Abstract:
A mat surface cleaner of the walk-behind type, comprising a wheeled housing having a forward roller brush cleaner, a rear squeegee device, user hand controls and an internal cavity for housing the device power means and cleaning elements. The cavity is accessed through flip-open hatch along the housing upper surface, which provides access to a cleaning solution reservoir attached thereto. Along the base of the cavity is a gel cell battery, electric motor and a pulley system for powering the device. Rear hand controls provide the user control over the cleaning spray application and vehicle speed, while a rearward A/C power plug is provided for recharging the battery. The forward roller brush is adapted to provide soft-contact bristles for the particular goal of sanitizing and cleaning athletic and wrestling mats after their use without causing damage thereto, while the lightweight design of the device allows improved handling and everyday use.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent Ser. No. 13/326,748 filed on Dec. 15, 2011, which claims the benefit of U.S. Provisional Application No. 61/423,868 filed on Dec. 16, 2010. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to floor surface and mat cleaning devices. More specifically, the present invention pertains to a powered, walk-behind floor surface cleaner comprising a wheeled housing having deployable cleaning solution, scrub brushes and rearward drying means that is adapted to clean and sanitize a surface by traveling thereover. The present cleaning device is specifically adapted to clean wrestling mats and other athletic mats, wherein the device sanitizes the mat after its use and eliminates infectious organisms and parasites. 
         [0004]    2. Description of the Prior Art 
         [0005]    Athletic mats and wrestling mats are support surfaces comprising a thick layer of rubberized material or cushion material wrapped in an outer shell of vinyl or similar material. These devices are useful for protecting participates from injuries due to contact with a hard ground surface, providing cushioning and reduced friction during contact with the mat surface. These surfaces quickly become dirty and contaminated after each use, as they are placed on a floor surface and come into contact with the athletes engaging in activity thereon. In wresting, in particular, it is common for wrestling mats to transfer ringworm, fungus or other parasites between participants during athletic activities. Several different users contact the same mat surface, and therefore allowing for transfer of such organisms therebetween. 
         [0006]    Generally, these mats are rolled up or folded into a stowed state after each use. It is common to sanitize these items before stowage, which includes spray pumps of disinfectant and hand wiping the surface of each mat. This can be particularly time consuming when utilizing a plurality of mats, or for those gyms and athletic events wherein a large surface area mat is utilized (i.e. a wrestling mat or continuous gym rubber mat). Sanitization in these situations can be difficult and cumbersome, and sometimes overlooked in favor of expediency. An improved method and device for cleaning such mats is clearly needed. 
         [0007]    Floor scrubbers and surface cleaners are well known articles in the art. These devices have similar design elements for the purposes of cleaning large floor surface areas using a scrubber assembly, cleaning solution and recollecting the solution after application. These devices are generally very large, and in some cases even ride-on devices, wherein their use with mats is limited. These devices are not adapted to clean smaller mats, and further are not adapted to work well with the softer vinyl coverings of some mats, which may tear or becoming worn if cleaned using a larger floor scrubber assembly. The present invention provides a smaller, lightweight and simply constructed assembly for the specific purpose of cleaning athletic and floor mats. In particular, the device is suited for distributing a film of cleaning solution and disinfectant, lightly scrub the solution and squeegee excess solution from the mat in a single pass. The device can easily be lifted onto a mat, as the elements of the device are lightweight and heavy solution recovery devices are not included. The device is adapted for use after each practice session or athletic event, wherein a plurality of large surface mat is required to be disinfected and cleaned. 
         [0008]    Several devices have been disclosed in the prior art that relate to floor scrubbers and surface cleaners. These devices are generally too large or cumbersome to accomplish the given task of the present invention. Most disclose a larger floor scrubbing assembly having a large reservoir and recollection system, along with elements of varying levels of sophistication. Their common drawback is their sheer size and lack of utility with regard to floor mats and athletic mats, which are more susceptible to damage than a tile or linoleum floor surface. The present invention utilizes a lightweight assembly and a roller brush adapted to clean floor mat surface without causing damage thereto, while removing dirt, sweat and contaminants thereon. 
         [0009]    One such device is U.S. Pat. No. 5,369,838 to Wood, which discloses an automatic floor scrubber device having its frame divided into a truck portion and an upper chassis assembly removable therefrom. The scrubber frame includes wheels, the drive motor for powering the brush scrub system and a rearward squeegee system. Controls, cleaning solution tanks and batteries to power the motor are mounted to the removable chassis. Connection between the chassis and truck is accomplish via a plurality of elastomeric isolator mounts that secure the two together, allowing electrical and mechanical connections to be created between the otherwise separated systems. The Wood device discloses a novel construction for a floor scrubber, wherein the structure is separable for maintenance and repair purposes. Its construction differs from the present invention, while employs a unitary body and hingeable access to the body interior for loading cleaning solution and maintaining the device. 
