UPRIGHT BATTERY POWERED FLOOR STAINING MACHINE

An upright device for applying stain to wood floors wherein a user walks behind the device. The device may be battery powered eliminating the need for a cord. A means for holding a gallon of stain is included so that a user may operate the machine continuously while using an entire gallon of stain. Pumps control the movement of stain from the gallon container of stain into three rotary-motion applicator pads: a large round central applicator pad surrounded by two, smaller round applicator pads that may reversibly move about the outer circumference of the large, central applicator pad.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application does not claim priority to any patent application.

DISCLOSURE REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR

The inventor has not disclosed this invention prior to the filing of this non provisional application.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention relates to upright rotary machines that are used to apply stain to wood floors during the finishing/refinishing process. Specifically, the device herein has an improved means for dispensing stain and an improved pad means for distributing the stain onto the wood floor.

(2) Disclosure of the Prior Art

A number of upright rotary devices that dispense stain onto a floor are disclosed in the prior art. May et al. (U.S. Pat. No. 4,881,288) discloses an upright rotary machine that cleans a floor by rotating a cleaning or buffing pad against the floor at high speed. The device includes a means to control the rate of fluid dispensed while cleaning the floor and a vacuum source to draw cleaning fluid out of an attached reservoir and into the central region of the cleaning pad. This device includes a bottle of cleaning fluid reversibly coupled to a tubing line. An operator places his thumb over a thumb hole and holds it there to impart suction onto the contents of the bottle. This causes fluid to be sucked out of the bottle until the fluid level in the bottle drops enough to create an equalizing vacuum in the bottle. Flow from the bottle stops, but the suction will then lower the liquid level in an air supply vent allowing air to enter. When the fluid level is pulled down low enough an air bubble will enter the bottle, reducing the vacuum above the fluid level and allowing more fluid to be drawn out of the bottle and into the pad housing.

The device of May et al. is specifically designed for floor cleaning wherein a variable rate of application of cleaning solution to the floors is permissible. The device of Sutton herein is specifically designed for application of stain to floors. Any variation in the application rate of stain onto the surface of wood floors will create variation in the floor color. For example, if the rate of stain application increases, more stain will be applied, creating darker colored wood floors. If the rate of stain application decreases, then less stain will be applied and the color and/or tint intensity of the wood floor will decrease. This can create streaks, blotches, smears, and other discernible differences in floor color that detract from the appearance of the floor.

Gary Rudolph (US 2017/0245721 A1) discloses an upright rotary floor machine that delivers fluid to and from a bottom center of a floor-operation pad with a fluid-delivery hub comprising a pad formed to create a flow of fluid along the circumference of the pad and inward toward the center of the pad via three separate channels. The hub further comprises a fluid management metering system comprising a bag of fluid coupled to the upright handle of the device wherein the pressure forcing the fluid through the pad originates solely from the weight of the fluid in the bag of fluid and the flow rate of the fluid from the bag of fluid is controlled via meters controlled by the operator.

The device of Rudolph manipulates the dispensing of liquid via gravity from the weight of fluid in a suspended bag of fluid. When the bag of fluid is full, then gravity is great forcing fluid into the pad at a high rate. Upon use, fluid leaves the bag of fluid reducing the weight of fluid within the bag, reducing the force of gravity upon the bag, resulting in a diminished flow of fluid into the pad as a user dispenses fluid. The difference in flow of fluid into the pad creates a difference in stain color wherein a deeper stain color is obtained initially when the bag is full of fluid and a light stain color when the bag is approaching empty. A method of controlling the flow of stain so that the flow is consistent is needed.

Both May et al. and Rudolph utilize power cords to power the spinning of the dispenser pads. If a user steps on a power cord while staining a floor, then the point of cord contact with the virgin floor causes the grain of the wood at that point to close altering the absorption of stain, which causes streaks in the floor. A user stepping on a cord must re-sand the floor to reopen the grain of the wood. This problem effectively mandates that a person applying stain to a wood floor have a helper to hold the cord through out the staining process. A cordless device would alleviate this problem.

