Abstract:
A disinfecting spray module that can either be retrofit to an existing housekeeping cart or integrated into the housekeeping cart. The disinfecting spray module includes a storage container for receiving a disinfectant or cleaner. An electric pump withdraws the disinfectant and supplies the pump through a spray hose. The spray hose includes a handle having a nozzle to direct the disinfectant onto the surface to be cleaned. The disinfecting spray module can include an internal power supply or be connected to a source of electricity within the room being disinfected.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application is based on and claims priority to U.S. Provisional Patent Application Ser. No. 61/466,093 filed Mar. 22, 2011. 
     
    
     BACKGROUND 
       [0002]    The present disclosure generally relates to a disinfecting spray module that can be utilized to sanitize equipment and disinfect and/or clean rooms. More specifically, the present disclosure relates to a disinfecting spray module that can be retrofit onto existing housekeeping carts or other types of mobile carts to provide a supply of disinfectant that can be evenly sprayed onto a surface to be cleaned. 
         [0003]    Presently, housekeeping staff typically carries one or more spray bottles of disinfectant on a housekeeping cart. The housekeeping staff utilizes the spray bottles to spray the disinfectant onto surfaces that need to be cleaned. Although a spray bottle is generally adequate to apply disinfectant to the surface to be cleaned, the size of the spray bottle is limited which requires the housekeeping staff to refill the bottle frequently or carry multiple bottles on the housekeeping cart. Additionally, spray bottles do not generally apply the disinfectant/cleaner in a smooth, continuous pattern. 
         [0004]    In addition to the limited supply of disinfectant that can be carried in a portable spray bottle, the distribution pattern of the disinfectant onto the surface to be cleaned is inconsistent and varied during the extended use of the spray bottle. The coverage and overall distribution of the disinfectant is affected by the type of nozzle used on the spray bottle and the action of the cleaning personnel utilizing the spray bottle. 
         [0005]    Therefore, a need exists for an improved system that provides a larger supply of disinfectant and allows the housekeeping staff to more effectively apply the disinfectant or cleaner onto the surfaces to be cleaned. 
       SUMMARY 
       [0006]    The present disclosure relates to a small, portable spray module that can be retrofitted to existing housekeeping carts or other types of mobile carts, such as luggage carts, or pre-assembled on new housekeeping carts. The small, portable spray module is used to disinfect rooms, equipment, solid surfaces and a variety of other surfaces such as fabric and wheelchairs. 
         [0007]    The disinfecting spray module is configured to apply any disinfectant or cleaner evenly and accurately over a desired surface. The disinfecting spray module creates a fine spray that allows the solution to penetrate hard-to-reach areas and dries in minutes. 
         [0008]    The disinfecting spray module includes an electric pump that is virtually silent and is either connected to a power supply in the room being cleaned or includes a rechargeable battery pack. The disinfecting spray module can be mounted to a housekeeping cart or a simple luggage cart such that the spray module is portable and can be easily moved throughout a facility. The disinfecting spray module does not take up any additional inner-cart space and thus maintains optimal storage on the cart. 
         [0009]    The disinfecting spray module includes an easy-to-use dispensing system and applies any disinfectant or cleaner within seconds. The disinfecting spray module includes a storage container that can be accessed by simply unscrewing a fill cap and filling the container with any desired solution. 
         [0010]    The disinfecting spray module of the present disclosure has been found to provide labor savings of up to 50%, reduces FTEs due to the mobility and ease of use. The disinfecting spray module is effective at applying a disinfectant to hard-to-reach areas that may be overlooked with traditional methods of disinfectant. 
         [0011]    The disinfecting spray module of the present disclosure has been designed to include a spray nozzle that creates a fine mist of the disinfectant while insuring that the disinfectant is not released in a mist. The selection of the nozzle design creates the desired droplet size and the desired pattern of coverage while controlling the size of the droplets to prevent the creation of a mist, which can be inhaled. 
         [0012]    Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings: 
           [0014]      FIG. 1  is a perspective view of a cleaning cart with a disinfecting spray module; 
           [0015]      FIG. 2  is a front perspective view of an alternate type of cleaning cart also incorporating the disinfecting spray module of the present disclosure; 
           [0016]      FIG. 3  is a front perspective view of another alternate type of cart that can be used to support and transport the disinfecting spray module of the present disclosure; 
           [0017]      FIG. 4  is a perspective view of the disinfecting spray module; 
           [0018]      FIG. 5  is a perspective view similar to  FIG. 4  with the outer housing of the module removed; and 
           [0019]      FIG. 6  is a front view of the operating components of the disinfecting spray module shown in  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]      FIG. 1  illustrates a housekeeping cart  10  that is typically used by cleaning personnel to disinfect or clean rooms, equipment and solid surfaces. The housekeeping cart  10  includes a waste receptacle  12  supported on a storage cabinet  14  by a pair of support arms  16 . The storage cabinet  14  is mounted to a platform  18  having a series of caster wheels  20  such that the entire housekeeping cart  10  is mobile and can be moved from room to room by housekeeping personnel. In accordance with the present disclosure, the housekeeping cart  10  is configured to include a removably mounted disinfecting spray module  22  constructed in accordance with the present disclosure. 
