CARPET AGITATION APPARATUSES AND METHODS

A method and apparatus for cleaning a carpet. In some embodiments, the appliance includes a pad attached to a cleaning head, the pad having a non-absorbent portion that agitates the carpet with a reciprocating movement to work an encapsulant or other cleaning agent into the carpet fibers. The pad also may include an absorbent portion to absorb moisture from carpet.

DETAILED DESCRIPTION OF INVENTION

Surface treatment appliances, such as cleaning appliances with rotating and oscillating brushes, are used with various cleaning solutions to clean carpets in the home, office, and other locations. Surface cleaning appliances with rotating and oscillating pads are also commonly used for cleaning low knap loop carpet in office environments, however, in these environments the appliances are often operated by trained technicians. In addition, the rotating and oscillating pads used with these appliances are composed of moisture and dirt absorbing materials such as wool and/or polyester microfiber that must be cleaned at regular intervals for proper carpet cleaning to be achieved. Applicant has recognized that the use of an encapsulant solution in combination with a cleaning pad that moves in a reciprocating motion on a carpet and that absorbs little to no moisture and dirt is effective in cleaning the carpet in a low-moisture manner. Embodiments disclosed herein include a cleaning appliance and methods of using the appliance to clean a carpet by applying an encapsulant to a carpet and agitating the carpet to work the encapsulant into the carpet with a cleaning pad that moves in a reciprocating motion. In some embodiments, the pad has a non-absorbent portion which is effective in agitating the carpet without absorbing the encapsulant before the encapsulant has been worked into the carpet to interact with the dirt.

According to one aspect of the invention, a carpet cleaning appliance includes an appliance body, a cleaning head with a moveable member that moves relative to the appliance body, a pad with non-absorbent portions that is mounted to the moveable member, a liquid reservoir filled with an encapsulant, and a liquid applicator to apply the encapsulant to the carpet. In one embodiment, the appliance agitates a carpet to work an encapsulant into the carpet fibers by moving the pad in a reciprocating manner. The pad may be attached to one, two, or any suitable number of moveable members on the cleaning head. In some embodiments, the pad includes first and second connected pad portions that move toward and away from one another to agitate the carpet. Two or more pads which are not connected may be used in some embodiments. The pad may be configured such that it has both non-absorbent and absorbent portions. In some embodiments, the non-absorbent portion includes plastic loops such as polyolefin loops. In some embodiments, the pad may have one or more glide portions, such as a glide strip, to facilitate movement of the appliance on the carpet. In some embodiments, the appliance operates in a reciprocating manner to more effectively agitate the encapsulant into the carpet with the pad while resolving the frictional forces inside the machine. This may result in an effective use of the encapsulant while keeping the load transmitted to the operator very low as compared to traditional methods.

Turning now to the figures,FIG. 1shows a cleaning appliance2according to one embodiment, the appliance including an elongated appliance body4and an appliance head, such as a cleaning head6. The cleaning head6includes two moveable members8to which the surface cleaning pad10is removably attachable by an attachment side12. The moveable members8may be driven by an electric motor via a gear drive, belt drive, or other drive system. The moveable members8may be used to provide reciprocating motion, and in some embodiments, the moveable members may move toward and way from one another. The reciprocating motion produced by the appliance2shown is a linearly reciprocating motion in some embodiments. The appliance2also includes a liquid reservoir14on the appliance body4that communicates with a liquid applicator16on the cleaning head6to apply an encapsulant to a carpet to be cleaned. In one embodiment, the liquid reservoir14is filled with a solution including an encapsulant. Although one liquid reservoir14is shown in this embodiment, other embodiments may include two or more liquid reservoirs14. Additionally, while the liquid applicator16is shown on only the front of the cleaning head6in this embodiment, one or more applicators16may be positioned on the sides of the cleaning head6and/or on the back of the cleaning head6so as to allow multi-directional use of the cleaning appliance2. In some embodiments, the applicators16are positioned on the appliance body4or at the base of the cleaning head6.

The attachment side12of the cleaning pad10is configured to removably attach the pad10to the cleaning head6in some embodiments. The attachment side may include a hook and loop fastening material, which attaches to complementary hook and loop fastening material on the moveable members8of the cleaning head6. The attachment side12instead may include any other suitable material for attaching the pad10to the cleaning head6as this aspect of the disclosure is not limiting. In some embodiments, the pad and the moveable members may be configured such that the pad wraps around the sides of the moveable members for attachment. Fastening devices such as clips, screws, snaps or interference fit arrangement may be used to removably attach the pads to the moveable members such that the attachment sides are removably attached to the moveable members even though, in some cases, the attachment sides themselves do not play a direct role in their attachment to the moveable members.