         [0010]    Similarly, U.S. Pat. No. 5,383,251 to Whitaker discloses a self-propelled floor cleaning machine or scrubber that comprises a one-piece molded main body, the body incorporating a cleaning solution tank. A recovery tank is adapted to be inserted into the main body central cavity, which houses the cleaning solution that is distributed to the floor brushes and suctioned back into the tank by a rearward squeegee assembly. Mechanical and plumbing connections between the main body and recovery tank allow the two to function as a single unit, wherein the recovery tank can then be removed to discard the used and circulated cleaning solution and contaminants from the floor cleaning operation. The Whitaker device, similar to the Wood device, comprises a unique construction that allows separation of the device into two primary components. In the case of Whitaker, the recovery tank housing a cleaning solution is removable. The present invention provides a hingedly attached door to its main housing, wherein cleaning solution and water tanks are removably secured. 
         [0011]    Another such device is U.S. Pat. No. 5,566,422 to Geyer, which discloses a small floor scrubbing machine comprising a centrally located battery pack, recovery tank for scrubbing solution and a vacuum fan to draw air and used solution into the recovery tank. Air is similar exhausted into the atmosphere from another chamber of the recovery tank. The arrangement of the Geyer device provides improved foam control and a consistent center of gravity as the cleaning solution empties from the recovery tank and is replenished by the vacuum fan. The Geyer device is specifically interested in a multi-chambered recovery tank and system to maintain consistent center of gravity during operation. Its elements differ from the present invention, wherein no recovery system is disclosed and a lightweight, water and cleaning solution scrubber is provided for use on wrestling and athletic mats. 
         [0012]    U.S. Pat. No. 6,842,940 to Christopher describes a floor scrubber having a forward cylindrical brush with adjustable down pressure on a working surface. Cleaning solution is uniformly sprayed onto the cleaning brush and is then recovered by a collection hopper. A floor engaging flap and a suction recovery device allow for the used cleaning solution to be absorbed into the machine, leaving the working surface free of standing water. The Christopher device employs a variable pressure scrubber, which varies the intensity and friction against the working surface. Its construction is more elaborate than required by the present invention, which utilizes a soft brush specifically for the purpose of removing dirt and contaminants from a floor mat or gym mat, and further spreading a disinfecting solution to remove germs and parasites therefrom. 
         [0013]    Finally, U.S. Pat. No. 6,088,873 to Pacchini describes a floor cleaning machine having a body and body cover assembly that is hollow and acts as a recovery reservoir for cleaning solution. A battery and drive motor power a transaxle drive and motor differential, which engages the axles coupled to the wheels. A linkage along the forward portion of the device allows for different floor scrubber modes, wherein the height and downward pressure of the scrubbers can be adjusted for different floor surfaces. The Pacchini devices disclose a motorized floor cleaning device with elaborate drive means and a variable height cleaning head. The present invention is belt driven using a first pulley for the wheels and a second, parallel pulley for driving the rotational scrubber brush. Its construction is markedly simpler, and is ideal for gymnasiums having athletic and wrestling mats that need attention after each use or practice session. The device is lightweight and simple to use in these everyday situations. 
         [0014]    The prior art devices provide floor cleaners and scrubbers with varying levels of complexity for the purposes of cleaning a floor surface. Most are provided for cleaning hallways and other hard surfaces, while others employ complex elements to facilitate the cleaning and reclamation of cleaning fluid during the process. The present invention is particularly designed for cleaning and sanitizing gym mats, athletic mats and wrestling mats after each use. The design is simple, lightweight and effective for working with mat surfaces. It is therefore submitted, in light of the prior art and the foregoing disclose, that the present invention substantially diverges in design elements from the prior art. Consequently it is clear that there is a need in the art for an improvement to existing floor mat cleaning devices. In this regard the instant invention substantially fulfills these needs. 
       SUMMARY OF THE INVENTION 
       [0015]    In view of the foregoing disadvantages inherent in the known types of walk-behind surface cleaners now present in the prior art, the present invention provides a new walk-behind surface cleaner wherein the same can be utilized for providing convenience for the user when cleaning and sanitizing athletic and wrestling mats between uses. 
         [0016]    It is therefore an object of the present invention to provide a new and improved walk-behind surface cleaner device that has all of the advantages of the prior art and none of the disadvantages. 
         [0017]    Another object of the present invention to provide a surface cleaning device having lightweight and simple construction for use specifically with athletic and wrestling mats. 
