Patent Publication Number: US-8522800-B2

Title: Tile cleanup apparatus

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to apparatus for manual cleaning, and in particular to an apparatus that effectuates cleaning a sponge and similar absorbent materials that can be heavily soiled with dust, mud and contaminates, as in the case of installing and maintaining tile and the like. 
     2. Prior Art 
     The process of laying tile requires multiple steps, each step typically requiring a cleanup, and therefore cleaning the tile is a substantial part of the overall total work load for the process. Prior to laying the tile clean up is required if the substrate on which the tile is to be laid needs to be prepped. Prepping can include mechanical grinding to achieve adequate flatness. Cleanup of the dust generated from the grinding process is a nuisance and potentially produces a hazardous dust, as the formed dust is normally derived from concrete, which in addition to being an irritant to a worker&#39;s lungs, the dust also usually contains silica, where crystalline is a listed carcinogen. There is another cleanup after applying the tile mud (or tile mortar) on the substrate and placing the tiles on it. This step normally is the “least messy” of the steps, but invariably some cleanup is required. For instance, the tile mud/mortar usually ends up on the face of the tile from handling the tile, and this has to be removed. Cleanup is much easier and more effective before the mud has time to cure. Curing normally takes about 24 hours. After curing, tile grout can then be filled in between the tiles in the grout groove. A common method of grouting is to dump a large pile of grout on the tiles and then squeegee the grout into the grooves. While quick, this method covers substantially the entire tile face leaving a residue of grout and (and potentially some mud), which must then be wiped clean. The cleanup is typically manual, where the worker uses a water absorbent material, such as a sponge, a towel or cloth. Normally the water absorbent material is damp, as the presence of in situ water softens the absorbent material, making it a more effective wipe and initially a faster absorbing material for the residue. Water is attracted to water, and the in situ water dilutes the grout, which is typically water based, where the dilution makes the residual grout easier to remove. The effectiveness of the absorbent material decreases as the diluted water based grout permeates and coats the absorbent material because there is less dilution, less absorbency, and the in situ water is about as contaminated with grout as the residue on the tile. 
     The prior art includes inventions that enhance the efficacy of using wringers to express the in situ water from the absorbent material. Ironically, a wringer which can leave the absorbent material with less in situ water is not necessarily more effective at cleaning up grout and mud, because the absorbent material is drier and the collected contaminating grout and mud are less diluted with situ water. The mixture of in situ water and grout approaches the same composition in the absorbent material as the composition of grout in the residue on the tiles. Cleaning is not improved if the absorbent material is as dirty as the residue, as wiping just smears around the grout. The prior art also teaches the use of large vats mounted on wheels to make the transportation of larger amounts of water more efficient. The use of wheeled vats poses a weight problem, especially on tile that is being grouted. The weight of the wheeled vats can be sufficient to dislodge or move the tile being installed. Planks can be utilized to distribute the weight of the vats, but laying planks requires additional work. 
     Without the use of vats multiple smaller quantities of clean water must be brought to the job site to have sufficient clean water on hand to wipe the tile down so that the face is free of grout, mud and other contaminates. Tile mud and grout are easiest to cleanup while they are still free flowing, and this only occurs if the grout and mud have not had time to cure. The cure rate in essence establishes a window of time for the cleanup. 
     SUMMARY OF THE INVENTION 
     The invention is an apparatus that operationally enables a worker to manually quickly clean a sponge, where a sponge is herein defined to include sponges, other water absorbent materials such as fabrics, brushes and devices comprised of water absorbent materials such as a mop; where the sponge is utilized to clean tile, stone or brick. The invented apparatus is especially efficacious for the process of cleaning a dirty sponge soiled with extraneous grout, cementitious mud, dust, contaminates, chemicals such as coatings and cleaning compounds, and sanitation matter such as pests, mold, mildew, food, bacteria, urine and feces (collectively referred to as detritus) from tile, stone, brick and substrate (collectively referred to as tile). In one variation the invention is a specialized tub-like apparatus, the apparatus is appropriately sized so that it is capable of fitting in the mouth of a bucket, such as a standard five gallon bucket, or in the absence of a bucket, in a sink, on a supporting surface, or in a basin. The bucket is utilized as a collection point for waste water, where waste water is defined as any water flowing into the bucket from the specialized tub-like apparatus. The bucket typically can be fitted with a drain line which, as needed, removes collected waste water from the bucket, either by siphoning off or pumping out the waste water. The specialized tub-like apparatus has a substantially flat bottom that is ribbed, where the ribbing adds structural strength to the bottom and focuses pressure applied to a sponge on the ribbing. The focused pressure facilitates expressing the contents of the sponge. The specialized tub-like apparatus has a replenished level of incoming clean water, which flushes away dirty water, so that a dirty sponge, one loaded with detritus, is cleansed with substantially clean water, making the process of cleaning the dirty sponge much more efficacious than a process that uses a mixture of dirty water and clean water. Incoming clean water is substantially continuously replenished to a desired level and at a controlled rate. Even with a constant incoming flow rate there can be a temporary change in the water level because, in part, when the sponge is squeezed emptying the contents into the apparatus or pressed on the ribbing, the expressed contents can cause a temporary increase in the water level, which produces an increase in head pressure of the water in the apparatus. The increased head pressure causes the water in the apparatus to flow out more quickly through the holes that drain the specialized tub-like apparatus until equilibrium is reestablished. The flow rate of the incoming clean water is established to be sufficient that the dirty water and any extraneous cleanup detritus and particulates are purged from the sponge and out of the apparatus as waste water. The incoming clean water is distributed so that much of it flows substantially between the ribs. The flow rate is adjusted to accommodate for the expected demand on the apparatus. The more workers using the apparatus, generally the higher the demand and the higher the flow rate. 
