RELATED APPLICATIONS

[0001] This application claims priority benefit of U.S. Provisional Patent Application Ser. No. 63/193,728 filed May 27, 2021, entitled "Polishing Brush System," the complete disclosure of which, in its entirety is herein incorporated by reference.

BACKGROUND

[0002] Concrete or cement is a very popular material for use in floors and construction materials because of its strength, durability and low costs. The concrete may be left in an unfinished state, a partially finished state, or a completely finished state where a high gloss finish is provided. Such concrete floors are often cleaned by rotary driven brush machines, but these floor cleaning machines tend to deteriorate the surface of the concrete floor. These floor surfaces must then undergo polishing treatment so as to restore the floor back to a desirable appearance. Such polishing function may be beneficial for other types of floor surfaces as well, for example, terrazzo, marble, and granite. Accordingly, an improved polishing brush system is needed that may be used with traditional rotary flooring machines.

SUMMARY

[0003] Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

[0004] In accordance with one aspect of the present disclosure, a brush assembly for a floor machine is provided. The brush assembly includes a base having a top side attachable to a floor machine and a bottom side opposite the top side. An annular moat is offset within the bottom side and is configured to hold a plurality of cleaning elements secured within the annular moat via a curable material.

[0005] In some embodiments, a brush assembly for a floor machine includes a base having a top side attachable to a floor machine and a bottom side opposite the top side, an annular moat recessed within the bottom side and a plurality of cleaning elements secured within the annular moat and extending from the bottom side of the base. In a further embodiment, the plurality of cleaning elements are secured within the annual moat via a curable material. In another further embodiment, the cleaning elements each include a base portion configured to attach the base and an abrasive portion. In another further embodiment, the abrasive portion is overmolded to a distal end of the base portion. In another further embodiment, the cleaning elements are oriented along an axis that is angled in relation to a radius of the base. In another further embodiment, the brush assembly further includes a plurality of pockets disposed within the annular moat, each pocket configured to receive a cleaning element of the plurality of cleaning elements. In another further embodiment, the brush assembly further includes a plurality of pocket sets disposed within the annular moat, wherein each pocket of a pocket set is configured to receive a portion of the cleaning element base. In another further embodiment, the base of the cleaning element includes at least two spaced apart legs, wherein each pocket of a pocket set is configured to receive one of the two spaced apart legs. In another further embodiment, each pocket set includes a pocket set axis that is offset at an angle from a radius of the base. In another further embodiment, each cleaning element extends from the bottom surface of the base at an angle between about 25 degrees to about 75 degrees.

[0006] In accordance with another aspect of the present disclosure, a method for manufacturing a brush assembly is described. An exemplary method includes providing a base with an recessed annular moat, providing a plurality of cleaning elements each including a base portion and abrasive portion, positioning the base portion of each cleaning element of the plurality of cleaning elements within the annular moat, flooding the annular moat with a curable material, and, securing the plurality of cleaning elements to the base by curing the curable material. In a further embodiment, providing the plurality of cleaning elements includes overmolding the abrasive portion on a distal end of the base portion. In another further embodiment, the recessed annular moat includes a plurality of spaced apart pockets, wherein positioning the base portion of each cleaning element comprising placement of the base of the cleaning element into an associated pocket. In another further embodiment, cleaning element is positioned to extend from a bottom surface of the base at an angle of about 30 degrees to about 65 degrees. In another further embodiment, wherein each of the cleaning elements are clocked along an axis that is angled in relation to a radius of the base.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

[0008] FIGURE 1 is a perspective view looking at the top of an exemplary brush assembly in accordance with the present disclosure.

[0009] FIGURE 2A is a perspective view looking at the bottom surface of an exemplary housing / base utilized in the brush assembly of FIG. 1.

[0010] FIGURE 2B is a bottom plan view of the bottom surface of the exemplary housing / base utilized in the brush device of FIG. 1.

[0011] FIGURE 3A is a perspective view of a cleaning element in accordance with the present disclosure.

[0012] FIGURE 3B is a front view of the cleaning element of FIG.3A.

[0013] FIGURE 4 is a cross-sectional view of a cleaning element and brush assembly base in accordance with the present disclosure. [0014] FIGURE 5 is a block diagram of an exemplary method for manufacturing a brush assembly in accordance with the present disclosure.