         [0021]      FIG. 2  illustrates another common type of housekeeping cart  10  that includes a similar waste receptacle  12  and platform  18  having the series of caster wheels  20 . As illustrated in  FIG. 2 , the disinfecting spray module  22  is supported by the platform  18  in a similar manner to the embodiment shown in  FIG. 1 . It should be understood by a comparison between  FIGS. 1 and 2  that various different types of housekeeping carts  10  can be utilized to support the disinfecting spray module  22  of the present disclosure. In the embodiments of  FIGS. 1 and 2 , the disinfecting spray module  22  is retrofit onto an existing cart. However, it is contemplated that the housekeeping cart  10  could be specifically designed to include the disinfecting spray module  22 . 
         [0022]      FIG. 3  illustrates yet another configuration and use for the disinfecting spray module  22  constructed in accordance with the present disclosure. In the embodiment shown in  FIG. 3 , the disinfecting spray module  22  is shown mounted to a conventional luggage cart  19  that includes an extendible handle  21  and a lower support platform  23 . A pair of wheels  25  allow the luggage cart  19  to support and move the spray module  22  to a desired location. In the embodiment shown in  FIG. 3 , a storage bin  27  is mounted to extend from the front face of the disinfecting spray module  22 . The storage bin  27  provides a convenient storage location for various different tools needed by cleaning personnel and also provides a storage location for a spray handle  32  positioned at the end of the spray hose  26 . In the embodiment shown, the front storage container  27  is formed from stainless steel, although other materials, such as plastic, are contemplated as being within the scope of the present disclosure. 
         [0023]      FIG. 4  illustrates the disinfecting spray module  22  constructed in accordance with the present disclosure. The disinfecting spray module  22  includes an outer housing  24  preferably formed from stainless steel. Stainless steel is a desirable material for the outer housing  24  since stainless steel can be easily sanitized and provides the required durability. 
         [0024]    The disinfecting spray module  22  includes a coiled spray hose  26  having a first end  28  connected to the spray module  22 . A second end  30  of the spray hose  26  is connected to a spray handle  32 . The spray handle  32  includes a handle  34 , trigger  36  and spray nozzle  38 . 
         [0025]    The housing  24  further includes an on/off switch  40  that allows an operator to control activation of the disinfecting spray module  22 . A power cord  42  having a plug  44  extends from the housing  24 . A fill cap  46  is accessible through the top of the outer housing  24 . The fill cap  46  provides an access point for filling the disinfecting spray module  22  with any hospital-grade disinfectant. 
         [0026]      FIGS. 5 and 6  illustrate the operating components of the disinfecting spray module  22  with the outer housing removed. The disinfecting spray module  22  includes a mounting board  48  formed from stainless steel. The mounting board  48  provides a convenient point of attachment for the remaining operating components of the disinfecting spray module  22 . 
         [0027]    A liquid container  50  is attached to the mounting board  48  by a pair of attachment flanges  52 . The attachment flanges  52  support the liquid container and are preferably formed from a metal material. The liquid container  50  may be formed from various different materials, but is shown in the embodiments of  FIGS. 5 and 6  as being formed from a molded plastic. The liquid container  50  receives the fill cap  46  which allows the liquid disinfectant or cleaner to be poured into the open interior of the liquid container. 
         [0028]    As best illustrated in  FIG. 6 , an outlet tube  54  extends from a bottom end of the liquid container  50  to an electric pump  56  through a strainer  55 . The electric pump  56  is operable to draw the liquid disinfectant from the liquid container  50  and supply the liquid disinfectant to the spray hose  26 . A discharge tube  58  extends from the pump  56  and is connected to the first end  28  of the spray hose  26  through a fitting  57 . 