FIG. 2shows an embodiment after application of the encapsulant by the liquid applicator16(shown inFIG. 1). Although referred to as an encapsulant, it is important to note that in some embodiments, the encapsulant does not encapsulate the dirt particles but rather attaches to dirt particles and dehydrates them. Accordingly, for purposes herein, the term “encapsulant” should not be limited to only agents which encapsulate dirt or other particles. In one embodiment, the cleaning pad10is attached to the moveable members8of the cleaning head6, and the appliance2is positioned on top of a carpet18to be cleaned. The surface cleaning pad10has a first pad portion20with a first surface-facing side24aand a second pad portion22with a second surface-facing side24b,and the surface-facing sides24a,24bare in contact with the carpet18. The first and second pad portions20,22may be connected by one or more connectors19.

In some embodiments, the first and second pad portions20,22reciprocate with the moveable members8to agitate the carpet18. This movement may be accomplished by using the pad10with an appliance2, which includes a reciprocating member at the cleaning head6.

In some embodiments, the first pad portion20and the second pad portion22move toward and away from one another to agitate the carpet18. In some embodiments, agitation also may be accomplished by rotating one or more pads on the carpet.

In one embodiment, upon agitation by the surface-facing sides24a,24bof the pad10, the encapsulant26penetrates and disperses throughout the carpet18being cleaned. When the encapsulant26contacts dirt particles28in the carpet18, as shown inFIG. 2, the encapsulant26interacts with the dirt particles28to chemically and/or physically affect the dirt particles. In some embodiments, the encapsulant is allowed to interact with the dirt particles28for an amount of time such that the encapsulant26can dehydrate the dirt particles28and/or reduce or eliminate the dirt particles' ability to bond to the carpet fibers. In some embodiments, the dirt particles28are dehydrated beyond their natural state into a powder. In one embodiment, the encapsulant26chemically effects the dirt28via emulsification. In some embodiments, the carpet18is left to dry and the dehydrated dirt particles28are removed from the carpet fibers18along with the dried encapsulant26. In one embodiment, the dirt particles28and encapsulant26are removed by vacuuming the carpet18. The encapsulant26may be a low moisture cleaning solution that, unlike some other carpet cleaners, is only lightly sprayed on the top surface of the carpet18. In some embodiments, one gallon of solution is sufficient for application to between 200 ft2and 400 ft2of the carpet18. As a result, in some embodiments, the agitation step does not substantially wet the carpet18.

In some embodiments, the surface-facing sides24a,24bof the cleaning pad are configured to clean a carpet. In one embodiment, a cleaning element (such as a solution including an encapsulant) is applied to a carpet and then agitated and/or absorbed by the surface-facing sides24a,24bof the pad10. In some embodiments, as shown by way of example inFIG. 3, the surface-facing sides24a,24binclude only non-absorbent portions30to agitate the cleaning element. In some embodiments, the non-absorbent portions30are a loop monofilament material. In one embodiment, the non-absorbent portions30include olefin to agitate an encapsulant, and in another embodiment, the non-absorbent portions30include a plastic material to agitate a polymer. In one embodiment, the olefin is 100% olefin, 489.9 g/m2, with 16.5 wales by 27.0 courses per inch. In some embodiments, the wales are parallel to an edge of a longer side23of each pad portion20,22. In other embodiments, the wales are parallel to an edge of a shorter side25of each pad portion20,22. The olefin loops may be configured to be parallel to the edge of the longer side23of the pad portions20,22, or parallel to the edge of the shorter side25of the pad portions20,22. In some embodiments, the olefin loops are at least 4 mm in length. In some embodiments, the surface-facing sides include a binding21that extends around the edge of the longer and shorter sides23,25of the pads20,22.

In some embodiments, the surface-facing sides24a,24band the attachment side12of the pad10all include the same material. In one embodiment, the sides12,24a,24binclude an abrasive material, e.g., a hook and loop fastener or any other abrasive material that is suitable for attachment and for agitation. In some embodiments, the non-absorbent portions30may include an abrasive sanding material such as sandpaper or a sanding pad. The non-absorbent portions30also may include any other suitable material for agitating a carpet, such as a material having a rake or teeth.