DETAILED DESCRIPTION

[0015] The present disclosure is related to floor maintenance machines and specifically to a new and novel construction of brush devices/assemblies and systems adapted for detachable connection to a floor maintenance machine of the type particularly suited for use in commercial, institutional and industrial floor maintenance applications such as cleaning, buffing, burnishing and polishing. Such machines may include a series of cleaning pads and have various abrasive characteristics that are rotated upon actuation of the machine to perform maintenance operations including buffing, burnishing, spray-buffing, polishing, and the like.

[0016] FIG. 1 is a perspective view of an exemplary brush assembly 100 that may incorporate the principles of the present disclosure. The depicted brush assembly 100 is just one example tool assembly that can suitably incorporate the principles of the present disclosure. Indeed, many alternative designs and configurations of the brush assembly 100 may be employed, without departing from the scope of this disclosure.

[0017] As illustrated, the brush assembly 100 (hereinafter, "the brush 100") includes a base (or housing) 102 and a plurality of cleaning elements 104 (or blades 104). The base 102 is generally circular in shape and configured for attachment to a floor maintenance machine such as a rotary cleaning machine whereby the assembly 100 is rotated in a clockwise or counter clockwise direction. In the illustrated example, the brush 100 is configured for counter clockwise rotational operation, but it will be appreciated that the brush 100 may instead be configured for clockwise rotational operation without departing from the present disclosure.

[0018] The base 102 includes a bottom side 106 and a top side 108, separated by a sidewall (202) of a desirable thickness. The cleaning elements 104 are attached to the base 102 such that they extend substantially downward from the bottom side 106 and, in this manner, the bottom side 106 is configured for cleaning, preparing, abrading, etc. a floor surface. The top side 108 of the base is configured for attachment to a floor machine. In some embodiments, the top side 108 may include an attachment feature 110 that facilitates attachment of the brush 100 to a machine, clutch plate, or riser. While the attachment feature 110 is illustrated as a substantially circular raised plate with three spaced apart radially extending lobes 111, it is to be appreciated that other configurations and shape for connecting to floor machines may be substituted herein without departing from the scope of the present disclosure. Thus, for example, a clutch plate may be provided on the top 108 of the base 102 whereby the clutch plate couples the base 102 to the machine. Also, one or more additional components may be provided for helping or facilitating attachment of the assembly 100 to a particular type of floor machine. For example, a riser may be provided on the top side 108 of the base 102 and extend upward from the top side 108. A clutch plate may be provided on the top side of the riser (i.e., on an end of the riser opposite the other the base 102) to provide clearance between the base 102 and the floor machine if desirable. It should be noted, however, that the clutch plate, drive lug, and drive gimbals are not illustrated in the figures. Also, it should be noted, that the top side 108 of the base 102 without any such attachment features such as feature 110 or lobes 111 but may instead be provided as a flat surface and differently secured to the machine.

[0019] FIGS. 2A-2B illustrate an exemplary configuration of the base 102 utilized in the brush 100 of FIG. 1. In the illustrated example, the base 102 is substantially circular in shape (or a disc shape), and has an outer circumference or peripheral edge or sidewall 202. As shown, the base 102 includes an annular ("ring-shaped") moat 204 having a depth D creating a moat surface 205 that is offset into the bottom surface 106 of the base at a depth D. The annular moat 204 is substantially concentric with a central axis 201 normal to the bottom surface 106. By forming the moat 204 within the base 102, a peripheral tip 207 of the sidewall 202 is defined. That is, the peripheral tip 207 is a portion of the sidewall 202 that extends vertically from the base of the moat 204. As illustrated in the exemplary embodiment, the annular moat 204 extends inward from an inner surface of the peripheral tip 207 of the sidewall 202 by a distance X.

[0020] In some embodiments, the annular moat 204 is milled/routed into the bottom face 106 of the base 102 using a CNC milling machine or the like. In other embodiments, the base 102, including the annular moat 204 is created in a casting/molding process. In yet still other processes, the base 102, including the annular moat 204 is created by additive manufacturing methods including 3D printing.

[0021] The annular moat 204 is configured to receive a volume of curable material, such as an adhesive or epoxy. A plurality of cleaning elements 104 may be positioned within the annular moat 204 and secured to the base 102 via filling (and curing) the annular moat 204 with the curable material. For example, a plurality of cleaning elements may be held in place or otherwise positioned within the moat and subsequently secured to the base by filling the moat 204 with a curable material and solidifying the curable material.

