Patent Publication Number: US-8992693-B2

Title: Cleaning station

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the field of cleaning 
     2. Brief Description of the Related Art 
     The use of resins, such as, for example, epoxy resin, polyester resin and vinylester resin, are common throughout a number of industries to provide coatings, surfaces or other structure to a component. The construction of marine craft often uses resins that are applied to cover a surface or in conjunction with fibers like fiberglass or carbon fiber to make the structure or parts. The application of resins often involves the use of tools, such as, for example, hand tools, tool heads, bubble rollers, shaping tools, scissors, chopper guns and other implements that come in direct contact with catalyzed resin that must be cleaned of resin before it cures rendering the tools useless. The resin must be cleaned from the tool, so the tool may be reused. In many cases, solvents are used to dissolve, loosen or remove the resin product from the tool. Resin application tools may include rollers, scissors, knives, spatulas, trowels and brushes. 
     One way of cleaning resin from tools is to use a solvent. Though acetone is a solvent that has been widely used for such purposes, it is very volatile and flammable, and therefore, storing quantities of acetone has inherent risks. In addition, acetone has drawbacks because it may contain traces of material that are hazardous to those who come in contact with it, is environmentally unfriendly and generally requires hazardous material disposal compliance. A method of removing polyester resins is disclosed in U.S. Pat. No. 5,582,650, entitled, “Process for Cleaning Parts Soiled or Encrusted with Polyester Resin”. The &#39;650 patent discloses a process for cleaning cured and partially cured polyester resins from tools, machinery, containers and the like, and involves four stages, each having one or more steps, including a pre-wash, an ultra-sonic wash stage, a rinse stage, and a drying stage. U.S. Pat. No. 3,865,628 relates to a “Removal of Polymer Residue from Surfaces of Processing Equipment” and discloses a process for removing a polymer residue from the surfaces of processing equipment used in the manufacture of terephthalate polyesters by contacting the surfaces with an aqueous solution which is at least 180° F. The equipment is then rinsed with water which is at least 160° F. 
     Tools used to apply material, such as, for example, resin application tools, require cleaning if they are to be re-used. Cleaning often involves removing the excess material that remains on the tool after its use. In the case of paint brushes, U.S. Pat. No. 7,200,891, entitled “Tool Cleaning Brush Assembly”, discloses a device for cleaning a variety of hand tools, where cleaning brushes are mounted within a container. 
     U.S. Pat. No. 5,652,993 relates to a “Knife Cleaner” and discloses a device comprising a container filled with solvent that has a brush suspended within the container. The brush also is submerged in the solvent. The &#39;933 device is described to be an improvement over the previous method of wiping the ink off a knife with a solvent saturated towel. 
     U.S. published application no. 2008/0257384 relates to a “Bucket Arrangement and Method of Using the Same” and discloses an apparatus for cleaning tools, utensils, and other objects. The wiping element is submerged in a liquid in the container to facilitate removal of undesirable material from the object. The &#39;384 method involves a two step process. First, the object wipes against the first wiping element while submerged in the liquid, and then the object wipes against the second wiping element after being at least partially removed from the liquid. The &#39;384 method was developed to reduce injuries from cuts or abrasions from contact with the object and is described to be more sanitary than previous systems. 
     U.S. published application no. 2004/0261819 relates to a “Coating Bush Cleaning and Storing Apparatus and Method” and discloses a brush cleaning and storing apparatus. The &#39;819 device is disclosed to be useful for storing paint and coating brushes and brushes of like material. The &#39;819 brush cleaning device provides a cleaning plate with a roughened grid or surface pattern, which is mounted on a plurality of posts that are secured to the base of the container. Solvent is then introduced into the container to at least a point above the irregular surface pattern. Then the brush is submerged into the solvent and rubbed against the irregular surface pattern which cleans the brush. 
     U.S. published application no. 2002/0152568 relates to a “System and Method for Cleaning Both the Interior and the Exterior of Drywall Tools” and discloses a standard bucket, preferably with a 5-gallon capacity, with brushes rigidly mounted to a metal frame in an orthogonal arrangement such that all of the bristles extend radially inward towards the center of the generally cylindrical frame, which is then placed inside the bucket. There is also a foot-actuated pump that is attached to the bucket and to the inlet port of the drywall tool by a delivery hose that shoots water into the interior of the drywall tool to clean compounds out of its interior chambers. 
