush disc, an aeration device fluidly
coupled to the reservoir for aerating the cleaning solution to
generate foam, the aeration device configured to dispense foam into
at least one of the opening of the glide plate and the bristle
region, a power source for providing power to the motor and the
aeration device, and a control system for controlling the motor and
the aeration device; wherein the aeration device dispenses foam at
a rate equivalent to between about 0.028 gallons of cleaning
solution per minute and about 0.042 gallons of cleaning solution
per minute.
2. The carpet cleaning system of claim 1, wherein foam contains
between approximately 2% to 10% water and 90% to 98% air and
anionic surfactant, by volume.
3. The carpet cleaning system of claim 1, wherein the glide plate
has at least one port extending through the walled periphery for
ejection of foam from the glide plate as the brush disc
rotates.
4. The carpet cleaning system of claim 3, wherein the glide plate
has six ports extending through the walled periphery, and wherein
each port has a diameter of approximately 0.25 inches.
5. The carpet cleaning system of claim 1, wherein the cleaning
agent is diluted with water in a ratio of 1 part cleaning agent to
12 parts water, by volume, to generate the cleaning solution.
6. The carpet cleaning system of claim 1, wherein the cleaning
agent comprises sodium lauryl sulfate and disodium lauromido MEA
sulfosuccinate.
7. The carpet cleaning system of claim 1, wherein the glide plate
supports substantially all of the weight of the carpet cleaning
apparatus.
8. The carpet cleaning system of claim 1, wherein the aeration
device dispenses foam at a rate equivalent to between about 0.0010
gallons of cleaning solution per square foot of carpet and 0.0016
gallons of cleaning solution per square foot of carpet.
9. The carpet cleaning system of claim 1, wherein: at least a
portion of the bristle region is located at least approximately
four inches from an axis of rotation of the brush disc, and the
brush disc rotates at no less than about 175 revolutions per minute
("RPM") in at least one mode of operation of the carpet cleaning
system.
10. A method of cleaning a carpet with a carpet cleaning machine,
the method comprising; at least one of diluting and dissolving a
concentrated cleaning agent in water to generate a cleaning
solution; aerating the cleaning solution; dispensing the cleaning
solution to at least one of a bowl-shaped glide plate and a
plurality of bristles of a brush disc at a rate equivalent to
between about 0.028 gallons of aerated cleaning solution per minute
and about 0.042 gallons of aerated cleaning solution per minute;
and rotating the brush disc to distribute the aerated cleaning
solution onto the carpet.
11. The method of claim 10, further comprising diluting
concentrated cleaning solution with water and aerating the diluted
cleaning solution such that it comprises between approximately 2%
to 10% water and 90% to 98% cleaning solution, by volume.
12. The method of claim 10, further comprising providing the glide
plate with a port extending through the walled periphery; aerating
the cleaning solution to generate a foam; directing foam to the
glide plate; and ejecting foam from the glide plate through the
port as the brush disc rotates.
13. The method of claim 12, further comprising providing the glide
plate with six ports extending through the walled periphery, and
wherein each port has a diameter of approximately 0.25 inches.
14. The method of claim 10, wherein the concentrated cleaning agent
comprises sodium lauryl sulfate and disodium lauromido MEA
sulfosuccinate.
15. The method of claim 10, further comprising dispensing the
aerated cleaning solution at a rate equivalent to between about
0.0010 gallons of aerated cleaning solution per square foot of a
carpet and 0.0016 gallons of aerated cleaning solution per square
foot of a carpet.
16. The method of claim 10, further comprising rotating bristles
located at least approximately four inches from an axis of rotation
of the brush at no less than about 175 RPM.
17. A carpet cleaning system comprising: a brush disc rotatable
about an axis and including bristles; a motor drivably coupled to
the brush disc; a reservoir; a cleaning agent being at least one of
dilutable with and dissolvable in water to generate a cleaning
solution contained in the reservoir; an aerator positioned to
receive and aerate the cleaning solution to generate foam; a port
through which foam is configured to be dispensed to the bristles at
a rate of between about 0.028 gallon of foam per minute and about
0.042 gallon of foam per minute.