May et al. and Rudolph utilize a single, large, round pad to apply fluid to a floor. The large round pad is unable to effectively reach corners of a square room. When a user is applying stain to a floor a helper is necessary to apply stain in the corners so that the stain can be applied evenly in a single coat. A device is needed that reaches into corners so that a 2ndhelper is not needed when applying stain.

May et al. and Rudolph allow bags of fluid/stain to be coupled to the devices. Stain is not readily available for purchase in small bags. Additionally, if a user needs to refill a bag of stain, then the user has to stop the machine and replace the bag. Anytime a user applying stain stops the application (stops and starts), the rate of stain deposition onto the virgin wood floor changes causing a change in the stain intensity and may even streak the floor. A device that will accept an entire gallon of stain is needed.

Today, professionals typically apply floor stain as follows: dip rag or sponge into stain and apply stain to floor, going with the grain rather than against. Work from one side of the room to the other, frequently wringing out rag or sponge so coverage is even and stain doesn't pool on floor. After 5 or 10 minutes, the floor is vigorously wipe to remove excess stain. Then the stain is allowed to dry before application of polyurethane. This hand application method is time consuming, strains the back of the user, and is subject to variations of color absorption because of lack of uniform application. A device that mechanically applies stain is needed to alleviate these issues.

BRIEF SUMMARY OF THE INVENTION

This device comprises an upright rotary machine that a user walks behind. It may be battery powered alleviating the need for a power cord. The battery provides power for the applicator pads and for movement of fluid onto the applicator pads. This device includes two small, round applicator pads proximate to a central, large applicator pad, which reduces stain work in the square corners of a room. Both small, round applicator pads move relative to the central, large applicator pad so that it will cover the corners more effectively. And, the device herein accepts an entire gallon of stain and includes a holder that a user inserts an opened can of stain into prior to using the machine.

A small applicator pad assembly is shown inFIG. 7, and an exploded view of a small applicator pad assembly is shown inFIG. 8.

A cage for storing a gallon of stain is illustrated inFIG. 9.

FIG. 10depicts a small pad attachment bracket.

The wheel assembly is illustrated inFIG. 11.

The gallon of stain anchoring assembly and the gallon of stain lid assembly are shown inFIG. 12.

An exploded view of the gallon of stain lid assembly is shown inFIG. 13.

FIG. 15illustrates a side view of the device with the applicator pads in the forward position, whileFIG. 16depicts an angled side view of the device with the small applicator pads in the forward position.

A illustration of the device with both small applicator pads in the side position is shown inFIG. 17.

FIG. 18depicts a top view of the device, whileFIG. 19depicts a bottom view of the device.

FIG. 20depicts a front, angled view of the handle assembly with advanced controls, and

FIG. 22illustrates an embodiment battery placement on the applicator pad mounting and cage.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many different forms, there are shown in the drawings and will herein be described in detail, several embodiments with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments so illustrated. Further, to the extent that any numerical values or other specifics of materials, etc., are provided herein, they are to be construed as exemplifications of the inventions herein, and the inventions are not to be considered as limited thereto.

FIG. 1depicts an angled front view of the device. Handles4stem from control panel2. Handles4allow are a means for a user to grip the device, while control panel4may include a on/off means, etc. Lever6may allow a user to control the amount of stain released onto the large stain disk. Lever10may allow a user to control the rate of spin of the large stain disk, which is mounted onto large mounting disk80. Lever8may allow a user to control the rate of spin of small left mounting disk50and the amount of stain released onto the small left stain disk. Lever12may control the rate of spin of small right mounting disk52and the amount of stain released onto the small right stain disk. Upright handle14couples control panel2to wheel base100, wheel base100forms a base to couple wheels32to the device. Gas shock20couples tension control bracket16to wheel base100. Gas shock20may be used to reduce the amount of motion transferred from the large stain disk and two smaller stain disks while staining a floor. This reduction in motion provides the user with greater comfort while using the device and greater control over the device. Gas shock20may be an air filled shock or other shock absorbing means. Battery pack30may be coupled to upright handle14.