         [0029]    In the embodiment shown in  FIGS. 5 and 6 , the pump  56  includes an electric drive motor that receives a supply of power from an electronic outlet within the facility being cleaned. Plug  44  contained on the power cord  42  provides the point of connection between the disinfecting spray module  22  and the main power supply for the facility. Power cord  42  is shown in the embodiments of  FIGS. 5 and 6  as stored on a reel  60 . The reel  60  is spring-biased and retracts the power cord  42  and can hold up to twenty-five feet of power cord. The reel  60  is mounted to the mounting board  48  by a support bracket  62  such that the reel  60  can rotate to dispense and accumulate the power cord  42 . 
         [0030]    Although the embodiment shown in  FIGS. 5 and 6  includes the retractable power cord that connects to a 110 volt GFI grounded electrical outlet, the disinfecting spray module could be configured to include a rechargeable battery pack that could run the pump  56  for up to eight hours. In such an embodiment, the battery pack would be positioned within the open interior defined by the outer housing and have a recharging terminal or terminals that would extend through the housing. Various different types of rechargeable batteries are contemplated as being within the scope of the present disclosure. 
         [0031]    In the embodiment shown in the drawing Figures, the liquid container  50  is sized to hold approximately 1.5 gallons liters of disinfectant, although other sizes for the liquid container are contemplated as being within the scope of the present disclosure. 
         [0032]    During operation, when an operator squeezes the trigger  36 , the built-up pressure of liquid within the spray hose  26  causes the disinfectant to be initially sprayed out of the spray nozzle  38 . As the pressure within the hose  26  decreases, the pump  56  senses the pressure drop and begins to operate. Operation of the electric motor in the pump  56  causes an additional supply of fluid to be drawn from the container  50  and supplied to the spray hose  26  and ultimately through the nozzle  38 . 
         [0033]    As illustrated in  FIG. 6 , the spray handle  32  includes a nozzle  38  that controls both the spray pattern and the droplet size of the spray of disinfecting solution from the spray module  22 . The specific design and configuration of the nozzle  38  was selected to insure that the liquid being dispensed from the disinfecting spray module  22  is dispensed in a fine spray and to avoid the creation of a mist. Since the disinfecting spray module  22  will be used in many different environments, including within a hospital, it is important to prevent the creation of a mist, since a mist can be inhaled by patients and cleaning personnel. Therefore, the nozzle  38  was specifically selected to create a desired size of droplets and spray patterns. 
         [0034]    In the embodiment shown in  FIG. 6 , the nozzle  38  includes a spray tip that creates a flat fan spray pattern with uniform distribution. At 40 psi, the nozzle creates a flat spray having a 65° spray pattern. Although a specific nozzle is described in the present disclosure, it should be understood that various different types of nozzles could be utilized while operating within the scope of the present disclosure. However, it is important that the nozzle size be selected to create a fine spray of liquid and not to create a mist. 
         [0035]    In accordance with the present disclosure, the nozzle  38  is selected such that at  40  psi, the nozzle creates a spray having droplet sizes preferably between 110 μm and 2500 μm. In the range of 100-2500 μm, the droplet size discharged from the nozzle  38  creates a fine spray and does not create a mist. As indicated above, it is important that the nozzle  38  create a fine spray rather than a mist to prevent uncontrolled inhalation and distribution of the mist in the area around the nozzle  38 . 
         [0036]    As illustrated in  FIG. 4 , the disinfecting spray module  22  is a self-contained unit that can be either mounted to the various types of cleaning carts shown in  FIGS. 1 and 2  or a luggage cart as shown in  FIG. 3 . Alternatively, the disinfecting spray module  22  can also be mounted at a stationary location, such as on a wall of a room where various products or equipment are disinfected on a regular basis. The self-contained disinfecting spray module  22  includes the self-contained cord such that the spray module  22  can be connected to a supply of power. Alternatively, a battery pack can be connected to the disinfecting spray module  22  to allow the spray module  22  to be driven by a rechargeable battery pack. 
         [0037]    The extendible, coiled hose  26  shown in the drawing Figures allows for a great range of movement of the spray handle  32  away from the module  22 . The nozzle  38  is selected to control the size of spray droplets from the disinfecting spray module  22  while providing a uniform, wide degree of spray coverage. 
         [0038]    In the preferred embodiment shown in the drawing Figures, the electric pump  56  was selected to both optimize the battery life and minimize the amount of noise created by the disinfecting spray module  22 . Since the spray module  22  is often used in a quiet, hospital environment, it is important that the electric motor that drives the pump  56  operate quietly to reduce the amount of noise created by the spray module  22 . Although various types of electric motors and pumps can be utilized while operating within the scope of the present disclosure, the specific electric motor selected minimizes the amount of noise created while providing the required pressure for distributing the disinfecting solution.