18. The carpet cleaning system of claim 17, wherein foam contains
between approximately 2% to 10% water, by volume.
19. The carpet cleaning system of claim 17, wherein the brush disc
includes a glide plate located adjacent the center of the brush
disc, and wherein the glide plate includes a walled periphery and
the port extends through the walled periphery to receive foam from
the aerator.
20. The carpet cleaning system of claim 17, wherein the port is
part of at least one nozzle positioned to dispense foam to the
bristles.
21. The carpet cleaning system of claim 17, wherein the port has a
diameter less than or equal to 0.25 inches.
22. The carpet cleaning system of claim 17, wherein the cleaning
agent is diluted with water in a ratio of no less than about 1 part
cleaning agent to 12 parts water, by volume.
23. The carpet cleaning system of claim 17, wherein the cleaning
agent includes sodium lauryl sulfate and disodium lauromido MEA
sulfosuccinate.
24. The carpet cleaning system of claim 17, wherein the glide plate
is positioned to support at least a portion of the weight of the
carpet cleaning system.
25. The carpet cleaning system of claim 17, wherein the aerator
dispenses foam at a rate equivalent to between about 0.0010 gallons
of foam per square foot of a carpet and 0.0016 gallons of foam per
square foot of a carpet.
26. The carpet cleaning system of claim 17, wherein: at least a
portion of the bristles is located at least approximately four
inches from the axis of the brush, and the brush rotates at no less
than about 175 RPM in at least one mode of operation of the carpet
cleaning system.
Description
BACKGROUND
[0001] Some conventional carpet cleaning machines use steam or hot
water extraction to clean carpet. These systems typically spray hot
water including a shampoo or cleaning solution into the carpet, and
quickly extract the solution from the carpet using vacuum. High
pressure jets of the hot water solution provide agitation of the
carpet fibers while the temperature of the water, which is
typically 100-180 degrees, increases cleaning effectiveness. In
many machines, the water-based cleaning solution is agitated by a
brush disc attached to the cleaning system to clean the carpet.
[0002] Some conventional carpet cleaning machines apply water-based
cleaning solution to the carpet using a rotatable brush that has
bristles engaging the carpet. Typically, the water-based cleaning
solution is gravity fed from a tank on the cleaning machine, and is
dispensed through holes in the brush. During operation, the
cleaning solution is dropped directly onto the carpet via the
holes. Agitation of the cleaning solution via rotation of the brush
disc generates foam in the carpet. Often, because the cleaning
solution associated with these brush discs is water-based, the
carpet becomes over-saturated with moisture. Over-saturating the
carpet leads to relatively long carpet drying times (e.g., 8-10 or
more hours). The longer the period of time the carpet remains wet,
the greater the chance that mold, mildew, or other microorganisms
will form in the carpet fibers. Also, long-term use of these
conventional brushes can damage or distort the carpet due in part
to over-saturation, and in some cases due to the carpet being
subjected to excessive wear from the weight of the conventional
cleaning machine resting on the bristles of the brush. In addition,
longer carpet drying times can prevent the carpeted space from
being used until the carpet is dry, which can be unacceptable in
certain circumstances (such as in high-traffic areas, in retail
business settings, and the like).
