SURFACES

TECHNICAL FIELD

[0001] The apparatus, method and system described below relate generally to caring for hard or soft surfaces, and more specifically, to a rotary head configured to rotate about a longitudinal centerline axis and contact a hard or soft surface to mop, scrub, polish or buff the hard or soft surface.

BACKGROUND

[0002] The typical method of cleaning surfaces such as hard floors is to use a wet mop.

The mopping process traditionally involves a cycle of dipping the mop in a bucket of water, moving the wet mop across the floor to clean the surface, and dipping the same mop back in the bucket of water to remove the dirty water trapped in the mop material. The mop can be repeatedly rubbed vigorously on the floor in order to scrub particularly dirty areas or to perform more thorough cleaning. This practice is laborious, manually intensive and time-consuming. Further, this method can be somewhat ineffective and unsanitary because the water in the bucket quickly becomes dirty, and it is that same dirty water which is re-used to mop remaining parts of the floor. [0003] Polishing or buffing a surface such as a hard floor typically requires expensive, cumbersome machinery that is specialized for those particular tasks. Thus the required equipment may not be ideally suited or economical for household use.

SUMMARY

[0004] In accordance with one embodiment, an apparatus comprises a rotary head having a longitudinally extending core with an outer surface and which defines a longitudinal centerline axis. The rotary head also has a covering that is disposed on the outer surface of the core and that includes a radially extending material. The rotary head is configured so as to couple to a rotatable shaft of a floor-care system and rotate about the longitudinal centerline axis.

[0005] In another embodiment, a method of treating a floor comprises rotating about a longitudinal centerline axis a rotary head that includes a longitudinally extending core having an outer surface and defining a longitudinal centerline axis, and a covering disposed on the outer surface of the core that includes a radially extending material. The method includes contacting the floor with the radially extending material of the rotary head and translating a floor-care system that includes the rotary head across the floor.

[0006] In another embodiment, a system comprises a floor-care system that includes a rotatable shaft and a detachable rotary head. The detachable rotary head includes a

longitudinally extending core having an outer surface and a longitudinal centerline axis, and a covering that is disposed on the outer surface of the core, which includes a radially extending material. The detachable rotary head is configured to couple to the rotatable shaft and rotate about the longitudinal centerline axis.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Certain embodiments will be better understood from the following description taken in conjunction with the accompanying drawings in which:

[0008] FIG. 1A is a perspective view depicting a rotary head in accordance with one embodiment;

[0009] FIG. IB is a side view of FIG. 1A;

[0010] FIG. 1C is a side view of a rotary head in accordance with another embodiment wherein the core has a partially hollow, ribbed configuration;

[0011] FIG. ID is a side view of a rotary head in accordance with another embodiment wherein the core is substantially solid;

[0012] FIG. 2A is a schematic representation of individual nap elements of the rotary head of FIG. 1 A, with the nap elements formed as strings;

[0013] FIG. 2B is a schematic representation of individual nap elements of the rotary head of FIG. 1 A, with the nap elements formed as loops; [0014] FIG. 3A is a front view depicting a rotary head rotatably mounted in a housing as part of a floor-care system;

[0015] FIG. 3B is a cross-sectional view taken along line 3B-3B of FIG. 3A;

[0016] FIG. 4A is a front view of the rotary head of FIG. 1 and a pair of associated bearing assemblies;

[0017] FIG. 4B is a side view of the rotary head of FIG. 1A and one of the bearing assemblies depicted in FIG. 4A;

[0018] FIG. 4C is a cross-section view taken along line 4C-4C of FIG. 4B;

[0019] FIG. 5A is a side view of the rotary head of FIG. 1A contacting an extraction structure;

[0020] FIG. 5B is an enlarged cross-sectional view of the rotary head of FIG. 1A and the extraction structure taken along line 5B-5B of FIG. 5A;

[0021] FIG. 5C is a side view similar to FIG. 5A, but with of the rotary head spaced from the extraction structure;

[0022] FIG. 5D is an enlarged cross-sectional view of the rotary head of FIG. 1A and the extraction structure taken along line 5D-5D of FIG. 5C;

[0023] FIG. 6 is a side view depicting an additional embodiment of a rotary head, with a reinforcement layer included between a core and a covering; [0024] FIG. 7A is an additional embodiment of a rotary head, with a belt engaging the nap of the rotary head;

[0025] FIG. 7B is an additional embodiment of a rotary head, but with a section of the core exposed for direct engagement with the belt; and

[0026] FIG. 7C is a further embodiment of a rotary head, but with a section of the core being exposed and having an indented portion for the belt to directly engagement the core.