     U.S. published application no. 2005/0273957 relates to a “Cleaning Apparatus” for washing eating utensils. The cleaning apparatus includes a housing and a pair of brushes that are positioned on opposing interior walls of the housing such that the bristles of one brush are close to or overlaying the bristles of the other brush. The base or floor of the housing has an opening that permits water to flow through the housing. 
     U.S. Pat. No. 4,439,884 relates to a “Container with Bristles for Cleaning Instruments” and discloses a device useful in the medical and dental fields which has an open ended container that has bristles attached to its walls. The &#39;884 container (5) accepts a replaceable support (13) with bristles (6) (see FIG. 5) for periodical cleaning and/or disinfection. 
     Though prior devices have been used for cleaning cutlery and other instruments, where solvents are used, in some cases, acetone and resin may be absorbed into the bloodstream when the resin/acetone mixture comes in contact with skin, since the acetone dissolves the resin, and the resin may be absorbed into the skin along with the acetone. Though, in some cases, acetone has been replaced with other solvents, it is beneficial to contain the use of the solvent and minimize the contact with individuals. 
     A need exists for an improved cleaning device that is economical to produce and that can contain and store solvents and be used for carrying out a cleaning process for tools used in the application of resin compounds. 
     SUMMARY OF THE INVENTION 
     The present invention provides a cleaning apparatus designed for facilitating the cleaning of tools, and, more particularly, for cleaning resin application tools. 
     It is an object of the invention to provide a cleaning apparatus that is useful in conjunction with a solvent for cleaning resins, such as, for example, Polyester Resin, from tools that are used to apply resin to a surface or other structure. 
     It is another object of the invention to provide a cleaning apparatus that includes a container having an opening at the top and is constructed from a material that is resistant to solvents (e.g., such as Bio-Solv®) that may be used for cleaning resin from tools. 
     Another object of the invention is to provide a cleaning apparatus that has a shelf with slots therein that is provided within the container so that solvent may drain into the area beneath the shelf, where solvent may be stored. 
     According to a preferred embodiment, the cleaning device has brushes that are situated within the container space to facilitate the cleaning of tools, such as, for example, resin application tools. The brushes aid in abrading the resin from a tool, preferably, in conjunction with the solvent which is held in the container. 
     According to a preferred embodiment, the cleaning apparatus has a second shelf that is slidably positionable within the container space. The second shelf, for example, may be used as a drying rack on which to rest tools that have been cleaned so they may dry. Also, tools to be cleaned may be set on the second shelf. 
     Another object of the invention is to provide an apparatus that facilitates the cleaning of resin from tools that has a recovery system that is configured to recover solvent for reuse and permit disposal of the resin substrate removed from the tools, and provide a method for cleaning resin tools that promotes the recovery of solvent and facilitates disposal of resin waste products removed from tools during a cleaning process. 
     These and other advantages of the invention are provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  is a front elevation view of a cleaning station according to a preferred embodiment of my invention. 
         FIG. 2  is a longitudinal sectional view of the cleaning station of  FIG. 1 , taken through the section line  2 - 2  of  FIG. 4 , shown with the cover of  FIG. 1 . 
         FIG. 3  is a sectional view taken through the section line  3 - 3  of  FIG. 4 . 
