Abstract:
The claimed carpet cleaning apparatus incorporates recesses in a rigid surface of a roller or in a rigid disk. As the roller or disk rotates or is moved across the soft surface to be cleaned, the roller or disk presses downward on the soft surface and compresses it. The soft surface decompresses to the original position when the soft surface is in contact with a surface of a recess and recompresses when the roller or disk presses downward again. The compression, decompression, and recompression, preferably in combination with a cleaning compound, provide the mechanical action necessary for removal of foreign material.

Description:
CLAIM OF PRIORITY 
     This application is a continuation of U.S. Nonprovisional application Ser. No. 11/249,671 filed on Oct. 13, 2005, which is a continuation in part of U.S. Nonprovisional application Ser. No. 10/964,015 filed on Oct. 13, 2004, now abandoned which claims priority to U.S. Nonprovisional application Ser. No. 10/832,519 filed on Apr. 27, 2004, and U.S. Provisional Application No. 60/513,689 filed Oct. 23, 2003. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to devices for soft surface cleaning, such as carpet or rug cleaning. In particular, the invention relates to a novel roller or disk used with carpet cleaning devices. Rather than the conventional brush arrangement that is present on conventional agitators, the claimed invention utilizes a novel configuration of indentations on the rigid surface of a roller or disk. 
     BACKGROUND OF THE PRIOR ART 
     Typically, soft surface cleaning involves the use of a soft surface cleaning device. A soft surface cleaning device typically comprises cylindrical agitators containing a brush or cloth. The agitator is moved across the soft surface or turned upon the soft surface to provide mechanical action to dislodge foreign matter and debris. 
     Traditional agitators can cause deterioration to the soft surface material. The damage caused can be attributed to the conventional agitator&#39;s orientation, pressure, and abrasiveness. Often times, conventional agitators will accomplish the opposite of that which they are designed to accomplish. That is, a conventional agitator having groupings of brush bristles have been known to thrust the debris into the irregularities of the soft surface, rather than simply dislodging the debris for eventual removal. Also, groups of bristles on a conventional brush could be pulled through the fiber of the soft surface, e.g., carpet, causing potential distortion and damage to the soft surface. 
     Thus, there exists a need for a soft surface cleaning apparatus that reduces damage to soft surfaces, such as carpet, while being equally if not more effective than conventional agitators. Further, there exists a need for a soft surface cleaning apparatus that will not thrust debris into the surface being cleaned, but rather will aid in the removal of such debris. 
     SUMMARY AND OBJECT OF THE INVENTION 
     In an embodiment, the soft surface cleaning apparatus of the claimed invention comprises a rotatable cylindrical roller having a rigid surface that incorporates recesses therein for contact with a soft surface to be cleaned, and a rotatable support means. As the roller rotates and/or is moved across the surface, the rigid surface contacts and presses downward on the soft surface to be cleaned and compresses it. The recesses in the surface of the roller provide the opportunity for areas of the soft surface to temporarily decompress to their original position and then recompress again when the rigid surface of the roller contacts and presses down on the soft surface again. This repeated compression, decompression, and recompression, preferably in combination with a cleaning compound, provides the mechanical action necessary for removal of foreign material from deep within the soft surface. The roller preferably comprises recesses having a cone shape, but may incorporate recesses of various lengths, depths, shapes, and configurations. 
     In another aspect of the invention, the soft surface cleaning apparatus comprises a rigid rotatable disk with a plurality of spaced-apart recesses therein for contact with a soft surface to be cleaned, and a rotatable support means. As the disk rotates and is moved horizontally across the soft surface, there is a repeated compression, decompression, and recompression of the soft surface, preferably in combination with a cleaning compound, that removes foreign matter from deep within the soft surface, as described above. 
     The recesses embedded in the rigid surface of the roller or the rigid disk insure consistent pressure with no build up of heat or sideward compression or rebound of the soft surface where such action could cause distortion or damage. 