DETAILED DESCRIPTION

[0027] Selected embodiments are hereinafter described in detail in connection with the views and examples of FIGS. 1A-1D, 2A-2B, 3A-3B, 4A-4C, 5A-5D, 6 and 7A-7C, wherein like numbers indicate the same or corresponding elements throughout the views.

[0028] A rotary head 10 in accordance with one embodiment is described in connection with FIGS. 1A-1D and other figures. As shown in FIG. 1A, the rotary head 10 can include a longitudinally extending, generally cylindrical core 20 and a covering 30. The longitudinally extending core 20 can define a longitudinal centerline axis 21. The rotary head 10 can be rotatable about the longitudinal centerline axis 21. The rotary head 10 can have a first end 22 and a second end 24. The core 20 can be hollow, partially hollow, or substantially solid and can have an outer surface 28. When hollow or partially hollow, the core 20 can have an inner surface 26 in addition to the outer surface 28. Preferably, the core 20 is at least partially hollow to allow for insertion of a bearing assembly in each of the first end 22 and second end 24. FIGS. Al and IB depict a hollow core, for example. In another embodiment, FIG. 1C depicts a rotary head 10 with a core 20 which is partially hollow and includes fins 23 that extend radially outward from the core 20 to contact the covering 30. In another embodiment, the core 20 can be filled or partially filled. In an additional embodiment shown in FIG. ID, the core 20 can be configured to be substantially solid.

[0029] The core 20 can be comprised of a one or more materials, and can generally be composed of plastics, metals or composites. A core 20 made of thermoplastic or thermoset material can have certain advantages in bonding with the materials used in the covering 30. One advantage, for example, is that when a covering 30 is secured by heat bonding or by an adhesive to a core 20 made of thermoplastic or thermoset material, the covering 30 can bond durably to the core 20 and generally will not delaminate from the core 20 even after prolonged exposure to fluids such as water, soaps, perfumes, disinfectants, cleaners, antistatic agents, polishing compounds or buffing compounds, as can occur with other materials such as, for example, high- density fiberboard. Likewise, a thermoplastic or thermoset core can also resist degradation. It will be understood by those having skill in the art that the core 20 can comprise natural materials, such as wood, or synthetic materials such as, for example, polyethylene, polypropylene, polyvinyl chloride (PVC), polyethylene terephthalate (PET), polycarbonate, polyurethane, or polyamide. In another embodiment, the core 20 can comprise a metal alloy, for example, aluminum, stainless steel, or titanium. Composites, such as carbon fiber-reinforced polymers, are also contemplated as materials used for the core 20.

[0030] The dimensions of the core 20 can be at least partially determined by the desired weight and rigidity for the core 20. In one embodiment, the core 20 has a thickness of approximately 0.58 mm, a length of approximately 12.22 mm ±0.01 mm, and an inner diameter of approximately 1.485 mm ±0.060 mm.

[0031] As shown in FIG. IB-ID, the covering 30 can include a backing layer 32 and nap

34 or pile. The covering 30 can be disposed on the outer surface 28 of the core 20 and can comprise any material or blend suitable to be disposed on the outer surface 28. As will be known to one skilled in the art, the covering 30 can be secured to the outer surface 28 of a core 20 by, for example, heat bonding or an adhesive. The bond formed between the covering 30 and the outer surface 28 can be permanent or semi-permanent, and can be a bond that is not subject to separation from exposure to fluids such as water, soaps, perfumes, disinfectants, cleaners, antistatic agents, polishing compounds or buffing compounds. Alternatively, it can be desirable for the covering 30 to be removable from the core 20 so as, for example, to wash or clean the covering 30 separately from the core 20. In such a case, the covering 30 can be removably secured to the core 20 by, for example, hook and loop fasteners or elastic, or another suitable means known to those skilled in the art.