         FIG. 4  is a top plan view of the cleaning station of  FIG. 1 , shown with the cover removed. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawing figures, a preferred embodiment of a cleaning station  10  is illustrated. The cleaning station  10  includes a container  11  having side walls  13 ,  14 ,  15   16  and a floor  17 . The side walls  13 ,  14 ,  15 ,  16  connect with the floor  17  and define an opening at the top of the container  11 . According to a preferred embodiment, the side walls are provided in pairs, with two opposing side walls  13 ,  14  at each container end being connected with the lateral opposing side walls  15 ,  16 . The cleaning station  10  includes a first shelf  20  that is provided within the container  11 . The first shelf  20  preferably is provided at a location above the container floor  17  so that the first shelf  20  is elevated from the container floor  17 . The first shelf  20  preferably is secured to the container  11 , and according to preferred embodiments, remains at a fixed location within the container  11 . According to one embodiment, the first shelf  20  is mounted to the container  11  using a suitable mounting mechanism, such as, for example, the mounting elements  21  shown engaging the first shelf  20  and connecting with the container  11 . Preferably, the mounting elements  21  are connected to a side wall, such as the lateral side walls  15 ,  16 . A removable fastening member, such as the wing nut  22  and bolt  23  may be used to secure the mounting elements  21  to the container side walls  15 ,  16 . According to a preferred embodiment, the mounting elements  21  may have a groove  24  therein for holding an edge of the first shelf  20 . This permits the mounting elements  21  to be mounted above a location where the solvent fill line is anticipated, thereby minimizing or preventing leakage from the fastening members  22 ,  23  used to secure the mounting elements  21  to the container  11 . Preferably, the bolt  23  may pass through a container side wall  15 ,  16  to which the mounting element  21  is mounted. Optionally, one or more sealing members (not shown), such as, for example, bushings may be used in connection with the mounting of the mounting elements  21  so the fastening members  22 ,  23  may secure the mounting elements  21  in a manner that prevents or minimizes any leakage of fluids from the container  11 . According to some embodiments, the fastening members  22 ,  23  may be provided as rivets or permanent fastening components, while according to alternate embodiments, the fastening members  22 ,  23  may be provided as removable components that are detachable and permit disassembly of one or more components of the device. The fastening members  22 ,  23 , for example, according to a preferred embodiment, alternately may be configured as locking pins, or other suitable fastening elements that allow easy removal of the first shelf  20  for removal of material that has accumulated at the bottom of the tank (such as resin sludge). The configuration with the mounting elements  21  being attached at a location above the first shelf  20  permits the solvent level to be maintained above the surface of the first shelf  20  yet below any mounting holes  25  provided in the side walls of the container  11  thereby preventing leakage of the solvent. The container  11  and first shelf  20 , according to a preferred embodiment, may be constructed from a polyethylene material. Preferably, the mounting elements or legs  21  are connected to the first shelf with suitable fastening members, such as the screws  29  which may be fastened through the first shelf  20  into the leg  21  (see  FIG. 2 ). The screws  29 , for example, may be machine type screws that are provided to fit within a threaded bore  26  of the leg  21 , or, alternately, may be self-tapping screws that form the bore  26  when installed. Although two screws  29  are illustrated, other numbers of screws may be used. Also, the screws are illustrated in connection with on of the legs  21 , but although not shown, the screws  29  may be provided to connect the other legs  21  with the first shelf  20 . Other suitable fastening members may be used to secure the legs  21  with the first shelf  20 . 
     According to a preferred embodiment, the first shelf  20  is shown held with four mounting elements, which according to a preferred embodiment are shown configured as the legs  21 . Preferably, a plurality of openings  27  are provided in the first shelf  20 . The openings  27  permit passage of material through the first shelf  20 , and preferably allow the passage of solvent and tool resin substrate to pass from above the first shelf  20  (i.e., the working section) to the area below the first shelf (the settling section). According to a preferred embodiment, as illustrated in the drawings, the openings  27  are configured as diagonally disposed slots to facilitate the transition of the catalyzed resin, dirt and fiberglass strands that may pass from the upper or working section of the container  11  (above the first shelf  20 ) to the lower or settling section of the container  11  (below the first shelf  20 ). 
     According to preferred embodiments, the first shelf  20  preferably is disposed at a level of about ⅓ from the top of the container  11 , so that about ⅔ of the container height is below the first shelf  20 . Though this is a preferred arrangement, other suitable configurations may be utilized. 
     The first shelf  20  preferably is provided with at least one opening therein  28  that accommodates a cleaning mechanism  30 . According to a preferred embodiment, the cleaning mechanism  30  has a pair of brushes  31  that are mounted in opposing relationship in the opening  28 . The brushes  31  are illustrated in a slightly overlapping relationship in the drawings figures, however, although not shown, according to an alternate configuration, the brushes  31  may be spaced apart from each other so that the ends of the brushes are separated by a space. The brushes  31  preferably are constructed from a material that is compatible with the solvent being utilized for cleaning. The brushes  31  preferably may be provided having bristles  32  that are designed to facilitate engagement with the surface of objects brought into contact with the bristles  32 , such as, for example, tools. The bristles  32  preferably are attached to a mounting structure  33  which may be mounted to the first shelf  20  with suitable fastening elements, such as for example the stainless steel screws  34 , bolts, rivets or other suitable means. Preferably, the brushes  31  are mounted so that the tools may engage the brushes  31  when the tools are placed within the opening  28 . The lower portion of the container  11  that is below the first shelf  20  may serve as the reservoir to hold a solvent that may be used for cleaning objects, such as, for example, tools. Preferably, the cleaning station  10  is provided to facilitate cleaning of resin application tools, and more particularly, to facilitate loosening of compound from the tools with the brushes  31  and with the aid of a solvent that may be used in conjunction with the brushes  31 . 