     Therefore, it is an object of the invention to reduce or eliminate damage to soft surfaces during cleaning, while retaining or surpassing the effectiveness of conventional style cleaning. 
     It is further object of the invention to remove debris from within the soft surface being cleaned, preferably in combination with a cleaning compound, while thrusting little or no debris into the soft surface. 
     It is still a further object of the invention to prolong the useful economic life of soft surfaces by effectively cleaning them without damaging or distorting them. 
     It is still a further object of the invention to cause less strain on the motor of the soft surface cleaning machine as compared to conventional bristle orientations, which create large amounts of friction. 
     It is still another object of the invention to provide a soft surface cleaning apparatus that requires minimum maintenance. 
     It is another object of the invention to provide an apparatus for cleaning soft surfaces that reduces cleaning costs and increases productivity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevational view of a cylindrical roller having cone shaped recesses according to the present invention. 
         FIG. 2  is a sectional view of the invention from line  2 - 2  in  FIG. 1 . 
         FIG. 3  is a side elevational view of a cylindrical roller having dimple shaped recesses according to the present invention. 
         FIG. 4  is a sectional view from line  4 - 4  in  FIG. 3 . 
         FIG. 5  is a side elevational view of a cylindrical roller having oblong recesses according to the present invention. 
         FIG. 6  is a sectional view from line  6 - 6  in  FIG. 5 . 
         FIG. 7  is a side elevational view of a cylindrical roller having dimple shaped recesses arranged in a v-shaped configuration according to the present invention. 
         FIG. 8  is a sectional view from line  8 - 8  in  FIG. 7 . 
         FIG. 9  is a side elevational view of a cylindrical roller having grooved recesses arranged in a V-shaped configuration according to the present invention. 
         FIG. 10  is a sectional view from line  10 - 10  in  FIG. 9 . 
         FIG. 11  is a side elevational view of a cylindrical roller having oblong shaped recesses according to the present invention. 
         FIG. 12  is a sectional view from line  12 - 12  in  FIG. 11 . 
         FIG. 13  is a side elevational view of a cylindrical roller having grooved recesses extending substantially the length of the roller according to the present invention. 
         FIG. 14  is a sectional view from line  14 - 14  in  FIG. 13 . 
         FIG. 15  is a side elevational view of a cylindrical roller having dimple shaped recesses according to the present invention. 
         FIG. 16  is a sectional view from line  16 - 16  in  FIG. 15 . 
         FIG. 17  is a side elevational view of a cylindrical roller having grooved recesses arranged in a v-shaped according to the present invention. 
         FIG. 18  is a sectional view from line  18 - 18  in  FIG. 17 . 
         FIG. 19  is a bottom view of a rotatable disk according to the present invention. 
         FIG. 20  is a front elevational view of an example of a soft surface cleaning device having a pair of cylindrical rollers mounted thereon. 
         FIG. 21  is a bottom view of an example of a soft surface cleaning device having a pair of cylindrical rollers mounted thereon. 
         FIG. 22  is a front elevational view of an example of an end of a cylindrical roller having a rotatable support means. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIGS. 1-18  show examples of an embodiment of the claimed soft surface cleaning apparatus. In the examples shown, the claimed apparatus comprises a rotatable cylindrical roller  10  having a rigid surface  15  with a plurality of spaced-apart recesses  30 ,  32 ,  34 ,  36 ,  38 ,  40 , in embodiment exemplified, therein for contact with a soft surface to be cleaned, such as, for examples, carpets or rugs. A rotatable support means  60  for rotatably supporting the roller  10  and for attaching roller  10  to cleaning device  200  is also shown. Alternatively, the cylindrical roller can be a solid cylinder with support means to permit rotation. The rigid surface is made of, for examples, polyethylene, polypropylene, thermoelastic polymer (TEP), polystyrene or like material, or a metal, such as stainless steel or aluminum. Preferably, the rigid surface  15  is non-absorbent. 