[0003] In some conventional rotary floor machines, a foamed
cleaning solution is deposited onto the carpet. This cleaning is
sometimes referred to as "dry foam cleaning," and typically
involves aerating a water solution containing a higher percentage
of shampoo or cleaner than the hot water extraction solution, to
generate a foam that is deposited on the carpet. Most often, foam
is worked into the carpet using a rotating brush, which also
agitates the carpet to assist in the removal of dirt. These
conventional cleaning machines typically direct a cleaning solution
(e.g., shampoo) into a foam generating pump of the cleaning machine
prior to dispensing foam onto the carpet through the brush. The
brush can take various forms, such as a disc brush with rings of
bristles, a star-patterned brush disc, and the like. During
operation, the low moisture foam dispensed onto the carpet keeps
the carpet relatively dry. Some dry foam systems include vacuum
extractors for removing foam, while in other systems foam residue
encapsulating the carpet dirt is vacuumed up after the carpet has
dried. While carpets cleaned with this type of conventional
cleaning machine are typically not over-saturated with water, the
carpet is still typically subjected to excessive wear and fiber
degradation due to the weight of the cleaning machine resting on
the bristles of the brush.
SUMMARY
[0004] In some embodiments, a carpet cleaning system is provided,
and includes a cleaning agent being at least one of dilutable with
and dissolvable in water to generate a cleaning solution; a brush
disc including a substantially bowl-shaped glide plate located
adjacent a center of the brush disc, the glide plate having a
bottom wall and a walled periphery extending upward from the bottom
wall to define an upward-facing opening opposite the bottom wall,
the brush disc further including bristles disposed in a bristle
region located radially outward from the glide plate; and a carpet
cleaning apparatus including: a reservoir for containing the
cleaning solution, a motor for rotatably actuating the brush disc,
an aeration device fluidly coupled to the reservoir for aerating
the cleaning solution to generate foam, the aeration device
configured to dispense foam into at least one of the opening of the
glide plate and the bristle region, a power source for providing
power to the motor and the aeration device, and a control system
for controlling the motor and the aeration device; wherein the
aeration device dispenses foam at a rate equivalent to between
about 0.028 gallons of cleaning solution per minute and about 0.042
gallons of cleaning solution per minute.
[0005] Some embodiments of the present invention provide a method
of cleaning a carpet with a carpet cleaning machine, wherein the
method comprises at least one of diluting and dissolving a
concentrated cleaning agent in water to generate a cleaning
solution; aerating the cleaning solution; dispensing the cleaning
solution to at least one of a bowl-shaped glide plate and a
plurality of bristles of a brush disc at a rate equivalent to
between about 0.028 gallons of aerated cleaning solution per minute
and about 0.042 gallons of aerated cleaning solution per minute;
and rotating the brush disc to distribute the aerated cleaning
solution onto the carpet.
[0006] In some embodiments, a carpet cleaning system is provided,
and comprises a brush disc rotatable about an axis and including
bristles; a motor drivably coupled to the brush disc; a reservoir;
a cleaning agent being at least one of dilutable with and
dissolvable in water to generate a cleaning solution contained in
the reservoir; an aerator positioned to receive and aerate the
cleaning solution to generate foam; a port through which foam is
configured to be dispensed to the bristles at a rate of between
about 0.028 gallon of foam per minute and about 0.042 gallon of
foam per minute.
[0007] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a carpet cleaning system
including a brush disc embodying the present invention.
[0009] FIG. 2 is a perspective view of the brush disc of FIG. 1,
including bristles and a glide plate.
[0010] FIG. 3 is a perspective view of a portion of the brush disc
of FIG. 2.
[0011] FIG. 4 is a cross-section view of the brush disc of FIG. 2,
taken along line 4-4 of FIG. 2.
[0012] FIG. 5 is a top view of the glide plate of FIG. 2.
[0013] FIG. 6 is a side view of the glide plate of FIG. 2.
DETAILED DESCRIPTION
[0014] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the accompanying drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items.
[0015] FIGS. 1-6 show an exemplary carpet cleaning system 10
embodying the present invention. As illustrated in FIG. 1, the
cleaning system 10 includes a cleaning machine 15, a brush disc 20,
and a cleaning agent (contained within reservoir 45) that can be
used to clean a carpet floor surface 25 or other similar floor
surfaces. The illustrated cleaning machine 15 has a base assembly
30, a handle assembly 35 connected to the base assembly 30 by a
frame member (embodied as a shaft 40 in the illustrated embodiment)
extending upward from the base assembly 30, and the reservoir 45,
which is shown coupled to the frame member 40 between the base
assembly 30 and the handle assembly 35.