         [0018]    Another object of the present invention is to provide a surface cleaning device having an internal cleaning solution, power means and spray means for communicating the solution, followed by a squeegee means for drying remaining solution on the mat surface. 
         [0019]    Another object of the present invention is to provide a surface cleaning device that utilizes a soft cleaning roller that does not damage an athletic mat surface, while removing dirt, debris and contaminants therefrom. 
         [0020]    Yet another object of the present invention is to provide a surface cleaning device having motive power and a walk-behind geometry. 
         [0021]    A final object of the present invention is to provide a surface cleaning device of simple and lightweight construction that is easily assembled and manufactured. 
         [0022]    Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTIONS OF THE DRAWINGS 
         [0023]    Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout. 
           [0024]      FIG. 1  shows a side view of the surface cleaning device, wherein its internal components are visualized. 
           [0025]      FIG. 2  shows a close-up view of the surface cleaning device hand controls. 
           [0026]      FIG. 3  shows an overhead perspective view of the surface cleaning device, wherein its internal components are visualized. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the athletic mat cleaner device. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for cleaning and sanitizing athletic and wrestling mat surfaces. The figures are intended for representative purposes only and should not be considered to be limiting in any respect. 
         [0028]    Referring now to  FIG. 1 , there is shown a side view of the mat surface cleaning device of the present invention, wherein the sidewall of the device is removed for visualization of its internal elements. The device comprises a housing  12  having a pair of front and rear wheels  15 , a hollow interior volume forming an enclosure for moving components and a volume of cleaning solution, and support for a rotating cleaning assembly along the front of the device. The housing  12  has a back wall, sidewalls and a hingeable lid  22  that allows access to the housing interior for maintenance and cleaning solution replenishment. Along the back of the housing are user hand controls within a handle  13  for which the user can direct the motion of the device during operation, while a squeegee element  13  is provided at the user&#39;s feet to absorb any residual cleaning solution on the mat surface. The device is driven forward by internal motive power in a walk-behind configuration, while the user guides the direction of the device along a mat surface. 
         [0029]    A cleaning roller  20  and spray nozzle means  21  are positioned along the front of the housing to dispense a mist of cleaning solution onto a mat surface therebelow while the roller  20  lathers the solution and disrupts and removes dirt therefrom. The nozzles  21  provide a means to distribute the solution along the entire length of the roller  20 , directed in front of the roller. The solution is housed within a reservoir  11  attached to the hingedly attached lid  22 , while a hose at the base of the reservoir and an inline pump distribute solution to the spray nozzles  21  during operation. The hose is adapted to form a flexible connection between the reservoir  11  and the spray nozzles  21 , allowing the lid to open freely and the reservoir to move therewith throughout its travel. Once opened, the cleaning solution fill level can be checked and replenished if necessary. Similarly, if internal maintenance is required, the lid can be rotated  31  into an open position for access to components within the housing  12 . 
         [0030]    The device is powered by an electric motor  28  and onboard battery supply  16 . The motor  28  spins a shaft connected to a double pulley device  19 , further connected to a pair of belts that travel fore and aft through the device interior. The first belt drives a rear wheel  15 , while the second belt spins the cleaning roller  20  at a higher rotational velocity. The double pulley provides two distinct speeds for the rear wheel and the roller brush, as the brush is required to spin at a faster rate than the rear wheel in order to achieve an effective means of dirt and contaminant removal from a mat surface. The speed of the motor  28  is controlled by the user through hand controls in the handle, wherein the speed can be varied depending on input to allow the device to travel at a faster or slow speed, and correspondingly a greater or slower roller brush rotational velocity. The faster the linear travel of the device, the faster the roller brush needs to spin in order to adequately clean the given floor mat surface area being rushed thereunder. 
         [0031]    The battery comprises a glass mat, lithium ion or similarly lightweight battery supply so as to reduce overall vehicle weight, while an NC power plug  14  allows the battery to be charged after extended usage. It may be desired to provide a low battery indicating lamp for the user to monitor the power level within the battery during usage, so as not to drain the battery and disrupt operations. Overall, the device utilized lightweight materials and components to allow the cleaning to operate on athletic mats and wrestling mats without damaging the mats or causing damage thereto. In place of a cleaning solution recirculation or recovery system, a squeegee along the rear of the device absorbs or wipes residual solution from the mat surface. This element may comprise of a rubber squeegee or alternatively a cloth or microfiber towel for wiping the mat after being wetted. In this way, the device employs a passive drying capability that reduces its overall mass and allows improved functionality, wherein larger and heavier device may be ill-suited. 