     In a preferred embodiment, a rotatable support means  60  comprises an axle attachment means that holds the axle in place (not shown). The axle rod extends through the center of cylindrical roller  10 . Rotation of the axle causes roller  10  to rotate. In the examples shown in  FIGS. 3 and 22 , the rotatable support means is a pair of end caps  70 , one inserted into each end  17 ,  18  of the roller  10 . Each end cap  70  has axle attachment means  60  inserted therein. In another embodiment, the rotatable support means is a pair of end caps  70 , each end cap  70  containing a first mating piece that has a complementary shape to a second mating piece on the soft surface cleaning device (not shown). The rotation of the second mating piece causes the first mating piece and the roller  10  to rotate. 
     The recesses  30 ,  32 ,  34 ,  36 ,  38 ,  40  in the rigid surface  15  of the roller  10  are indentations of various depths. Preferably each recess configuration is the same on a particular roller to facilitate manufacture. The selected recesses  30 ,  32 ,  34 ,  36 ,  38 ,  40  do not extend through the rigid surface  15  (i.e., they are not openings through the cylinder). Recesses  30 ,  32 ,  34 ,  36 ,  38 ,  40  are formed in rigid surface  15  by any method well known in the art, including routing, molding, or milling for example. As shown in  FIGS. 1-18 , recesses may comprise a cone  30 , groove  38 , circle  36 , dimple  32 , oblong  34 ,  40 , cross (not shown), or any other configuration. Preferably, at least one perimeter edge  20  of each recess  30 ,  32 ,  34 ,  36 ,  38 ,  40  is beveled so that the edge  20  provides a transition zone for the fibers or carpet, thereby minimizing damage to the soft surface being cleaned by creating an edge that is not likely to snag fibers of the soft surface. In another preferred embodiment, there is a frusto-conical bevel that surrounds a cone-shaped recess (not shown). In these embodiments, no part of the recesses  30 ,  32 ,  34 ,  36 ,  38 ,  40  protrudes above the rigid surface  15  of the roller  10 . Preferably, the recesses have a depth “C” at their deepest point that ranges from about 1/16 inch to about 1 inch. More preferably, “C” ranges from about ⅛ inch to about ½ inch. Most preferably, “C” is about ¼ inch. Preferably, the recesses have an outermost diameter “D” that ranges from about ⅛ inch to about 2 inches, and more preferably from about ¼ inch to about 1 inch. In those examples where the recesses have a larger diameter “D”, there are fewer recesses in the rigid surface. In those examples where the recesses comprise oblong channels or grooves, the recesses may have a length “L” ranging from about ⅛ inch to a length that is a subset the length of the cylinder. These oblongs or grooves may have a width “W” that ranges from about ⅛ inch to about 1 inch. As shown in  FIGS. 1-18 , recesses  30 ,  32 ,  34 ,  36 ,  38 ,  40  may be arranged on the rigid surface  15  of the cylindrical roller  10  in any of a variety of configurations. In a preferred example shown in  FIG. 1 , the recesses  30  substantially cover the rigid surface  15  of the roller  10  and are arranged in a circular configuration around the diameter of the roller  10 . In another example shown in  FIG. 3 , the recesses  32  are arranged in a spiral row that substantially extend the length “A” of roller  10 . In other examples, the rows of recesses are substantially V-shaped (see  FIGS. 7 ,  9 ,  17 ). Other examples are also shown in  FIGS. 1-18 . In examples, the arrangement or configuration of the recesses may determine or influence the number and/or size of the recesses. 