[0016] The illustrated base assembly 30 includes a housing 75 and a
shroud 80 or brush support that is disposed below the housing 75.
Wheels 85 are rotatably coupled to the housing 75 such that an
operator can tilt the cleaning machine 15 rearwardly to permit
movement of the machine 15 to a different area when the machine 15
is in an "off" state. As illustrated in FIG. 1, when the machine 15
is in an "on" state, the wheels 85 are displaced or spaced apart
from the floor surface 25.
[0017] With continued reference to the illustrated embodiment, the
housing 75 is attached to and supports a motor 90 and a foam
generator (aeration device 95 in the illustrated embodiment). The
motor 90 and the aeration device 95 are connected to a controller
(e.g., coupled to the handle assembly 35 or disposed in the housing
75) and to a power source via a power cord 100 that extends from
the cleaning machine 15. In some embodiments, the motor 90 and the
aeration device 95 can also or instead be powered in other manner
(e.g., one or more batteries, etc.). The motor 90 of the
illustrated embodiment is mounted to the top of the shroud 80, and
has a shaft (not shown) that is oriented substantially vertically
adjacent a center of the shroud 80. In the illustrated embodiment,
the motor 90 is offset from the center of the shroud 80, and is
engaged with a brush disc 20 driver (not shown) via a chain, gear,
belt, or other connection. In other embodiments, the motor 90 can
be located over the center of the shroud 80 to directly engage the
brush disc 20 or mechanical elements rotatably and drivably
coupling the brush disc 20 to the motor shaft.
[0018] The illustrated aeration device 95 is fluidly coupled to the
reservoir 45 by a hose 105 coupled to and extending from the
reservoir 45. In some embodiments, the hose 105 is coupled to a
bottom of the reservoir 45. The aeration device 95 of the
illustrated embodiment is located downstream of and substantially
below the reservoir 45, and is also located above and in fluid
communication with the brush disc 20 (e.g., via one or more tubes
or hoses or channels).
[0019] In the illustrated embodiment, the shroud 80 is disc-shaped
and supports the handle assembly 35, the reservoir 45, the motor
90, and the aeration device 95. As shown in FIG. 1, the shroud 80
encloses a portion of the brush disc 20. In some embodiments, the
shroud 80 can include a resilient material 110 adjacent the
periphery of the shroud 80 to protect the shroud 80 from damage due
to impact with walls or furniture.
[0020] The illustrated handle assembly 35 is located above and
coupled to the base assembly 30 via the shaft 40, and includes
handles 120 and handle controls 125 that are located adjacent a
distal end of the shaft 40. The handles 120 include grips that
allow an operator to maneuver the cleaning machine 15 on the floor
surface 25. In some embodiments, the handles 120 are
adjustable.
[0021] With particular reference to FIG. 1, the illustrated handle
controls 125 are located adjacent the handles 120 so the operator
can reach the handle controls 125 while guiding movement of the
cleaning machine 15. The handle controls 125 of the illustrated
embodiment generally include a motor activation switch 130 (e.g.,
for varying the cleaning machine 15 between an "off" state and an
"on" state) and one or more levers 135 for controlling
characteristics of the cleaning machine 15 (e.g., the speed of the
cleaning machine 15, rotation of the brush disc 20, etc.).
[0022] The reservoir 45 of the illustrated carpet cleaning system
10 is coupled to the shaft 40 and holds cleaning solution.
Generally, the reservoir 45 can be formed or manufactured from any
material suitable for supporting or containing the liquid cleaning
solution. As shown in FIG. 1, a reservoir filler cap 140 is
positioned over an opening at the top of the reservoir 45.
[0023] The illustrated cleaning machine 15 also includes a first
control mechanism 145 and a second control mechanism 150 coupled to
a top portion of the reservoir 45 for controlling the cleaning
characteristics of the cleaning machine 15. In some embodiments,
the cleaning machine 15 may include fewer or more than two control
mechanisms.