         [0032]    Referring now to  FIG. 2 , there is shown a view of the user handle  13  and associated hand control elements of the present invention. The handle  13  attaches to the rear of the device housing and provides a means for the user to control the direction and speed of the device during operation. Two adjuster handles are provided along the handle: a vehicle speed controller  23  for the motor input on the rear wheel (wheel speed) and a spray controller  24  for the forward nozzles. The controllers are movable handles that translate a physical input to a change in electrical output sent to the electric motor and spray pump. Preferably, the controller handles actuate a linear potentiometer  25  or similar electro/mechanical device that can be utilized to control both the speed of the electric motor and the cleaning solution spray pump while the device is being utilized to clean a floor mat. Input travels from first and second wire  26 ,  27  to the motor controller and spray pump, respectively. The vehicle speed can be increased or decreased, as well as the volume and intensity of fluid spray from the nozzles can be adjusted. This allows certain areas of a floor mat to be intensely or lightly cleaned as necessary, and the speed of the operation to be controlled by the user. 
         [0033]    Referring now to  FIG. 3 , there is shown an overhead perspective view of the present floor mat cleaner. The near-side surface of the device housing is hidden to visualize the internal components that comprise the cleaning elements and means for operating the device. Within the internal volume of the device housing is a cleaning solution reservoir  11 , a fluid pump  29  for communicating solution therefrom and a plurality of spray nozzles  21  that project a mist of solution onto a mat surface in front of the rotating roller brush  20  and the direction of travel of the housing. The roller brush  20  is a soft bristle cleaning implement that is particularly suited for athletic mats and softer materials, as opposed to hardwood, tile and laminate floor cleaning implements. The rotation of the brush  20  is controlled by a belt  18  that attaches to an electric motor  28  by way of a double-pulley  19 . A second belt  17  extends from the double-pulley  19  to drive the rear wheel  15  of the device, allowing forward or rearward travel of the housing. Power for the electric motor  28  is provided by a battery power supply  16 , which is wired to the electric motor and controlled by a motor controller and the user input  23 . Wires  26 ,  27  route from the handle  13  to the motor  28  and the pump  29  within the housing, while a majority of the internal cavity is left unoccupied. The goal is to provide a lightweight device that is easily maneuvered onto and over a floor mat surface, wherein a larger device would not be ideally suited. A rear A/C plug is provided for charging the battery pack  16 , allowing the device to operate without a cord for extended periods of time, whereafter the power supply can be recharged using a wall outlet and extension cord. 
         [0034]    The lid of the device allows access within the internal cavity of the housing, which allows the reservoir  11  to be replenished and the internal components to be maintained as necessary. It is preferred that the roller brush  20  be mounted on the exterior of the housing, wherein its bristles cannot spray solution, dirt and floor contaminants into the interior of the housing. This ensures components within the housing are not damaged or sprayed with solution, which could otherwise affect their operation and longevity. A shroud that is built into the housing around the roller brush  20  deflects any ejected dirt or solution therefrom. Solution is sprayed onto the mat surface directly in front of the roller brush  20 , which is then brushed over using the rotating motion of the brush, liberating dirt and grime, and primarily sanitizing the mat between uses. Once passed over, the sprayed area is whipped dry using the squeegee  13  mounted on the rear of the housing. The squeegee  13  is preferably a replaceable cloth or microfiber material that absorbs moisture as is passes over the thin film cleaning solution sprayed onto the mat surface. It is not desired to recollection the cleaning solution or to provide a device that sprays large volumes of fluid onto the mat surface. Rather, the nozzles are adapted to spray a mist of sanitizing solution that is brushed into the mat surface, while the squeegee wipes the moistened area dry. The mat will remain moist for a short period of time prior to completely drying, but no pooling of solution will occur and only a thin film that rapidly evaporates will be left behind the squeegee. 
         [0035]    The primary function of the present invention is to provide a means to sanitize athletic floor mats and wrestling mats, which generally develop dirt, sweat and fungus after prolonged use. The cleaning solution is ideally one that can destroy any germs or fungus from the mat surface, which would otherwise transfer between users of the mat. The solution is applied in a thin film by the nozzles and whipped dry using the rearward squeegee assembly. The elements of the device, including the housing, battery, electric motor and roller brush are adapted to be lightweight and specifically designed for mat surfaces, including those with foam interiors or those that are of uniform material. Using a lightweight assembly allows the device to be lifted or rolled onto the mat and operate thereon without damaging the mat surface. Additionally, the roller brush bristles are adapted to be a soft material to prevent tearing or removal of material from the mat surface. The primary application is to treat the mat surface with an antiseptic or sanitary solution to remove sweat, germs and fungus, while allowing the user to easily manipulate and rapidly deploy the device during athletic events or between sessions requiring an athletic mat. 
         [0036]    With regard to the present disclosure, it is therefore submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. 
         [0037]    Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.