     In a preferred variation the specialized tub-like apparatus has a quasi-circuline side wall extending substantially upward and contiguous from a shelf that is elevated and contiguous with most of a perimeter of the bottom. A first shelf has a first level control hole which is an outlet for water in the apparatus, and it functions as one of several control elements for the water level in the apparatus. At least a portion of an upper edge of the side wall is flanged, where the flange has a width, such that the flange extends beyond a diameter of a mouth of the bucket, thus securing the apparatus in the mouth of the bucket. The side wall has at least one deviation. Formed in a first inward deviation of the side wall is a novel hose fastening element that includes a restraining wall with two wedged shaped holes that are substantially orthogonal to each other. The restraining wall provides strength to the quasi-circuline side wall and the bottom. The shape and relative positioning of the wedged shaped holes enable a water hose to be secured without any auxiliary fastening elements. Operationally, a conventional water hose is threaded through a top wedged shaped hole and flexed to curve through a side wedged shaped hole, the combination of these holes causing the water hose to be wedged in place, such that an end of the water hose exits proximate to an indentation in the bottom. 
     The indentation serves several functions. In one function it disburses flow of the incoming clean water exiting from the end of the water hose. In a second function the indentation also adds strength to the bottom, as the indentation has wall elements that are substantially orthogonal to the bottom. In one variation the indentation has a sloped floor and a tapered block shape, which functions to fan out the flow so that much of the water flows from the indentation near a center of the ribbed bottom approximately outwardly across the ribbed bottom. In another variation the apparatus has a second inward deviation of the quasi-circuline side wall where the second inward deviation curves forming a substantially serpentine loop. The loop provides an access port to a point below the bottom of the apparatus, for example for drain lines and wires to the interior of the bucket. The access port is large enough to accommodate the drain line and wiring. The second deviation is preferably approximately opposite the first deviation, and it also provides rigidity to the apparatus. 
     The rate of water flow can be controlled by numerous methods (valve at hose end, valve at hose beginning, etc). As the incoming clean water enters the apparatus, the water level rises until it encounters the shelf having the first level control hole. In one variation of the invention there are a plurality of shelves and a plurality of level control holes. The level control holes are sized appropriately to allow a wide range of water flow to occur before drainage from the apparatus is not as fast as the flow rate of the incoming clean water. When the flow rate of the incoming clean water exceeds drainage eventually the level control holes will be overcome causing the apparatus to overflow. When the water level reaches the level control holes, the water flow rate is adjusted to match the amount of water that is required to meet the cleaning demands. Rinse time should be fast enough that workers are not standing around waiting to clean their sponge. Extra sponges can be on hand to handle surges. In one variation of the invention the quasi-circuline side wall is marked with indices corresponding to a known flow rate. The indices also make it easy to determine if equilibrium has been reached. Furthermore, a user can coordinate a mark on the indices with a demand, in part to conserve the use of water. 
     In another variation, the invention has legs depending from the underside of the bottom. The legs are particularly useful when the apparatus is used in a sink. Each leg preferably has a tapered annular drain hole through which detritus, precipitates and waste water can exit. A plurality of annular drain holes work in unison to remove heavier detritus. 