Stain can40is shown mounted within mounting cage44, that is affixed to large mounting disk80. Stain can40may contain a quart or gallon of liquid stain that is to be applied to flooring. Lid200reversibly couples to stain can40and provides the means for the transport of stain from the stain can to stain pads. Hose62provides stain from stain can40to the large stain pad120(shown inFIG. 2). Hose60provides stain from stain can40to small stain pad(s)188(shown inFIG. 7) that are coupled to small mounting disks50and52.

FIG. 2is an exploded view ofFIG. 1. Tension control bracket16is coupled to upright handle14. Battery pack30has been removed from handle14. Electric cord31transfers power produced by battery pack30to the motor130, which provides the means that causes large mounting disk80to rotate when stain is being applied to flooring. And, electric cord31transfers power produced by battery pack30to small motors174, which cause small mounting disks50and52to rotate while stain is being applied to flooring. Shock20reduces the vibration experienced by the user.

Motor130is coupled to large mounting disk80. Large stain hub122reversibly couples to large mounting disk80. Large stain hub122provides a platform for large velcro pad120, which reversibly couples to large stain hub122. Large velcro pad120includes one or more areas of velcro that allow a user to quickly, easily, and reversibly attach large stain pad400(not shown). Large stain pad400may be composed of a carpet textile, such as polypropylene, nylon, polyester wool, cotton, cotton terry, or acrylic. The carpet textile should provide a smooth and streak-free finish with effortless application. Large stain hub122includes hub stain channel307, which allows stain to move from hose64to large velcro pad stain channel310. Large velcro pad120includes large velcro pad stain channel309that allows stain to flow through onto large stain pad400.

Wheel base100secures large mounting disk80. Wheels32allow the device to be moved about a floor. Stain can40is shown installed within mounting cage44. Air pump157may be utilized to pump air into stain can40via air hose159while stain is being pumped out of stain can40to enable continuous, smooth flow of stain. Female “T”208provides stain from stain can40to hose60and hose62. Hose60provides stain

to small right mounting disk52, and hose62provides stain from stain can40to small left mounting disk50. The device may include small battery199to provide power to the small left mounting disk50and the small right mounting disk52. Small batter199may be contained within small battery receptacle197. Small battery receptacle197may provide power to small motor174in order to power the rotation of the small left mounting disk50and the small right mounting disk52.

An angled side view of the device with the small motors in the rear position is depicted inFIG. 3. Small left motor52is shown in the rear position where is it located proximate to wheel32. Small left motor52is secured to large mounting disk80via motor mounting bracket140and small disk mounting bracket142. Small stain pad188is shown on the bottom surface of small left motor52. Small stain rotor bumper172may be included to protect any wall surfaces from contact with small left mounting disk52. Shutoff valve61allows a user to manually terminate all stain flow from hose62.

Large stain pad400can be seen on the bottom surface of large mounting disk80. Large mounting disk80secures mounting cage44. Motor130is contained within mounting cage44. Motor130provides enables the rotation of large stain pad400. Stain can40is secured within mounting cage44. Lid200has been placed onto the top of stain can40. The following may be found coupled to lid200: pressure release valve207, which regulates pressure within stain can40; female “T”208that splits a flow of stain from stain can40to hose60and hose62, and powered solenoid valve220that regulates and controls the movement of stain out of stain can40and into hose64. Pressure release valve207receives and regulates a flow of air traveling from air pump157via air hose159.