     The cylindrical roller  10  may be either solid or hollow. Those skilled in the art will appreciate that the length “A” and diameter “B” of the cylindrical roller  10  may be determined by the specifications of the soft surface cleaning device  200  to which the roller  10  will be attached. The environment in which roller  10  will be used may also determine length “A” and diameter “B” of the roller. For example, a roller for use in a commercial environment may have a longer length “A” and greater diameter “B” (see  FIGS. 1 ,  3 ,  5 ,  7 ,  9 ,  11 ) compared to those for use in a residential environment (see  FIGS. 13 ,  15 ,  17 ). In examples shown, length “A” of cylindrical roller  10  preferably ranges from about 10 inches to about 60 inches, and more preferably ranges from about 15 inches to about 40 inches. Most preferably, length “A” of cylindrical roller  10  is about 25 to 30 inches. Diameter “B” of cylindrical roller  10  preferably ranges from about 2 inches to about 12 inches, and more preferably from about 3 inches to about 8 inches. Most preferably, diameter “B” of cylindrical roller  10  is about 4 inches. 
     In another embodiment shown in  FIG. 19 , the soft surface cleaning apparatus is a rigid rotatable disk  110 . As described above for the cylindrical roller  10 , the rigid rotatable disk  110  has a plurality of spaced-apart recesses  130  therein for contact with a soft surface to be cleaned. There is a rotatable support means (not shown) for rotatably supporting the disk and for attaching disk  110  to cleaning device  200 . 
     The range of depths C 1  and diameters D 1  or lengths (not shown), depending on shape, of the recesses  132  in the rigid disk  110  are about the same as those described above. The recesses  132  may be arranged on the rigid disk  110  in any variety of configurations. In the example shown in  FIG. 6 , the recesses  132  are arranged in a series of circular patterns over a contacting surface  115  of the disk  110 . The skilled artisan will appreciate that the thickness (not shown) and diameter B 1  of the rotatable disk  110  may be determined by the specifications of the soft surface cleaning device  200  to which the disk  110  will be attached and/or by the environment in which the disk  110  will be used. For example, a rotatable disk  110  for use in a commercial environment may have a larger diameter B 1  than those for use in a residential environment. In examples, the diameter B 1  of the rotatable disk  110  preferably ranges from about 6 inches to about 20 inches, and more preferably is about 10 inches. In examples, the thickness of the rotatable disk  110  preferably ranges from about ¼ inch to about 1 inch, and most preferably is about ½ thick. 
     There is a rotatable support means for rotatably supporting the disk and for attaching the disk to the cleaning device  200 . Examples are similar to those described above. 
     In use, the claimed soft surface cleaning apparatus is attached to a soft surface cleaning device  200 . An example of a conventional soft surface cleaning device  200  having a pair (only one roller is visible from this front view) of cylindrical rollers  10  mounted thereon is shown in  FIG. 20 . There is a rotatable support means  60  and a means for powering the rotatable support means (not shown) so that the pair of rollers  10  can contact and rotatably engage a soft surface, as described below. The means for powering the rotatable support means  60  is a gear driven motor, for example. A bottom view of the device  200  having a pair of cylindrical rollers  10  mounted thereon is shown in  FIG. 21 . 
     In another alternate embodiment, the claimed apparatus is an adapter in the form of a sleeve or cover that can be placed on or attached to a conventional soft surface cleaning device; i.e., one that does not have spaced-apart recesses. In one embodiment, the adapter is a cylindrical sleeve having a rigid surface with a plurality of spaced apart recesses therein for contact with a soft surface to be cleaned. In another embodiment, the adapter is a rotatable rigid disk-shaped cover with a plurality of spaced apart recesses therein for contact with a soft surface to be cleaned. The adapters have a configuration that is complementary to an attachment means on the soft surface cleaning device. In an example, the cylindrical sleeve is placed over a conventional core and an inner surface of the sleeve is in frictional engagement with an outer diameter of the conventional core. In another example, the disk-shaped cover is placed over the conventional disk core and may have a securing means such as an elastic band or cinching straps around its perimeter to more effectively secure the cover to the core. Once placed on or secured to the core, the adapter will function in the same way and will provide the same advantages as described herein and above. The method of using the adapters is substantially the same as the methods of use described above. 