     The cleaning station  10  preferably has a second shelf  40  that is provided in the container  11 . The second shelf  40  preferably is located above the first shelf  20  and is movably mounted in the container. According to a preferred embodiment illustrated in the figures, the first shelf  20  is provided between the opposite adjacent walls  13 ,  14 . Preferably, the second shelf  40  is provided to have a length that is smaller relative to the length of the interior of the container  10  (that is, the lateral container dimension as measured between the adjacent side walls  13 ,  14 ). This preferred configuration permits the second shelf  40  to be positioned at a range of locations. A mounting mechanism  42  for securing the second shelf  40  is provided. The mounting mechanism  42 , according to a preferred embodiment, is configured having a pair of lateral ledges  43 ,  44  provided on the lateral side walls  15 ,  16  of the container  11 . The second shelf  40  preferably is supported on the ledges  43 ,  44  and may be slidably moved along the ledges from one end of the container  11  to the other (e.g., between the adjacent side walls  13 ,  14 ). The ability to position the second shelf  40  facilitates the utilization of the cleaning station  10  by being able to position the second shelf  40  to hold tools for drying while the brushes  31  are exposed for use, as well as being able to position the second shelf  40  over the brushes so that the portion of the first shelf  20  may also be used for holding tools. Preferably, the second shelf  40  is removably provided for facilitating cleaning of the second shelf  40 , or to make use of the first shelf  20  for larger sized or uniquely shaped tools that may require additional space in the container  11  when they are being cleaned. According to a preferred configuration, the second shelf  40  has a plurality of slots  46  therein, which in the embodiment illustrated are diagonally disposed. Additionally, a logo slot  47  may be provided, and may be used to display a logo, name, symbol or other indicia. The indicia may be provided to identify a type of cleaning station, a brand, a use or to distinguish one cleaning station  10  from another. 
     According to preferred embodiments, the cleaning station  10  is provided with a cover  45  that is configured to cover the container opening  18 . The cover  45  covers the opening of the container  11  to prevent dust and dirt from entering the container  11  and to reduce evaporation of the solvent when the cleaning station  10  is not in use. The cover  45  is shown in a preferred configuration having a handle  46  that is provided on the exterior of the cover  45  to facilitate removal and installation of the cover  45  on the container  11 . The cover  45  preferably may have a sealing element (not shown) for sealing the cover with the top perimeter of the container side walls  13 ,  14 ,  15 ,  16 . The sealing element, for example, may be a gasket, o-ring, or other suitable sealing component, and preferably is made from a material that is resistant to degradation by the solvents and materials that are anticipated being used in connection with the cleaning station  10 . The cover  45 , according to a preferred embodiment, may be constructed from a polyethylene material. 
     Preferably, the cleaning mechanism  30  is disposed in a location relative to the first shelf  20  so that the cleaning mechanism  30  aligns with at least one opening of said first shelf  20 , such as the opening  28  that is designed to receive the cleaning mechanism  30 . Preferably, the second shelf  40  is disposed at a height in the container higher in relation to the first shelf  20 , and the second shelf  40  is positionable at least one location that is a location that is spaced from the cleaning mechanism  30  to provide access to said cleaning mechanism  30  to facilitate introduction of tools to the cleaning mechanism  30 . 
     The cleaning station  10  may be used with a solvent. According to a preferred method of using the cleaning station  10 , the solvent may be provided in an amount that covers the brushes  31  and/or first shelf  20 . The solvent preferably may be Bio-Solv® (an acetone replacement solvent) that may be dispensed into the container  11 . The cleaning station  10  cover  45  may be installed over the opening  18  so the solvent contained in the cleaning station may be stored and reused. The cover  45 , when used, also prevents or minimizes evaporation of the solvent during storage. The cleaning station  10  second shelf  40  may be used for resting tools when the tools are drying. The second shelf slots  46  preferably may allow drainage of solvent from tools to pass through. 