[0022] In some embodiments, and with continued reference to FIGS. 2A-2B, the base 102 includes a plurality of pockets 210 (or recesses) extending into the moat surface 205 of the annular moat 204. Each pocket 210 is generally shaped to receive a corresponding cleaning element 104 for securement therein, for example, via a curing material. As illustrated in FIGS. 2A-2B, the base 102 may include a plurality of pocket sets 212, with each such pocket set 212 including at least two pockets 210 extending into (or formed within) the surface 205 of the annular moat 204.

[0023] When a cleaning element 104 is engaged with a corresponding pocket 210, the cleaning element 104 may be positioned such that an abrasive face of the cleaning element leans away from the direction of rotation of the base 102. (See FIG. 4) In some embodiments, portions of a cleaning element 104, such as portions of a cleaning element base abut surfaces/edges of the corresponding pocket 210, which provide support, strength and structural rigidity to the plurality of cleaning elements 104. [0024] Pockets 210 (or set 212) are arranged such that each pocket 210 (and therefore each cleaning surface of a cleaning element 104) is offset (clocked) at an angle b from a radius R of the base. In the exemplary embodiment of FIGS. 2A and 2B, each pocket 210 of the pocket set 212 is arranged within the annular moat 204 along a shared pocket set axis 214 wherein each pocket set 212 is configured to receive and mount a single cleaning element 104 to the base 102. In embodiments with a single elongated pocket 210, the long axis of the pocket is equivalent to the shared pocket axis 214.

[0025] As discussed in greater detail below, each cleaning element 104 associated with a pocket set 212 may having a cleaning element face that is substantially in line with the pocket set axis 214. That is, each pocket set axis 214 (and therefore each cleaning surface of a cleaning element 104) is offset (clocked) at an angle b from a radius R of the base. In other words, cleaning elements 104 inserted into pockets 210 and aligned with a pocket set axis 214 do not radially align along a radius R from a center point 201 of the base 102.

[0026] The cleaning elements 104 are mounted within the pockets 210 of the base 102 such that they are aligned or oriented along a secant or chord of the base 102 rather than along a radius R of the base 102. Thus, the pockets 210 and/or pocket sets 212 provided in the base 102 are positioned so as to orient and align the cleaning elements 104 along a secant or chord rather than a radius R of the base 102. In this manner, the cleaning elements 104 are clocked outward (i.e., generally face outward from the peripheral sidewall 202) to push (or kick) debris outside of the footprint of the brush assembly 100 during rotational operation of the brush 100.

[0027] In some embodiments, each pocket 210 is symmetric about a plane normal to the surface 106 and passes through the pocket set axis 214, for example each pocket 210 may show mirror symmetry about the pocket set axis 214. However, it is to be appreciated that symmetry of pockets is not limiting. [0028] In some embodiments, and as illustrated in FIGS. 2A- 2B, each pocket 210 has a horizontal cross-section that is substantially dog- bone-shaped (or letter H-shaped) as best viewed in FIG. 2B. However, it is to be appreciated that the shape of the horizontal cross-section is not limiting and that other cross-sectional pocket shapes may be used in accordance with the present disclosure. Each of the pockets 210 may be shaped so that the cleaning element 104 provided therein may be set with the front facing cleaning face oriented in a direction for counter-clockwise rotation of the housing 102 or instead may be set therein with the front facing cleaning face oriented in a direction for clockwise rotation of the housing 102.

[0029] FIGS. 3A and 3B illustrate an exemplary cleaning element 104 in accordance with one or more embodiments of the present disclosure. Each cleaning element 104 includes a base portion 302 having a thickness Y and an abrasive portion 310. The base portion 302 may be made of various materials, for example, a polymer material. The base portion 302 is configured to be set within a pocket 210 recessed into the annular moat 204. The pocket 210 is then filled with a curable material that secures the cleaning element to the base 102.

[0030] In the illustrated embodiment, each cleaning element 104 is configured to set within a pocket set 212. In these embodiments, the base portion 302 may include at least one leg 304a, 304b, shaped for insertion into a respective one of the pockets 210 of the set 212 and having a bottom most edge 306. In embodiments wherein the base portion 302 includes two legs 304a, b, each leg may be spaced apart via a saddle potion 303. In some embodiments, the saddle portion 303 is configured to abut and rest upon the moat surface 205 when the legs 304a, b, are inserted into corresponding pockets 210. In other embodiments, no such saddle portion 303 is provided, but instead the bottom most edge 306 of the base 302 is unbroken and contacts the base of the moat pocket 210.