FIG. 4depicts the large stain pad assembly that mounts or locks onto the bottom of large mounting disk80. Large stain hub122may include at least one stain hub channel307that permits stain to travel from hose64through large stain hub122to large velcro pad122. Hub disk124may be the means by which large stain hub122locks onto a 3 prong extension on the bottom, or underside, of large mounting disk30. Large velcro pad120may include at least one large velcro pad stain channel309, that provides stain from stain hub channel307to stain pad channel310(not shown), which delivers the stain to the floor being stained.

FIG. 5illustrates the large motor and large applicator pad assembly, whileFIG. 6depicts an exploded view ofFIG. 5. Motor130provides the mechanical force to cause rotational movement of large mounting disk80. The amount of mechanical force provided by motor130is minimal because the device is merely applying stain to a previously prepared and finished floor. The minimal mechanical force requirements of motor130allow the device to be operated with DC power produced from a battery/battery pack instead of AC power provided by an electrical outlet. Small motor174provides the rotational movement of the small left mounting disk50that it is paired with, and rotational movement of the small right mounting disk52that it is paired with. Small left mounting disk50and small right mounting disk52are mounted onto large mounting disk80via motor mounting bracket140that attaches to the large mounting disk80and small disk mounting bracket142that attaches to the small left and right mounting disks50and52.FIG. 5depicts the small left and right mounting disks50and52in the front position.

The exploded view ofFIG. 6also depicts screws101securing the components onto large mounting disk80. Large stain pad hub122is shown separated from large mounting disk80. Large staining rotor bumper170is positioned along the outer perimeter of large mounting disk80to protect wall surfaces when a user presses the device against a wall. Large mounting disks80includes at least one cam roller slot151that allows the small left and right mounting disks50and52to move through cam roller guides150allowing the small left and right mounting disks50and52to move about large mounting disk80, which allows the small left and right mounting disks50and52to move from the forward position to the rear position. The small left and right mounting disks50and52may be moved about the cam rollers by a user pushing the device along a wall causing said small left and right mounting disks50and52to freely rotate within cam roller slot151. Instead, small motor174may provide the force that moves small left and right mounting disks50and52upon user command.

FIG. 7depicts a side view of the small left and right mounting disks50and52, whileFIG. 8illustrates an exploded view. Shutoff valve61allows a user to manually terminate the flow of stain into the small left and right mounting disks50/52. Pressure gauge63regulates pressure within the shutoff valve maintaining a consistent, smooth flow of stain into the small left and right mounting disks50/52. Small motor174receives power battery30and operating instructions from control panel2(both shown inFIG. 1) via wires182. Small motor174, pressure gauge63, and small stain disk hub184are shown unmounted from small left and right mounting disks50/52. Small motor174may be any motor that provides sufficient mechanical power to cause the small mounting disks to rotate. The mechanical power provides will be minimal because the small mounting disks are merely rotating about the finished surface of the flooring. The minimal mechanical force requirements of small motor174allow the device to be operated with DC power produced from a battery/battery pack instead of AC power provided by an electrical outlet.

Small staining rotor bumper172is mounted onto the perimeter of each small left and right mounting disks50/52to protect damage to wall surfaces from contact with the small left and right mounting disks50/52. Small stain disk hub184may include small stain disk hub channel407that allows stain that has traveled to the small left and right mounting disks50/52to travel through small stain disk hub184to small velcro disk186. Small velcro disk186allows small stain pad188to be reversibly coupled to small stain disk hub184. Small velcro disk186includes small velcro disk channel409that allows stain received from small stain disk hub184to be transmitted to small stain pad channel410. Stain received in small stain pad channel410is applied onto flooring to stain the flooring.

FIG. 9depicts mounting cage44which is tightly secured onto large mounting disk80. Motor130may be mounted below mounting shelf45, while stain can40may be positioned on top of mounting shelf45. Motor mounting bracket140and small disk mounting bracket142are shown inFIG. 10. Motor mounting bracket140is mounted onto large mounting disk80. Wheel base100is shown inFIG. 11. Wheels32are shown separated from wheel base100and axle33has been removed from wheels32.