     Throughout the cleaning process, the second shelf  40  may be adjustably positionable by sliding it along the ledges  41  disposed on each lateral side wall  15 ,  16  of the container  11 . Preferably, the tools to be cleaned are brought into contact to engage the brushes  31  and the tool is moved relative to the brushes  31  so that the bristles  32  abrade the material from the tool. During the cleaning process, the tool may be lowered below the brushes  31  and into the solvent that is in the reservoir at the bottom of the container  11 . The tools may be lowered to pick up solvent from the bottom of the container  11  as needed, and then brushed with the brushes  31 . This may be repeated until the material from the tool is removed from the tool or the tool is cleaned to a desired condition. According to a preferred embodiment, the solvent is provided to be compatible with the substrate on the tool to be removed from the tool. For example, one preferred embodiment involves the brushing of the resin material from the tool so the material is received into the bottom of the container  11  occupied by the solvent. Where the method utilizes a solvent, such as, for example, Bio-Solv® (a registered US trademark of Phoenix Resins, Inc.), the resin substrate may form with the solvent a material. The material may be liquid or viscous, and may be stored within the container  11 , preferably with the cover  45  in place. When the suitable amount of substrate has been removed from tools, whether over one cleaning, or over a period of time after several tool cleanings, then the solvent and substrate resin mixture may be removed from the container  11 . According to a preferred embodiment, the first shelf  20  also is removably provided so that the first and second shelves  17 ,  40 , respectively, may be removed from the container  11 . This permits access to the solvent and substrate contents, and the solvent and substrate mixture may be removed from the container  11 . The solvent and substrate mixture may be set aside for drying. When dry, the solvent, such as Bio-Solv® and substrate, in this example, forms a substantially solid material that may be broken up for ease of disposal. The use of the cleaning station  10  facilitates the method wherein the solvent may be contained and used to take up the substrate that is removed from the tool, and the disposal of the substrate material may be effected without the need for hazardous solvent disposal, since the debris is substantially a solid material. The cleaning station  10  may permit the use of the brushes and storage of solvent and removed substrate to effect a concentration of the solvent to substrate composition that will provide a solid disposal product. 
     The method of cleaning tools to provide a solid disposal by product is provided. The method is carried out using the cleaning station  10 . The cleaning station  10  provides for removal of the debris from the tool in a manner that facilitates the collection of the material and permits the reuse of the solvent. At the end of the cleaning process, the solvent and substrate material that has been removed from the tools may be dried and disposed of as a solid product. Preferably, the solvent is poured off from the container  11  to leave behind the “sludge” which is formed from the catalyzed resin, glass fibers and other contaminants that settle out of the solution at the bottom of the container  11 . The solvent liquid can be poured off and reused. The solvent may be transferred to a second cleaning station  10  for reuse. The sludge (along with any solvent left behind) will form a hardened solid form. This reduces or eliminates hazardous waste and allows the recycling of the liquid solvent, such as Bio-Solv®. 
     The configuration of the cleaning station  10  provides a solvent reservoir that is accessible during cleaning of the tools, yet the cleaning station  10  is configured so that material that is removed from the tools during the cleaning process substantially is delivered to the solvent compartment or reservoir and stored there until it may be disposed of. The disposal procedure may be carried out with the cleaning station  10 . One disposal method involves pouring off the mixture through a plurality of openings provided in the first shelf  20 . Another method involves the removal of the first shelf. In the former method, the first shelf  20  may remain installed. In the latter method, the first shelf may be removed and the mixture permitted to dry in the bottom of the container  11 , preferably, by first removing any excess solvent that is present (for reuse). Accordingly, though it is preferred to have a lower level of material to facilitate drying of the resin components left behind from the cleaning process, the material from one container  11  may be transferred to a second or other container  11  so that drying of material may be accumulated. 
     The container  11  holds the solvent, and preferably is divided into two sections, an upper section (or working section) where the tools can be cleaned, scrubbed and agitated with minimal disturbance to a lower section (the settling section) where the catalyzed resin, fibers and dirt (sludge) will settle out. 
     While the invention has been described with reference to specific embodiments, the description is illustrative and is not to be construed as limiting the scope of the invention. Various modifications and changes may occur to those skilled in the art without departing from the spirit and scope of the invention described herein and as defined by the appended claims.