Abstract:
The invention is a cleaning tool housing assembly and a replaceable cleaning assembly. The manifold, in combination with a fluid intake element, also delivers fluid (under pressure through holes in the manifold located in a longitudinal channel) to a sponge. Two spaced apart fluid barriers are longitudinally disposed in the sponge. As fluid is introduced into the center of the sponge, between the fluid barriers, the fluid travels toward the opposite surface of the sponge. The fluid is prevented from traveling laterally due to the fluid barriers. As vacuum pressure, negative pressure, is exerted on the outer portions of the sponge (on each side of the fluid barriers), fluid is pulled back through the sponge, through the manifold and through the nozzles into the hollow housing body.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to cleaning tools and, in particular, to cleaning tools for use on floors, walls and ceilings. The cleaning tool has a replaceable cleaning assembly.  
         BACKGROUND OF THE INVENTION  
         [0002]    The prior art has a number of devices that provide various means of applying cleaning solution to a surface to be cleaned and scrubbed. The prior art further provides various means of removing the cleaning solution. Application of the cleaning solution may be by direct spray, application through a bristle brush, and application through the body of a sponge. Removal of the cleaning solution may be by squeegee and vacuum combination, vacuum without squeegee, and vacuum applied through some other structural element.  
           [0003]    U.S. Pat. No. 3,195,165 discloses a wall washing tool having a wall contacting head which includes three side-by-side longitudinal sponge pads separated by barrier members so that the vacuum drawn through the side pads will not affect the center pad. Vacuum apertures are provided in the side sections. Leaking and dripping is a problem, as weep holes have been added in the center section.  
           [0004]    U.S. Pat. No. 3,591,889 illustrates a later version of a sponge pad cleaning head, wherein the sponge has longitudinal slots receiving sidewalls therein for retention purposes. The sponge pad is a single element with various apertures or bores for permitting fluid to pass to the cleaning surface.  
           [0005]    These prior art inventions have a problem in that droplets and dripping results. Such droplet formation or dripping is undesirable. For example, when droplets or dripping is assured, furniture and equipment and floors must all be covered prior to cleaning. The process for covering important items is very time consuming, and much time and money could be saved if these problems are eliminated.  
         SUMMARY OF THE INVENTION  
         [0006]    The invention is a cleaning tool housing assembly and a replaceable cleaning element assembly. The housing assembly provides dual tapered nozzles to exert negative pressure through a manifold to pull fluid from a sponge. The manifold, in combination with a fluid intake element, also delivers fluid (under pressure through holes in the manifold located in a longitudinal channel) to a sponge. Two spaced apart fluid barriers are longitudinally disposed in the sponge. As fluid is introduced into the center of the sponge, between the fluid barriers, the fluid travels toward the opposite surface of the sponge. The fluid is prevented from traveling laterally due to the fluid barriers. As vacuum pressure, negative pressure, is exerted on the outer portions of the sponge (on each side of the fluid barriers), fluid is pulled back into the manifold, into the nozzles.  
           [0007]    The gasket performs, among other things, the function of providing a seal between the pressurized outgoing fluid and the pulled incoming fluid.  
           [0008]    The dual nozzle housing of the present invention provides a greater and more forceful vacuum (less loss) due to the geometry of each nozzle, including the relatively small size of and decreasing cross sectional area of the openings within the nozzles.  