[0024] In the illustrated embodiment, the first control mechanism
145 controls the level of cleaning (e.g., levels 0-4) provided by
the machine 15 based on desired cleaning characteristics. For
example, level 0 can correspond to a standby mode for the cleaning
machine 15 (i.e., no cleaning), level 1 can correspond to a light
cleaning level, level 2 can correspond to an intermediate cleaning
level, level 3 can correspond to an advanced cleaning level, and
level 4 can correspond to a near extraction cleaning level. Other
levels of cleaning are also possible and considered herein. The
quantity of cleaning solution that is dispensed from the reservoir
45 to the aeration device 95 is based at least in part on the
desired level of cleaning. Generally, the higher the level of
cleaning that is selected, more cleaning solution is dispensed from
the reservoir 45.
[0025] The second control mechanism 150 of the illustrated
embodiment controls a vent on the cleaning machine 15 to allow
excess air to escape from the reservoir 45. The second control
mechanism 150 is removable from the reservoir 45 so that the
control mechanism 150 can be cleaned, if necessary.
[0026] Generally, the handle controls 125 and the first and second
control mechanisms 145, 150 define a portion of a control system of
the cleaning machine 15 that controls various parameters associated
with the cleaning machine 15. The reservoir 45, the motor 90, the
aeration device 95, the power source (not shown), and the control
system (also not shown) define a carpet cleaning apparatus of the
cleaning system 10.
[0027] With continued reference to the illustrated embodiment, the
brush disc 20 is located under the shroud 80, and is coupled to the
motor shaft such that the brush disc 20 rotates about an axis 50 to
agitate carpet during cleaning. As shown in FIGS. 2-6, the brush
disc 20 includes a brush disc adapter 55, a brush base 60 that
supports a plurality of bristles 65, and a glide plate 70. As
illustrated in FIG. 4, the brush disc 20 is detachably coupled to
the cleaning machine 15 below the shroud 80 via engagement of the
brush disc adapter 55 with a brush disc driver (not shown). The
brush disc adapter 55 is located at the center of the brush base
60, and is secured to the brush base 60 using suitable attachment
elements or structure (e.g., fasteners, adhesive, clamping force, a
press fit, etc.). For example, the brush disc adapter 55 can
include engagement portions that rotatably engage and interlock
with corresponding attachment portions on the brush disc driver to
secure the brush disc 20 to the cleaning machine 15. In this
manner, the brush disc 20 can be coupled to the brush disc driver
without the use of tools.
[0028] The brush base 60 is defined by a diameter (e.g., 17 inches,
20 inches) and includes a hole 155 that supports the brush disc
adapter 55 at the center of the brush base 60. In the illustrated
embodiment, a plurality of fasteners 160 attach the bristles 65 to
the brush base 60. As shown in FIG. 2, the bristles 65 are disposed
in a bristle region 165 located radially outward from or
circumferentially around the glide plate 70. The bristle region 165
defines a cleaning area of the brush base 60. At least a portion of
the bristle region 165 is located at no less than about four inches
and no greater than about twelve inches from the axis 50. In other
embodiments, at least a portion of the bristle region 165 is
located at no less than about six inches from the axis 50 and no
greater than about nine inches from the axis 50. Other distances of
the bristle region 165 relative to the axis 50 are possible and
considered herein.
[0029] The illustrated brush disc 20 defines a ratio of the bristle
region area of the brush base 60 to the glide plate area of the
brush base 60 that is approximately 8 (e.g., the bristle region 165
has an area that is approximately 89 percent of the total area of
the brush base 60 and the glide plate 70 has an area that is
approximately 11 percent of the total area of the brush base 60).