     The indentation can have a indentation drain hole or a plurality of indentation drain holes. The leg drain holes and the indentation drain holes work in combination as outlets that allow the apparatus to drain substantially dry when there is no incoming clean water. The combination of drain holes also function as outlets for detritus and precipitates that are too heavy to be conveyed to the level control holes, which are higher. Typically, the drain holes are located at the lowest point in the legs and of the indention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing invention will become readily apparent by referring to the following detailed description and the appended drawings in which: 
         FIG. 1  is a perspective overhead view of a specialized tub-like apparatus, which is utilized as a tile cleanup apparatus for cleaning sponges soiled with detritus, where the detritus is collected during the preparation of the substrate, the installation and the maintenance of tile; 
         FIG. 2  is a top planar view of the specialized tub-like apparatus illustrated in  FIG. 1 ; 
         FIG. 3  is a bottom planar view of the specialized tub-like apparatus illustrated in  FIG. 1 ; 
         FIG. 4  is a frontal planar view of the specialized tub-like apparatus illustrated in  FIG. 1 ; 
         FIG. 5  is a side end-on planar view of the specialized tub-like apparatus illustrated in  FIG. 1 ; 
         FIG. 6  is a perspective overhead end-on top view of the specialized tub-like apparatus illustrated in  FIG. 1 ; and 
         FIG. 7  is a perspective overhead view of the specialized tub-like apparatus seated in the mouth of a bucket, where the tub-like apparatus is hooked up to a water hose bringing in clean water and the bucket is being emptied by a drain hose conveying away waste water containing detritus from soiled sponges that were used to clean tile. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The illustrated invention is a specialized tub-like apparatus, where the tub-like apparatus in one application is employed as a tile cleanup apparatus for cleaning a sponge soiled with detritus collected during the preparation of the substrate, the installation and the maintenance of the tile. The reader is reminded that the term “detritus” collectively includes extraneous grout, cementitious mud, dust, contaminates, chemicals such as coatings and cleaning compounds, and sanitation matter such as pests, mold, mildew, food, bacteria, urine and feces; that the term “tile” collectively includes tile, stone, brick and substrate; and that the term “sponge” collectively includes sponges, other water absorbent materials such as fabrics, brushes, and devices comprised of water absorbent materials such as a mop. 
     The utility of the invention is that it enables a worker to manually quickly clean a dirty sponge soiled with detritus from cleaning tile. The specialized tub has a replenished level of incoming clean water which flushes away the detritus. In one embodiment the specialized tub-like apparatus is a molded integral piece that includes a novel hose fastening element having a restraining wall with two wedged shaped holes that are substantially orthogonal to each other. The specialized tub-like apparatus also has an indention that fans out a stream of incoming clean water, and the indention drains off detritus and precipitates removed from the sponge to a collection point for waste water, keeping the apparatus substantially free of the buildup of detritus and heavy precipitates displaced from the sponges. Drainage continues until the specialized tub-like apparatus is substantially dry. 
     Referring to  FIG. 1 , which is a perspective overhead view of the specialized tub-like apparatus  12 , and  FIG. 7  where the tub-like apparatus  12  is being utilized as a tile cleanup apparatus  10  seated in a bucket  120 , the specialized tub-like apparatus  12  operationally is typically partially filled with a replenished level of clean water that flows approximately outwardly towards the quasi-circuline side wall  34 . The quasi-circuline side wall  34  extends substantially upward and contiguous from a first shelf  26  on a first riser  54 . The first riser  54  is contiguous with a portion of a perimeter of a flat bottom  14  that has tapered ribs. The first shelf  26  has at least one first level control hole  28 , and as illustrated in  FIG. 1  the first shelf  26  has a plurality of first level control holes  28 , where four holes  28  are visible and, accordingly, similarly numbered. In a preferred variation of the specialized tub-like apparatus  12 , as illustrated in  FIG. 2 , (but not visible in  FIG. 1  and  FIG. 7 ) the tub-like apparatus  12  is symmetrical with respect to the shelf and tapered ribs, and there is a second shelf  30  with at least one second level control hole  32 . The illustrated first level control hole(s)  28  and second level control hole(s)  32  function primarily to set the water level in the specialized tub-like apparatus  12 . 
     As readily apparent in  FIG. 5 , which is a side end-on planar view of the specialized tub-like apparatus, the quasi-circuline side wall  34  is tapered from the flange  40  to the bottom  14 . The tapering facilitates the ease of de-molding of the integral molded piece of the specialized tub-like apparatus  12 . It also makes the specialized tub-like apparatus  12  nestable, so that multiple apparatus can be stored more efficiently (i.e. take up less volume) and shipped at less cost. 