[0031] In some embodiments, at least one leg 304a, 304b of the base portion 302 includes at least one adhesive aperture 305. The adhesive aperture 305 is positioned such that when the base portion 302 (and/or legs thereof) are inserted into the pocket, the adhesive aperture 305 or a portion thereof is also within the pocket 210. Curing material may flow through the adhesive aperture 205 and when cured, interlock the polymer base portion 302 within the moat 204.

[0032] Each cleaning element 104 also includes an abrasive portion

310 (adjacent to the base portion 302) having at least one abrasive face

311 that faces the direction of travel of the brush in the offset manner described above. In some embodiments, the abrasive portion 310 is overmolded to a bottom/distal end 307 (illustrated as the portion in dashed lines of FIG. 3B) of the base portion 302. The overmolded abrasive portion 310 may be a mixture of epoxy and abrasive particulate (e.g., diamond grit), and the abrasive particulate may have various grit sizes or combinations of grit. The at least one face 311 of the cleaning element 104 is configured for contacting a floor surface and thereby provide the abrading or cleaning function of the brush 100 when utilized. The abrasive material may include various types of particulate or grit (e.g., diamond grit) of various grit sizes or combinations of grit sizes.

[0033] The distal end 307 of the base portion 302 is may be configured to lock to the over-molded abrasive portion 310. In some embodiments, the distal end 307 of the polymer base portion 302 may include at least one aperture 309 through which the overmolded material may flow and thus interlock the abrasive portion 310 onto the polymer base 302. In the illustrated example, the distal end 307 also includes a distally extending tab 313 that will be contained within the overmolded material of the abrasive portion 310 and may help provide stiffness or enhance stiffness of the abrasive portion 310. In the illustrated example, the base 302 includes just one tab 313 aligned with the central aperture 309, but more than one such tab 313 may be provided, for example, with two or more such tabs 313.

[0034] FIG. 4 illustrates a vertical cross-section of the base 102 about a pocket 210 with the base portion 302 of cleaning element 104 inserted within at least one pocket 210. Each pocket 210 includes a bottom pocket surface 216 at a pocket depth P within the moat 204. Each pocket 210 also includes a first substantially vertical sidewall 217 and an opposing second substantially vertical sidewall 218 connected via a substantially horizontal bottom surface 216. Each pocket 210 has a bottom width W that provides a spaced apart distance from the first sidewall 217 to the second sidewall 218.

[0035] Each cleaning element 104 is configured for insertion into a pocket 210 and/or pocket set 212. Generally, the thickness Y of the base 302 of the cleaning element 104 is less than the width W of the pocket 210. This allows each cleaning element 104 to be positioned such that the cleaning element "leans" in a desired direction. That is, the bottom edge 304 of the base portion contacts the bottom surface 216 of the pocket proximate to the first wall 217. A rear surface 318 of the polymer base portion 302 leans on, and is supported by a top edge 219 of the second wall 218. Once placed, a curing material is flooded into the moat 204 and pockets 210 and cured, thereby securing each cleaning element 104 to the base at a preferred orientation. The "lean" may be defined by an interior angle 405 between a rear face 340 of base portion 302 of cleaning element 104 and the surface 205 of the moat 204 and/or the bottom surface 106. That is, the cleaning elements 104 extend from the bottom surface 106 and an angle 405 generally rearward (away from the direction of rotation). The angle 405 may range from about 30 degrees to about 65 degrees. In some preferred embodiments the angle 405 is about 55 to about 65 degrees. In some other preferred embodiments, the angle 405 is about 59 degrees.

[0036] It is to be appreciated that the cleaning elements 104 may be placed in an opposite orientation. That is, rather than having the bottom edge 306 contact the first walls 217 and bottom surface 216 of the pocket (while leaning against the second wall), the cleaning element 104 may be placed such that the bottom edge 306 contacts the second wall 218 and bottom surface 216 (while having a portion lean against the first wall 217). In this way, only one base configuration is needed for manufacturing brush assemblies 100 that may be configured for clockwise (CW) rotation or counter clockwise (CCW) rotation. In other embodiments, the cleaning elements 104 may be placed in corresponding pockets 210 such that the cleaning element 104 is substantially perpendicular to the base 102, i.e., not an at angle.