In other embodiments, the surface-facing sides24a,24bof the pad10include both absorbent portions32and non-absorbent portions30. In some embodiments, the absorbent portions32and/or the non-absorbent portions30are capable of agitation or scrubbing. One such material capable of both scrubbing and absorbing is a mini-shag material with strands and/or loops. As shown inFIG. 4, the surface-facing sides24a,24bof the pad portions20,22may include a quilted, absorbent portion32with a non-absorbent portion30in the center of each pad portion20,22. Although only one non-absorbent portion30is shown on each pad portion20,22, the number of non-absorbent portions30and the position of those portions30on each pad portion20,22may vary. In one embodiment, the non-absorbent portion is quilted.

In some embodiments, the absorbent portions32and/or the non-absorbent portions30are quilted. The quilting stitches may extend from the exterior edges of the first and second pad portions20,22at a 30 degree angle, a 45 degree angle, a 60 degree angle, or any other suitable angle, in two directions to the opposed fabric edges. In one embodiment, the cross patterns form quadrilateral shapes or other polygon shapes. In some embodiments, the stitch pattern limits or prevents slippage of the pad layers relative to each other. Such slippage could reduce a pad's effectiveness at transmitting motion to the carpet in some embodiments.

In some embodiments, the surface-facing sides24a,24binclude a glide portion to reduce friction while cleaning the carpet. For purposes herein, a glide portion is a portion of the surface-facing sides24a,24bwhich has a lower coefficient of friction than one or both of an absorbent portion32and an agitation portion32. One type of glide portion is a glide strip27, as shown inFIG. 5. For purposes herein, the term “glide strip” refers to a section on a surface-facing side of a pad which extends from near one edge of the pad to near an opposite edge. The glide strip does not necessarily have to reach the absolute edge of the pad to be considered a glide strip. For example, in some embodiments disclosed herein, glide strips extend only to a binding which runs along the perimeter of the pad. In one embodiment, as shown inFIG. 5, the surface-facing sides24a,24binclude glide strips27positioned adjacent to the non-absorbent portion30, extending along the shorter sides25of the pad portions20,22to reduce friction while cleaning the carpet. Although two glide strips27are shown in this embodiment, it should be appreciated that the number of glide strips27may vary in other embodiments. It should also be appreciated that while the glide strips27are shown adjacent the shorter sides25of the pad portions20,22in this embodiment, the glide strips also may be positioned adjacent the longer sides23of the pad portions20,22or positioned in any other suitable location. It should further be appreciated that while the glide portions are shown to be rectangular glide strips27inFIG. 5, the glide portions may be any suitable shape.

The glide strips27may include polyester taffeta, 100 g/m2and 70 Denier yarn. In one embodiment, there are a series of linings below the taffeta. As seen in the sectional view of the glide strips27inFIG. 6, in one embodiment, a polyester non-woven interlining layer36, an olefin loop layer38, a second polyester non-woven interlining layer36, and a nylon loop backing layer40are positioned below a polyester taffeta layer34. In some embodiments, a twill binding21is placed along the edge of the longer and shorter sides23,25of the pad portions20,22. In some embodiments, the glide strips27are quilted. In some embodiments, the glide strips27have a coefficient of friction that is less than the coefficients of friction of the absorbent portions32and/or the non-absorbent portions30.

In another embodiment, as depicted inFIG. 7, the pad portions20,22include an absorbent portion32in the middle of the surface-facing sides24a,24b,non-absorbent portions30surrounding the absorbent portion32on two sides, and glide strips27adjacent to the non-absorbent portions30. The absorbent portion32may include nylon loops, although absorbent portion32may include any material or combination of materials suitable for absorption. In one embodiment, the absorbent portion32is a mini-shag material with a plurality of strands or loops having a pile length P, as shown inFIG. 8, of at least 5 mm. In some embodiments, the strands or loops may have a pile length P of between 2 mm and 10 mm. In still further embodiments, the strands or loops may have a pile length P of between 1 mm and 15 mm. In one embodiment, the mini-shag material is 100% polyester, 15.45 oz/yd2, with 20 wales by 26 courses per inch.

In some embodiment, the mini-shag material is weft terry knit on a course gauge machine 8 to 14 gauge. In one embodiment, the mini-shag material is 100% microfiber polyester, 8 oz./yd2In some embodiments, the microfiber lengths are twisted together to form strands or loops.