       
    
    
     DESCRIPTION OF THE DRAWINGS  
       [0009]    In the drawings:  
         [0010]    [0010]FIG. 1 is a side exploded view of the cleaning tool housing assembly and the replaceable cleaning assembly of the present invention;  
         [0011]    [0011]FIG. 2 is a side exploded view of the cleaning tool housing assembly of the present invention;  
         [0012]    [0012]FIG. 3 is an elevated perspective view of the cleaning tool housing of the present invention;  
         [0013]    [0013]FIG. 4 is an elevated perspective view of the fluid intake element of the present invention;  
         [0014]    [0014]FIG. 5A is a lower perspective view of the manifold of the present invention;  
         [0015]    [0015]FIG. 5B is a lower perspective view of the gasket of the present invention;  
         [0016]    [0016]FIG. 5C is a top plan view of the manifold of the present invention;  
         [0017]    [0017]FIG. 6 is an exploded view of the replaceable cleaning assembly of the present invention;  
         [0018]    [0018]FIG. 7 is a cross-sectional view taken along line  7 - 7  of the sponge of the present invention; and  
         [0019]    [0019]FIG. 8 is a plan view of two fluid barriers of one embodiment of the present invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0020]    The invention will be described with reference to the drawings, in which like numbers designate like elements. FIG. 1 illustrates a side exploded view of the present invention illustrating the cleaning tool, shown generally at  10 , which comprises cleaning tool housing assembly shown generally at  12  and replaceable cleaning assembly shown generally at  62 .  
         [0021]    As best shown in FIGS. 1, 2,  3 ,  4 ,  5 A,  5 B, and  5 C, cleaning tool housing assembly  12  comprises hollow cleaning tool housing body  14  equipped with fitting  13 , first nozzle  16 , second nozzle  22 , and manifold assembly  28 . First nozzle  16  is provided with first end  18 , second end  20 , and opening  17  disposed between first end  18  and second end  20 . Opening  17  is in fluid communication with the interior of hollow cleaning tool housing body  14 . Similarly, second nozzle  22  is provided with first end  24 , second end  26 , and opening  23  disposed between first end  24  and second end  26 . Opening  23  of second nozzle  22  is in fluid communication with the interior of hollow cleaning tool housing body  14 . Preferably, cleaning tool housing  14  and nozzles,  16  and  22 , are made from a relatively rigid material such as plastic, so that the tool can be used without a significant flexing of housing body  14  or nozzles  16  or  22 .  
         [0022]    As can be seen best from FIG. 3, at the first end  18  of first nozzle  16 , opening  17  has an area which is larger than the area of the opening  17  at the second end  20  of first nozzle  16 . Similarly, opening  23  at the first end  24  of second nozzle  22  has a larger area than the area of opening  23  at the second end  26  of second nozzle  22 . In other words, the openings  17  and  23  decrease in cross-sectional area going from the first to the second ends of the nozzles  16  and  22 . This difference in area enhances the ability of cleaning tool  10  to exert substantially consistent negative pressure across the longitudinal bottom surface  68  of the sponge  64  by increasing the velocity of fluid traveling through nozzles  16  and  22  within Openings  17  and  23 .  
         [0023]    Manifold assembly shown generally at  28  comprises fluid intake element  30 , manifold body  34 , and gasket  52 . Fluid intake element  30  defines a threaded hole  32  for connection to a source of pressurized cleaning fluid. Manifold body  34  has top surface  36 , first longitudinal opening  37 , longitudinal channel  38 , second longitudinal opening  39 , at least one hole  40 , bottom surface  42 , first side gap  44 , second side gap  46 , first end hole  48  and second end hole  50 . Gasket  52  is provided with at least one fluid delivery opening  54  and at least two fluid suction openings  56 . Preferably, manifold body  34  and fluid intake element  30  are made from a relatively rigid material, just as the housing  14 . Preferably, fluid intake element  30  is chamfered at its ends to prevent snagging during use. Fluid intake element  30  is disposed directly above longitudinal channel  38  of manifold body  34 . Gasket  52  is preferably a closed cell rubber, with pressure sensitive adhesive on one side to assist in the fixation of gasket  52  to bottom surface  42  of manifold body  34 . Although manifold body  34  is shown in FIG. 5A with a plurality of serially spaced, longitudinally oriented holes  40 , this element may be comprised of alternate suitable arrangements including, but not limited to a single thin longitudinal hole in the manifold body  34 . Similarly, although the longitudinal openings  37  and  38  are shown as longitudinal slits, these elements may be comprised of alternated arrangements as well, including but not limited to, a plurality of serially spaced, longitudinally oriented holes.  