The area ratio can be larger or smaller than 8 depending on the
location of the bristle region 165 relative to the axis 50 and the
size of the glide plate 70. Also as illustrated, the bristles 65
are substantially equally spaced apart from each other. Generally,
the bristles 65 can be arranged on the brush base 60 around the
glide plate 70 in any manner desired (e.g., bristles 65 spaced
apart different distances from each other, star pattern,
radially-extending spokes of bristles, etc.).
[0030] With reference now to FIGS. 2-6, the illustrated glide plate
70 is substantially bowl-shaped, and is located adjacent the center
of the brush disc 20 below the brush disc adapter 55, and in some
embodiments can support substantially all of the weight of the
carpet cleaning machine 15. The glide plate 70 can be formed from
any suitable material (e.g., metal, plastic, composite, etc.). In
other embodiments, the glide plate 70 supports at least some of the
weight of the cleaning machine 15.
[0031] As shown in FIGS. 4-6, the illustrated glide plate 70
includes a bottom wall 170 and a walled periphery 175 that
cooperate to define a foam receptacle 180. The bottom wall 170 has
a middle portion 185 and an outer radial portion 190 that is
slightly lower than the middle portion 185 (as viewed in FIG. 4).
Fastening mechanisms 195 (e.g., rivet-nuts or t-bolts) are attached
to and spaced around the outer radial portion 190 to adjustably
couple the glide plate 70 to the brush base 60 using fasteners 200
(one shown) that extend downward (as viewed in FIG. 4) through
fastener apertures 205 (one shown) in the brush base 60. Two or
more fastening mechanisms 195 can be used to adjustable attach the
glide plate 70 to the brush base 60. In other embodiments, other
manners of releasably securing the glide plate 70 to the brush base
and/or brush disc adapter 55 are possible, such as fastening
mechanisms 195 located in the middle portion 185 of the glide plate
and extending to engagement with the brush base 60 or brush disc
adapter 55, fasteners radially extending between the walled
periphery 175 and the brush base 60 and/or brush disc adapter 55,
and the like.
[0032] The walled periphery 175 of the illustrated glide plate 70
extends upward from and circumferentially around the bottom wall
170 to define an upward-facing opening opposite the bottom wall
170. As shown in FIGS. 2-6, the walled periphery 175 includes a
plurality of holes or ports 210 that are in communication with foam
receptacle 180 to distribute foam outward from the glide plate 70
into the bristle region 165. Generally, the ports 210 are sized and
arranged in sufficient quantity to provide desired foam flow rates
and to thereby achieve desired carpet cleaning characteristics. In
the illustrated embodiment, the glide plate 70 includes six ports
210 that are equally spaced around the circumference of the glide
plate 70, and that have a diameter of about 0.25 inches. In some
embodiments, the glide plate 70 can include fewer or more than six
ports 210. Also, the ports 210 can be spaced apart from each other
at non-uniform distances, and/or can have the same or different
diameters from one another.
[0033] In some embodiments, the ports 210 each have a diameter of
at least about 0.1 inches and no greater than about 0.5 inches. In
other embodiments, such ports each have a diameter of at least
about 0.25 inches. In still other embodiments, the ports 210 can
have the same or different diameters. The size and quantity of the
ports 210 can be selected or modified based on the desired level of
cleaning. The larger the diameter(s) of the ports 210 allows more
cleaning solution to be dispensed from the glide plate 70.
[0034] Although a wide range of cleaning agents can be used in the
carpet cleaning system 10 of the present invention, the inventors
have discovered that certain cleaning agents provide excellent
cleaning results. Such cleaning agents include (by way of example)
sodium lauryl sulfate and disodium lauromido MEA sulfosuccinate.
The cleaning solution is disposed in the reservoir 45, and the
cleaning agent is dilutable or dissolvable with water to generate a
cleaning solution that can be used to clean carpet or other similar
surfaces. The cleaning agent can be diluted or dissolved in water
before, when, or after the cleaning agent is poured into the
reservoir 45. In some embodiments, the cleaning agent is diluted
with water according to a ratio of 1 part cleaning agent to 12
parts water, by volume. Some formulations of cleaning solution
generated from the cleaning agent contain between approximately 2%
to 10% water and 90% to 98% air and anionic surfactant, by volume.