[0037] In some embodiments, the saddle portion 303 between legs 304a, 304b is configured to contact and rest upon a surface 205 of the moat 204 between two adjacent pockets 210 (see FIG. 2B). In other embodiments, the saddle portion 303 is shaped to provide a gap between the surface 205 of the moat 304 allowing curing material to flow therethough and strengthen the attachment of the cleaning element 104 to the base 102.

[0038] FIG. 5 illustrates an exemplary method 500 for manufacturing a brush assembly, similar in many aspects to the brush assembly 100 of FIG. 1, in accordance with the present disclosure. At block 502, a base 102 is provided. In some embodiments, this includes providing a disc of machineable material, for example and without limitation, metals or plastics. The base or disc 102 is then machined to mill/cut an annular moat 204 within the base 102 at a depth D, creating a recessed surface 205 configured to hold a volume of curable material. In other embodiments, the base 102 cast into a shape including an annular moat 204. In yet still other embodiments, the base 102 along with an annular moat 204 is created via additive manufacturing methods, e.g., 3D printing.

[0039] In some embodiments, at block 502 the exemplary method 500 includes providing a plurality of pockets 210 in a spaced apparat relationship within the annular moat 204. In some embodiments, this may include milling/cutting pockets 210 and or pocket sets 212. In other embodiments, the pockets 210 may be formed while casting or 3D printing the base.

[0040] Separately and with reference to block 504, the method includes providing cleaning elements 104 configured for insertion into the pockets 210. As briefly mentioned above, this includes providing a polymer base portion 302 and an adjacent abrasive portion 310. In some embodiments, the abrasive portion 310 is overmolded on a distal end 307 of the base portion 302.

[0041] At block 506, a determination is made regarding the desired rotation of the brush assembly 100. That is, a brush assembly may be configured for clockwise (CW) rotation or counter clockwise rotation (CCW). The determined rotation direction will further determine any lean and positioning of the cleaning elements 104 within the moat 204.

[0042] At block, 508, the cleaning elements 104 are positioned within the moat 204 of the base 102 based on the determined rotation of the brush assembly 100. In embodiments without pockets 210, the cleaning elements are held in place having a "lean" away from a direction of rotation. In some embodiments, the cleaning elements 104 are clocked outward (i.e., generally face outward from the peripheral sidewall 202) to push (or kick) debris outside of the footprint of the brush assembly 100 during rotational operation of the brush 100. In some embodiments, each cleaning element 104 is clocked at an angle b from a radius R of the base such that the face 311 does not radially align with a center point 201 of the base 102.

[0043] In embodiments including pockets 210 or sets of pockets 212, the base portion 302 or legs 304a,b of cleaning elements 104 are placed into the pockets 210 such that the corresponding cleaning element 104 "leans" away from a direction of rotation and is supported by an edge, e.g., edge 219 pf the pocket 210.

[0044] At block 510, a volume of curing material is added to the moat 204 such that the curing material fills in spaces between the cleaning elements 104 and base 102. The curing material may be an adhesive material and/or epoxy that solidifies under certain conditions. For example, the curing material may be a UV curable material, wherein ultraviolet light is used to initiate a photochemical reaction that generates a cross-linked network of polymers. In other embodiments, the curable material is a heat curable material wherein application of heat produces a hardening of a material, e.g., by cross-link polymer chains. In some embodiments, the curing material is an epoxy resin, which may be cured with a catalyst/ reactant to initiate cross-linking. While the present disclosure lists several examples of curable materials, it is to be appreciated that this list is not limiting and that other materials that flow to conform to a shape (e.g., within the moat) and harden to attach a cleaning element 104 may be used without departing from the scope of this disclosure.

[0045] At block 512, the curable material is cured in accordance with the material's characteristics. For example, UV curable material is curved with the application of UV light to the curable material and thermos curable material is cured with the application of heat. The cured brush assembly (with attached cleaning elements 104) may then be connected to a floor machine and rotated to treat a floor surface.

[0046] Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of" or "consist of" the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

[0047] The terms "proximal" and "distal" are defined herein relative to a user of a floor machine having an interface configured to mechanically couple a tool to a rotary portion of the machine. The term "proximal" refers to the position of an element closer to the user or the rotary portion of the machine and the term "distal" refers to the position of an element further away from user or the rotary portion of the machine. Moreover, the use of directional terms such as above, below, upper, lower, upward, downward, left, right, and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

[0048] As used herein, the phrase "at least one of" preceding a series of items, with the terms "and" or "or" to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase "at least one of" allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

[0049] To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112(f) unless the words "means for" or "step for" are explicitly used in the particular claim.