         [0024]    Fluid delivery openings  54  of gasket  52  are in fluid communication with holes  40  of longitudinal channel  38 , which is in fluid communication with fluid intake element  30 .  
         [0025]    Fluid suction openings  56  of gasket  52  are in fluid communication with first and second longitudinal openings  37  and  39 , respectively, which are in fluid communication with openings,  17  and  23 , respectively, of first and second nozzles,  16  and  22 , respectively. Although most elements of the housing assembly  12  and other aspects of the invention are shown as separate, they may be combined into one or more unitary parts. For example, body  14 , nozzles  16  and  22 , fluid intake element  30  and manifold body  34  may be a single molded or cast plastic part.  
         [0026]    As best shown in FIGS. 1, 6,  7  and  8 , replaceable cleaning assembly  62  comprises sponge  64 , first fluid barrier  88 , second fluid barrier  90 , backing plate  92 , and moisture barrier  110 . Specifically, sponge  64  is provided with a rectangular top surface  66 , rectangular bottom surface  68 , first angled side  70 , second angled side  72 , first end  74 , and second end  76 . Sponge  64  has a trapezoidal cross sectional area, as shown in FIG. 7. Thus, the area of rectangular top surface  66  is greater than the area of rectangular bottom surface  68 . Preferably, sponge  64  is an open cell sponge, having a pore structure of approximately 60 to 90 ppi with a preferred structure of approximately 77 ppi.  
         [0027]    Sponge  64  has first slit  84  and spaced apart second slit  86 , both disposed longitudinally along top surface  66  of sponge  64 . As shown best in FIG. 7, first slit  84  and second slit  86  extend from top surface  66  towards bottom surface  68 . However, it can be seen that the slits,  84  and  86  do not extend all the way to bottom surface  68 . To make the extension of slits  84  and  86  clear, the following preferred dimensions are provided. Specifically, dimension a is 2.05 inches, dimension b is 1.63 inches, dimension c is 0.50 inches, dimension d is 0.69 inches, dimension e is 0.69 inches, dimension f is 0.68 inches, dimension h is 0.12 inches, and the depth of slits  84  and  86  are 0.38 inches.  
         [0028]    As seen in FIG. 6, the ends  74  and  76  of sponge  64  are preferably provided with a moisture barrier  110 . Moisture barrier  110  may be closed cell foam, sealing tape, epoxy or any other material that prevents the egress of water.  
         [0029]    First fluid barrier  88  and second fluid barrier  90  are preferably permanently inserted into slits  84  and  86  of sponge  64 . First and second fluid barriers,  88  and  90 , may be a rectangular section of thin plastic, epoxy, or glue (such as 3M epoxy, DP-105 clear), or any other material that provides a fluid barrier. However, another limitation on the fluid barrier is that it must not cut through the sponge  64 . The proposed plastic material for the fluid barriers  88  and  90 , respectively, may be between 1- 4  mm thick.  
         [0030]    Backing plate  92  has a top surface  94 , bottom surface  96 , first end tab  98 , second end tab  100 , first side tab  102 , second side tab  104 , fluid delivery openings  106 , and fluid suction openings  108 . Bottom surface  96  of backing plate  92  is textured to enhance the permanent fixation (gluing) of bottom surface  96  of backing plate  92  to top surface  66  of sponge  64 . In addition, fluid barriers  88  and  90  may be integral to backing plate  92  as shown in FIG. 6 and inserted into slits  84  and  86  upon assembly of the backing plate  92  with the sponge  64 . Alternatively, fluid barriers  88  and  90  may be separate from and not affixed to or part of the backer plate  92  at all.  