In some embodiments, the mini-shag material may be configured such that when the pad is placed on a carpet for cleaning, the shag material is compressed such that the shag height is even with the height of the glide strip(s). In some embodiments, this configuration would result in the compressed mini-shag material being between 4 mm and 5 mm lower than the extent of the olefin or other non-absorbent scrubbing section(s).

In some embodiments, the surface-facing sides24a,24bof the pad portions20,22are configured differently from one another. In one embodiment, as shown inFIG. 9, the first surface-facing side24aincludes only non-absorbent portions30and the second surface-facing side24bincludes an absorbent portion32and a non-absorbent portion30. As depicted in this figure, the second surface-facing side24bincludes an absorbent portion32with a non-absorbent portion30extending down the center of the second surface-facing side24b.It should be appreciated that the number of non-absorbent portions30and the position of those portions30on the second surface-facing side20bmay vary. It also should be appreciated that the pad10could have an inverted configuration to the one shown in the figure. In another embodiment, as shown inFIG. 10, the first surface-facing side24aincludes an absorbent portion32surrounded by glide strips27on two sides and the second surface-facing side24bincludes a non-absorbent portion30surrounded by glide strips27on two sides. In one embodiment, the absorbent portion32is a terry knit material and the non-absorbent portion30is olefin loops.

In some embodiments, the absorbent portions32are separate from the non-absorbent portions30. For purposes herein, a separate portion does not necessarily mean that a first section is distanced from a second portion. Instead, separate portions, such as sections30and32in one embodiment, may be immediately adjacent to one another and be considered separate portions. In some embodiments two types of material overlap one another, but if each material has a section that does not overlap with the material, there would still be considered to be two separate portion.

In some embodiments, the pad10includes one or more connectors19. The connectors19may be made of elastic straps, elastic cords, or any other suitable material for connecting the pads and maintaining their relative positions. The connectors19also may be made of any other suitable material for permitting the first and second pads20,22to move relative to one another when attached to the moveable members8. In some embodiments the elasticity of the connectors19is greater than the elasticity of the first and second pads20,22. The elasticity of the connectors19also may be configured such that the first and second pads20,22can move relative to one another, irrespective of the positions of the moveable members8, when the pad10is attached to the appliance head6. In some embodiments, the connectors19may not necessarily pull the treatment cleaning pads20,22toward one another. For example, the connectors may be made of a non-elastic material such as string. In embodiments where the connector(s) do not include elastic material, the pad10, and in particular the connector(s)19, may be sized such that the arrangement10is sufficiently long to remain attached to the moveable members8when the moveable members8are in their outermost position on the appliance head6. Although two connectors19are shown inFIGS. 3-5,7, and9-10, in other embodiments one connector or more than two connectors may be used. In some embodiments, the connectors19may be made of the same material as the surface-facing sides24a,24bof the first and second treatment cleaning pads20,22. The connector(s)19also may be integral to the first and second pads14,16.

In some embodiments, the pads20,22comprise a series of layers including a scrubbing layer, such as a monofilament material, a nonwoven or terry knit layer, and an attachment backing layer with hook and look fastening material. In one embodiment, the scrubbing layer, the nonwoven or terry knit layer, and the attachment backing layer are sewn together in a cross pattern. In some embodiments, the stitch pattern forms quadrilateral shapes or other polygon shapes. Other layers may be included with the pads in some embodiments.

Examples of other pads that can be used to clean a carpet are described in the U.S. non-provisional application filed Mar. 1, 2013, entitled Cleaning Pad Arrangement (attorney docket number E0465.70235US00), which is incorporated by reference herein in its entirety.

In yet another embodiment, a method of cleaning a carpet with an appliance2that has a pad10mounted to a cleaning head6includes applying an encapsulant26to the carpet18to be cleaned, agitating the carpet18with the pad10via reciprocating movement, allowing the encapsulant26to interact with the dirt particles in the carpet, and vacuuming the dirt particles28and encapsulant26from the carpet18. In one embodiment, the encapsulant26is allowed to interact with the dirt particles28for an amount of time such that encapsulant26can penetrate, emulsify, and dehydrate the dirt particles28. In some cases, the pad10includes non-absorbent portions, or is entirely non-absorbent. Two or more moveable members may be used to provide reciprocating motion, and in some embodiments, the moveable members may move toward and way from one another. The reciprocating motion produced by the appliance2may be a linearly reciprocating motion in some embodiments. In some embodiments, two or more moveable members may simultaneously move in the same direction.