     Referring again to  FIG. 1 , at least a portion of the rim  36  of the side wall  34  has a flange  38 , where the flange has a width  40 , such that the flange extends beyond a diameter of the mouth of the bucket in which the specialized tub-like apparatus is seated. A preferred bucket is a 5 gallon bucket, and its nominal dimensions are about 11¾ top×10⅜ bottom×14½ deep in. As shown in  FIG. 5 , the overall diameter  48  from one outer edge  46  of the flange  38  to the opposing outer edge  46 ′ would therefore be greater than 11¾ inches for a standard 5 gallon bucket. A diameter  58  of the exterior quasi-circuline side wall  34 ′ would be less than 11¾ inches. 
     The specialized tub-like apparatus  12  has a plurality of ribs  16  on the bottom  14 . The illustrated ribs  16  are substantially parallel and tapered. The ribs add structural strength to the bottom and focuses pressure on the sponge. The focused pressure facilitates expressing the contents of the sponge, because by pressing the sponge down on the ribs the downward force is concentrated producing zones within the sponge that are more highly compressed. The expressed detritus is initially compressed in the channel-like areas  18  between the ribs, and the flow of the clean water through these channel-like areas  18  (also see  FIG. 2 ) carries the detritus to the level control holes and other drain holes. The tapering makes de-molding easier, and therefore faster, as less cooling between molding cycles is required. 
     Returning to  FIG. 7 , clean water  106  is flowing into the specialized tub-like apparatus  12  through the clean water hose  100  that is a conventional garden hose. The clean water level is marked by the first of four indices  110 . Waste water  104  is collected by the bucket  120  (shown in dashed lines), and is removed from the bucket  120  by the drain line  102 . The drain line  102  can be attached to a bulkhead connector (not shown) mounted at the bottom of the bucket. The waste water  104  is gritty with extraneous grout, cementitious mud, and dust. As is evident from viewing  FIG. 7  the incoming clean water  106  is substantially continuously replenished to the desired level (depth in the specialized tub-like apparatus  12 ), the water flowing from the indentation  70  in the bottom outwardly over and between the ribs to the shelves  26 , 30  (see  FIG. 2 ), and then exiting through the plurality of flow control holes  28 , 32 . 
     The quasi-circuline side wall  34  of the specialized tub-like apparatus  12 , as shown in  FIG. 4  and  FIG. 6 , has at least one deviation, where the wall deviates inward. The first inward deviation  60  of the side wall is a novel hose fastening element  62  having a restraining wall  68  with two wedged shaped holes, a top wedged shaped hole  64  and a side wedged shaped hole  66 , that are substantially orthogonal to each other. The restraining wall  68  has a number of wall sections. As indicated in  FIG. 4  the restraining wall sections include a left wall section  68   a , a right side wall section  68   b , an indented wall section  68   c , and a top wall section  68   d . The wall sections provide strength to the quasi-circuline side wall and the bottom. The shape and relative positioning of the wedged shaped holes enables the clean water hose  100  to be secured without any auxiliary fastening elements. Operationally, as shown in  FIG. 7  a conventional water hose is threaded through the top wedged shaped hole  64  in the top wall section  68 d and flexed to curve through the side wedged shaped hole  66  in the indented wall section  68   c , the combination of these holes causing the water hose to be wedged in place, such that an end of the water hose exits proximate to an indentation  70  in the bottom  14 . The indentation  70  disburses the incoming clean water from the clean water hose  100  adds strength to the bottom. The indentation, as shown in  FIG. 2 , has lateral walls  72  that are slightly tapered and indented in the bottom  14 , and is located approximately in the center of the specialized tub-like apparatus  12 , bisecting a pair of parallel rows of ribs  16 . The indentation has a sloped floor block “V” shape, which functions to fan out the water flow so that much of the water flows from the indentation near a center of the ribbed bottom outwardly through the channel-like areas  18  across the ribbed bottom. The sloped floor  74  of the indentation is feeds to a center wall  76  of the block “V”shape. The center wall  76  disrupts and splits the flow of the incoming water, and the “V” diverters the water outward from the indention  70 . The indentation has an indentation drain hole  78 , and in the illustrated embodiment there are a set of indentation drain holes  78 . These indentation drain holes are discussed in greater length at a later time. 
     The specialized tub-like apparatus  12  has a second inward deviation  80  of the quasi-circuline side wall where the second inward deviation curves forming a substantially serpentine loop  82 . The loop  82 , as illustrated in  FIG. 7 , provides an access port to a point below the bottom of the apparatus, gaining access to the interior of the bucket  120 . The access port is large enough to accommodate the drain line  102  and wiring. The drain line  102  conveys waste water  104 . The wiring, for example, may be for the purpose of supplying electrical power to a lift pump (not shown) in the bucket. The lift pump could be actuated by the depth level of waste water  104  in the bucket  120 . The second deviation  80  is preferably approximately opposite the first deviation  60 , and it also provides rigidity to the apparatus. The second deviation  80  is also tapered for the reasons previously discussed. 