Other formulations of cleaning solutions containing water, air, and
one or more anionic surfactants are also possible and considered
herein. Alternatively, any suitable dry foam or other cleaning
solutions currently on the market can be used with the carpet
cleaning system 10.
[0035] In operation, the cleaning machine 15 is connected to a
power source, and an operator grips the handles 120 and operates
the handle controls 125 to maneuver the cleaning machine 15 over
the floor surface 25. When the cleaning machine 15 is in the "on"
state and one or more levers 135 are engaged, the cleaning solution
is dispensed from the reservoir 45 through the hose 105 to the
aeration device 95, which aerates the cleaning solution to generate
foam. The inventors have discovered that a foam dispense rate of
between about 0.028 gallons of cleaning solution per minute and
about 0.042 gallons of cleaning solution per minute produces
cleaning results that are substantially better than anticipated
despite the very low foam dispense rate. Also, when used in
conjunction with the manner of dispense (i.e., via ports 210 as
described above and/or via brush base ports as described below),
brush speed (as also described in greater detail below), and/or
cleaning agents described herein, the inventors have discovered
that excellent cleaning results are achieved--again at a very
unexpected level. In other embodiments of the present invention,
other foam dispensing rates are also possible and considered
herein.
[0036] In some embodiments, the aeration device 95 dispenses foam
at a rate equivalent to between about 0.0010 gallons of cleaning
solution per square foot of the floor surface 25 and about 0.0016
gallons of cleaning solution per square foot of the floor surface
25. The inventors have discovered that such foam dispense rates
produce cleaning results that are substantially better than
anticipated despite the very low dispense rate. Also, when such
foam dispense rates are used in conjunction with the manner of
dispense (i.e., via ports 210 as described above and/or via brush
base ports as described below), brush speed (as also described in
greater detail below), and/or cleaning agents described herein, the
inventors have discovered that excellent cleaning results are
achieved--again at a very unexpected level. Other foam dispensation
rates are also possible and considered herein.
[0037] In the illustrated embodiment, foam is directed from the
aeration device 95 toward the brush disc 20, which rotates when the
cleaning machine 15 is in the "on" state and at least one of the
handle controls 125 is engaged or activated by the operator. The
brush disc 20 rotates between about 175 rotations per minute
("RPM") and 200 RPM in at least one mode of operation of the carpet
cleaning system 10. Generally, the brush disc 20 can rotate at any
speed that is adequate for cleaning the floor surface 25. The
rotational speed of the brush disc 20 generally produces bristle
speeds between about 6,000 inches per minute and 13,000 inches per
minute. For example, the bristles 65 located adjacent the glide
plate 70 can have a bristle speed of approximately 7,500 inches per
minute, and the bristles 65 located adjacent the outer periphery of
the brush base 60 can have a bristle speed of approximately 11,300
inches per minute. Other speeds of the bristles 65 are also
possible and considered herein.
[0038] During operation, the illustrated brush disc 20 distributes
foam to the bristles 65 using the glide plate 70. Foam accumulates
in the foam receptacle 180 of the glide plate 70 before being
dispensed to the bristles 65 via the ports 210. The bowl-shaped
glide plate 70 can allow foam to accumulate prior to ejection
through the ports 210 so that foam can be dispensed to the bristles
65 substantially uniformly. The level of cleaning selected using
the first control mechanism 145 generally determines the amount of
foam that is provided to the bristles 65. Rotational or centrifugal
force of the brush disc 20 during operation ejects foam from foam
receptacle 180 to the bristles 65 through the ports 210. Foam
ejected from the ports 210 enters the bristle region 165 and is
worked into the carpet to remove soil and debris from the
carpet.