         [0031]    In operation, the replaceable cleaning assembly  62  is first attached to cleaning tool housing assembly  12 . Specifically, first side tab  102  and second side tab  104  are grasped by the user. Then first end tab  98  is inserted into first end hole  48  of manifold body  34 . Then second end tab  100  is inserted into second end hole  50  of manifold body  34 . Then, replaceable cleaning assembly  62  is released, and first side tab  102  and second side tab  104  are released into first side gap  44  and second side gap  46  of manifold body  34 . The assembly portion of the operation is completed. It is assumed that the cleaning tool housing assembly  12  is already connected to a source of pressurized fluid via connection to fluid intake element  30 , and already connected to a source of negative vacuum pressure via fitting  13  of cleaning tool housing  14 .  
         [0032]    Next, the cleaning tool  10  needs to be used. Accordingly, the source of pressurized fluid and the source of negative pressure are both activated (i.e. the cleaning machine is turned on). Upon activation, pressurized fluid enters fluid intake element  30 , and travels into longitudinal channel  38 . The fluid would be retained within longitudinal channel  38  due to the constraints imposed by the location of fluid intake element  30  directly above longitudinal channel  38 . However, holes  40  within longitudinal channel  38  ensure that fluid is forced out by hydraulic pressure through fluid delivery openings  54  of gasket  52 , through fluid delivery openings  106  of backing plate  92  into sponge  64 . Gasket  52  creates a seal between the source of negative pressure and the source of pressurized fluid.  
         [0033]    As is evident from FIGS. 5A, 5B,  6  and  7 , pressurized fluid enters the sponge in the area covered by dimension e. As the pressurized fluid enters through top surface  66  of sponge  64 , negative pressure is being exerted through sponge  64  in the areas covered by dimension d and dimension f. However, this negative pressure is unable to draw fluid through fluid barriers  88  and  90 . Thus, for the depth of insertion of fluid barriers  88  and  90 , fluid is pushed forward through sponge  64 .  
         [0034]    Once the pressurized fluid is past the fluid barriers  88  and  90 , the fluid reaches bottom surface  68  where it is used in conjunction with a wiping or scrubbing action by manipulation of the sponge. Dirty (used) cleaning fluid may be pulled back into sponge  64  due to negative pressure into the areas marked by dimension d and dimension f. Accordingly, the fluid path through sponge  64  is illustrated by the arrows indicated on the sponge  64 . It is pointed out that a steady volume of cleaning fluid flow is produced that reaches bottom surface  68  of sponge  64 .  
         [0035]    The trapezoidal cross section of sponge  64  provides some benefits. First, if the cross section had been rectangular, the negative pressure may be unable to pull cleaning fluid from the farther corner edges of the sponge  64 . When the cleaning fluid is not circulated properly, the sponge retains unpleasant dirty corner edges. In addition, any retention of cleaning fluid that is not returned by negative pressure will result in a buildup of excess cleaning fluid within the sponge. This situation results in droplet formation, and dripping on the surface that is being cleaned. Accordingly, with the chamfered sponge sides,  70  and  72 , respectively, cleaning fluid is able to circulate through substantially the entire sponge  64  cross section. This avoids an unsightly sponge appearance and prevents dripping. Second, the trapezoidal cross section facilitates use of the tool as the corner edges do not impede the movement of the tool across the surface to be cleaned by, for example, rolling up under the tool as it is pulled along the surface.  
         [0036]    Once fluid is drawn back by negative pressure to top surface  66  of sponge  64 , the fluid is pulled through fluid suction openings  108  of backing plate  92 , pulled through fluid suction openings  56  of gasket  52 , and pulled through first and second longitudinal openings  37  and  39  respectively. Then, the fluid travels to openings  17  and  23 , respectively, of first and second nozzles  16  and  22 , respectively, and then into the interior of cleaning tool housing  14 .  
         [0037]    In examining the preferred pressurized fluid rates, both positive and negative, it is preferred that the fluid be pressurized at a rate of between 0.4 and 0.55 gallons per minute. In addition, it is preferred that the negative pressure, or vacuum, is between 94 and 104 inches of water lift at the interior of the housing  14 .  
         [0038]    It will be seen that the description of the present invention provides a broad inventive concept. It is the intention that the description is written to provide a clear and complete understanding of the invention, and should not be interpreted to limit the scope of the claims in any way.