       FIG. 3 , which is a bottom planar view of the specialized tub-like apparatus illustrated in  FIGS. 1 and 2 , shows that the elements, such as the ribs  16 , that are raised in the top view are recessed, and that the indention  70  is raised. Furthermore, the flange  38  is supported on the underside with a series of spokes  20 . 
       FIG. 4  and  FIG. 5  illustrate an embodiment where the specialized tub-like apparatus  12  has legs  90  depending from the underside  14 ′ of the bottom  14 . The legs  90  are tapered. The legs are particularly useful when the tub-like apparatus  12  is used in a sink, positioned in a basin or on a surface (not shown). Each leg  90  preferably has a leg drain hole  92 , which is substantially a tapered annular passage, through which detritus, precipitates and dirty water can exit. A plurality of leg drain holes drains the entire bottom, except for the indentation  70 , which has an indentation drain hole  78 . The combination of the leg drain hole(s)  92  and the indentation drain hole(s)  78  will drain the apparatus dry if there is no incoming clean water, making the apparatus largely self-cleaning. The combination also serves as outlets for detritus and precipitates that are too heavy to be conveyed to the level control holes  28 , 32 . 
     Operationally, the rate of water flow can be controlled by numerous methods (valve on the clean water hose, spigot, etc.). As the incoming clean water enters the apparatus, the water level rises until it encounters the level control hole(s). A minimum flow rate is higher than the flow rate of the combination of drain holes, such that the water level rises to the level control holes on the shelf or shelves. The level control holes are sized appropriately to allow a wide range of water flow to occur before the flow rate of the incoming clean water is fast enough to overcome the total rate of flow through the level control holes, irregardless of the head pressure, therein causing the apparatus to overflow. Typically, the water flow rate is adjusted to match the amount of water that is required to meet the cleaning demands. Rinse time should be fast enough that workers are not standing around waiting to clean their sponge. Extra sponges can be on hand to handle surges. In one variation of the invention the quasi-circuline side wall is marked with indices  110  corresponding to a known flow rate. The indices also make it easy to determine if equilibrium has been reached. Furthermore, a user can coordinate a mark on the indices with the demand, in part to conserve the use of water. The cleaning capacity is the cycle time of the apparatus to clean a sponge, and generally it is preferable slightly higher than the demand. The cleaning capacity can be lengthened if there are excess sponges on hand. A plurality of the specialized tub-like apparatus  12  can be employed to accommodate a higher demand. 
     In applications where the tub-like apparatus is employed as a tile cleanup apparatus for cleaning a sponge soiled with detritus collected during the installation and maintenance of the tile, the clean water can be premixed with surface active agents, such as soaps, and solvents, such as isopropyl alcohol to enhance the cleaning efficacy of the sponge. Furthermore, the ambient temperature of the incoming clean water can be pre-warmed or pre-cooled to a desired temperature to augment the specialized tub-like apparatus  12  being utilized as a tile cleanup apparatus. 
     In some cases it is desirable to use the apparatus in a sink. For instance if one is cleaning a countertop, the invention is placed in a proximate sink, and the spigot is turned on. Collection and disposal of the waste water is accomplished by the sink and its associated plumbing. 
     It is anticipated that the specialized tub-like apparatus  12  can be employed in other applications for example cleaning water based paint and varnishes from rollers and sponge brushes; and cleaning spackling, caulking and joint from spatulas and other tools. The apparatus can also be utilized in maintenance applications, such as the maintenance of tile. Examples include removing cleaning compounds such as grout cleaners and sanitary cleaning where sanitation matter such as pests, mold, mildew, food, bacteria, urine and feces are removed the tile. The apparatus can be used facilitate cleaning shower, counters, bathtubs, floors, backsplashes, and components thereof. The apparatus is also useful in cleaning cars, and in particular those heavily soiled areas like wheels, fenders, and bumpers. In applications where strong cleaning chemicals are used, a mop or brush can be rapidly flushed clean with the apparatus as it has a replenished level of clean water which displaces the detritus. 
     It is to be understood that the foregoing description and specific embodiments are merely illustrative of the best mode of the invention and the principles thereof, and that various modifications and additions may be made to the invention by those skilled in the art, without departing from the spirit and scope of this invention, which is therefore understood to be limited only by the scope of the appended claims.