[0039] In some embodiments, foam can be dispensed through the brush
disc 20 directly into the bristle region 165 (e.g., via ports in
the brush base 60 coupled to one or more fluid lines extending to
the aeration device 95) without passing through the glide plate 70,
or in addition to foam being dispensed through the glide plate 70
as discussed above. In other embodiments, the cleaning machine 15
can include one or more tubes or hoses that fluidly couple the
aeration device 95 directly to the ports 210. In all such
embodiments, the aggregate flow rates described above can be used
to achieve the desirable cleaning results also described above.
[0040] After foam is dispensed onto the carpet by the bristles 65,
foam containing the soil and debris can be vacuumed up using
another device. In some embodiments, the cleaning system 10 can
include an integrated vacuum device that picks up foam and debris
during or after operation of the cleaning machine 15.
[0041] The quantity and size of the ports 210, in large part,
determine the amount of foam that ejects from the glide plate 70
during rotation of the brush disc 20. Generally, the centrifugal
force of the illustrated rotating brush disc 20 forces foam out of
the glide plate 70 at a relatively slow rate to deliver foam
without over-saturating the carpet. In this manner, the amount of
foam applied to the floor surface 25 can be substantially
controlled. In addition, brush discs with different quantities
and/or sizes of ports 210 can be provided to clean different floor
surfaces.
[0042] In the illustrated embodiment, the glide plate 70 supports
at least a portion (and in some cases, the majority) of the weight
of the cleaning machine 15, which reduces the weight supported by
the bristles 65 and reduces drag of the cleaning machine 15 as the
machine 15 moves along the carpet. Also, because the glide plate 70
can support most or substantially all of the weight of the cleaning
machine 15, the rotating bristles 65 gently but firmly loosen soil
in the carpet without damaging the carpet. In some embodiments, the
glide plate 70 height is adjustable to accommodate wear on the
bristles 65 due to repeated use of the cleaning machine 15. To
adjust the height of the glide plate 70 in the illustrated
embodiment, the brush disc 20 can be removed from the cleaning
machine 15. An operator can then tighten the fasteners 200 that are
coupled to the fastening mechanisms 195 to raise the glide plate 70
to the desired orientation relative to the length of the bristles
65. If, on the other hand, the bristles 65 are too long relative to
the height of the glide plate 70, the fasteners 200 can be loosened
to lower the glide plate 70. The brush disc 20 is then reattached
to the cleaning machine 15 for subsequent use. In this manner, the
bristles 65 are kept at a proper cleaning height throughout the
life of the cleaning machine 15 and the brush disc 20. Also, the
location of the glide plate 70 on the brush disc 20 protects the
carpet and reduces drag by not allowing the bristles 65 to dig too
deeply into the carpet.
[0043] Due to the low water content of foam generated by the
aeration device 95, carpet drying time is significantly reduced as
compared with cleaning solutions used in conventional cleaning
machines. In particular, depending on the cleaning level selected,
carpet cleaned with the cleaning system 10 can dry between
approximately 25 minutes and 35 minutes. Also, the anionic
surfactant in foam generated by the aeration device 95 has a
negative charge, pulling soil away from the carpet and holding the
soil in suspension within foam until the soil can be vacuumed
without leaving a sticky residue on the carpet and without
over-saturating the carpet.
[0044] Although the cleaning system 10 has been described in detail
with regard to the upright, walk-behind cleaning machine 15
illustrated in FIG. 1, it should be understood that the cleaning
system 10 can be used with other cleaning machines (e.g.,
ride-along machines, etc.). Furthermore, it should be understood
that the cleaning system 10 described herein can be used on floor
surfaces other than carpet.
[0045] The embodiments described above and illustrated in the
figures are presented by way of example only and are not intended
as a limitation upon the concepts and principles of the present
invention. As such, it will be appreciated by one having ordinary
skill in the art that various changes in the elements and their
configuration and arrangement are possible without departing from
the spirit and scope of the present invention as set forth in the
appended claims. Various features and advantages of the invention
are set forth in the following claims.
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