The clamping weldment stain can retainer190and the lid assembly are shown inFIG. 12, and an exploded view is shown inFIG. 13. The clamping weldment stain can retainer190is mounted on top of mounting cage44. Stain can40fits within clamping weldment stain can retainer190. Swivel L-hook clamp192swivel on top of stain can40securing stain can40into mounting cage44. Lid assembly includes lid200that is positioned on top of stain can40. Lid handle201is used by a user to grip the lid assembly to move the lid assembly relative to stain can40. Pressure release valve207is mounted on top of lid200. Small pipe204provides stain from stain can40to female “T”208, where the stain is distributed to hose60and62. Tube fitting206connects pressure release valve207to lid200. Large pipe202provides stain from stain can40to hose64via 90° elbow210. Powered solenoid valve220regulates flow of stain from large pipe220to 90° elbow210. Manifold212directs and distributes airflow to support powered solenoid valve220. Fittings211couple manifold212to lid200. Seal230prevents airflow into and out of stain can40.

FIG. 14illustrates battery30placed on the front of upright handle14above tension control bracket16. Battery30may be place in any suitable position that does not interfere with operation of the deviceFIG. 15shows a side view of the device wherein battery30is positioned inFIG. 14. Small disks on/off switch402may be positioned on control panel2. Small disks on/off switch402allows a user to turn small left and right mounting disks50/52off and on as needed. Control panel2may also include solenoid flow adjustment404switch and air compressor on/off switch406. Solenoid flow adjustment404controls the operation of powered solenoid valve220. Air compressor on/off switch406controls the operation of air pump157. Battery30is positioned above tension control bracket16. Motor130is shown engaging disk hub124. Large stain pad400and small stain pad188are in contact with the floor. Stain from stain can40travels through female “T”208to hose60and small stain pad188. Stain from stain can40travels through 90° elbow210to large stain pad400while being controlled by powered solenoid valve220utilizing manifold212. Lid handle201is shown.

FIG. 16illustrates optional tension release handle495which may be manipulated by a user to move upright handle14relative to tension control bracket16, which causes movement of air within gas shock20. Small left and right mounting disks50/52are shown in the forward position and hose62is visible.FIG. 17illustrates the device wherein small left and right mounting disks50/52are in the rear position. Hose60is shown coupled to small right mounting disk52.

FIG. 18depicts a top view of the device, and a bottom view of the device is depicted inFIG. 19. Wheels32, control panel2, upright handle14, small left and right mounting disks50/52, motor mounting bracket140and small disk mounting bracket142are shown in both figures. Lid200, pressure release valve207, female “T”208, powered solenoid valve220, and 90° elbow210are shown inFIG. 18. Small stain pads188, large stain pad400, small stain pad channel410, and large stain pad channel310are shown inFIG. 19.

FIG. 20illustrates a front, angled view of the handle assembly andFIG. 21depicts an exploded view of the handle assembly. Handle release button490may be pulled in an up motion to release tension control bracket16releasing tension on upright handle14allowing upright handle14to pivot relative to large mounting disk80. One small disk on/off switch402is paired to small left mounting disk50, and a separate small disk on/off switch402is paired to small right mounting disk52. Lever6may allow a user to control the amount of stain released onto the large stain disk. Lever10may allow a user to control the rate of spin of the large stain disk, which is mounted onto large mounting disk80. Lever8may allow a user to control the rate of spin of small left mounting disk50and the amount of stain released onto the small left stain disk. Lever12may control the rate of spin of small right mounting disk52and the amount of stain released onto the small right stain disk. Air compressor on/off switch406is centered on control panel2. Handle wiring opening496allows wires from the control handles and levers to be run through upright handle14.

An optional embodiment wherein air pump157is positioned within air pump mount502is shown inFIG. 22.FIG. 23illustrates an optional embodiment wherein the device utilizes two batteries30for power. Each battery30is positioned within multiple battery mount500.