     A method of using the cylindrical soft surface cleaning apparatus is described as part of the invention. In a first step, the cylindrical roller  10  is attached to the soft surface cleaning device  200  by the rotatable support means  60 , as shown in  FIGS. 20-21 . Next, the means for powering the rotatable support means is started. Then, the device  200  with the roller  10 , and optionally a pair of rollers  10  attached is moved forwards and backwards across the soft surface to be cleaned so that the roller  10  rotatably contacts and engages the soft surface. The cylindrical roller  10  rotates about the x-axis. As the roller  10  rotates, a plurality of points on the soft surface come into contact with or are engaged by the rigid surface  15  of the roller  10 . Each of the points of the soft surface that is in contact with the rigid surface  15  is compressed. As the roller  10  rotates, each of the points of the soft surface eventually comes into contact with a surface of one of the plurality of recesses, in this case recess  30 . When a point on the soft surface is in contact with a surface of one of the recesses  30 , the point on the soft surface is decompressed. As the roller  10  continues to rotate, the point on the soft surface again eventually comes into contact with the rigid surface  15  of the roller  10 , recompressing the point. The alternating compression, decompression, and recompression of the soft surface are achieved by the spaced-apart recesses  30  and provide a gentle and effective mechanical action necessary to massage the soft surface. The design of the claimed invention enhances removal of foreign matter from deep within the irregularities of a soft surface without pulling on the soft surface material. The steps of moving the apparatus and compressing, decompressing, and recompressing the soft surface may be repeated at least one time to maximize removal of debris and foreign matter from the soft surface. The claimed method may further comprise the step of applying cleaners to the soft surface, as described below. 
     A method of using the rigid disk shaped soft surface cleaning apparatus is also claimed. In a first step, the disk  110  is attached to the soft surface cleaning device (not shown) by the rotatable support means. Next, the means for powering the rotatable support means is started. Then, the device  200  with the disk-shaped apparatus attached is moved horizontally across the soft surface to be cleaned so that the disk  110  rotatably contacts and engages the soft surface. The disk  110  rotates about the y-axis. As the disk rotates, a plurality of points on the soft surface come into contact with or are engaged by the rigid disk  110 . Removal of debris and foreign matter is enhanced from deep within the soft surface, as described in detail above. As the disk  110  rotates, there is an alternating compression, decompression, and recompression of the points on the soft surface as the points alternately come into contact with a plurality of points on the rigid disk  110  and a surface of one of the plurality of recesses in the rigid disk  110 . As described above, the steps of moving the apparatus and compressing, decompressing, and recompressing the soft surface may be repeated at least one time to maximize removal of debris and foreign matter from the soft surface. The claimed method may further comprise the step of applying cleaners to the soft surface, as described below. 
     The claimed design allows for the use of both wet and dry cleaning chemicals or compounds to be used to assist in foreign matter removal. The skilled artisan will appreciate the variety of cleaning compounds used for soft surface cleaning. There is no restriction on what cleaning compound could be used with the present invention. It has been found that the recesses or indentures in the rigid surface of the roller or the rigid disk facilitate the insertion of a cleaning chemical or compound into the irregularities of the soft surface to assist in causing the release of foreign matter that is adhered to and within the soft surface. The compression and decompression of the soft surface caused by the claimed agitator, along with a cleaning compound, assists in the removal of foreign matter. As described above, this is because the recesses facilitate the mechanical removal of foreign matter as the soft surface cleaning apparatus moves across the soft surface. 
     While the foregoing has been set forth in considerable detail, it is to be understood that the drawings and detailed embodiments are presented for elucidation and not limitation. Design variations, especially in matters of shape, size and arrangements of parts maybe made but are within the principles of the invention. Those skilled in the art will realize that such changes or modifications of the invention or combinations of elements, variations, equivalents or improvements therein are still within the scope of the invention as defined in the appended claims.