[0032] The covering 30 can be composed of any suitable material and can be configured to absorb fluid, carry fluid, distribute fluid, trap fluid and debris, and release fluid and debris. Examples of suitable materials for the covering 30 can include natural materials such as cotton, or synthetic materials, such as foam, sponge, acrylic, nylon, rayon, silicon, rubber, polyester or polypropylene, among others. The covering 30 can also be a blend of natural and synthetic materials.

[0033] The backing layer 32 and nap 34 can be formed to be contiguous. For example, the entire covering 30 can be polyester. Alternatively, the backing layer 32 and nap 34 can be separate, distinct and even materially different components. For example, backing layer 32 can be silicon and nap 34 can be an antimicrobial sponge. Additional combinations for the materials of the backing layer 32 and nap 34 are possible. [0034] The nap 34 extends generally radially outwardly from the core 20. The nap 34 can be formed or distributed on the backing layer 32 in a variety of configurations, for example, in a particular patterned arrangement. As schematically depicted in FIGS. 2A and 2B, the nap 34 can be composed of a single strand or individual elements 36 which can be configured as strings or loops or another suitable configuration. In another embodiment, the nap 34 can further be formed in a tufted configuration in which a cluster of individual elements 36 are grouped together. The individual elements 36 can be created from a single strand or multiple strands. The formation of the individual elements 36 can aid in cleaning and scrubbing. For example, a looped nap 34 can carry and distribute polishing or buffing compounds. In one embodiment, as shown in FIG. 2B, the individual elements 36 can be intertwined or interwoven as part of the backing layer 32 to inhibit dropping (shedding, coming off, or falling out) of the individual elements 36 during mopping, scrubbing, polishing or buffing. Individual elements 36 can also be composed of two or more materials. For example, a portion of individual elements 36 can be made of cotton the remaining individual elements 36 can be made of polyester.

[0035] The rotary head 10 can be configured to be rotatably mounted to a housing 52 in a floor-care system 50, as shown for example in FIGS. 3A and 3B. The floor-care system 50 can be a vacuum cleaner, mop, scrubber, polisher and buffer. The rotary head 10 can be utilized as part of a single-function, stand-alone floor-care system, e.g. a mop or buffer. Alternatively, the rotary head 10 can be used to convert between different floor-care systems for increased functionality. For example, replacing the brushroll (not shown) of a vacuum cleaner with the rotary head 10 can convert a vacuum cleaner into a mop, scrubber, polisher or buffer thereby providing increased functionalities apart from simply vacuuming.

[0036] When the rotary head 10 is seated in the housing 52 of a floor-care system 50, the rotary head 10 can be firmly held in place by bushing or bearing assemblies or any other such structure configured to reduce friction that is created by rotation of the rotary head 10. For example, as is depicted in FIGS. 4A and 4B, bearing assemblies 54 and 56 are seated respectively in the first and second ends 22 and 24, and support the rotary head 10 as it rotates about longitudinal centerline axis 21. In FIG. 4C, an example internal structure of and engagement between the rotary head 10 and bearing assemblies 54 and 56 is shown. Bearing assemblies 54 and 56 can be provided as part of floor-care system 50, with the same bearing assemblies 54 and 56 capable of interchangeable use between a brushroll (not shown) and the rotary head 10 for attachment to the floor-care system 50. Alternatively, bearing assemblies 54 and 56 can be provided specifically for the rotary head 10 and thus can remain with the rotary head 10 when it is detached and a brushroll is attached to the floor-care system 50. Bearing assemblies 54 and 56 can also be configured to be integral to either housing 52 or to rotary head 10, rather than as separate assemblies distinct from housing 52 and rotary head 10. For example, bearing assemblies 54 and 56 can be formed as part of housing 52, and rotary head 10 can simply be snap-fit into housing 52. Likewise, bearing assemblies 54 and 56 can be formed as part of rotary head 10, and rotary head 10 can be snap-fit into housing 52. Incorporating bearing assemblies 54 and 56 into either the housing 52 or the rotary head 10 can reduce the number of discrete parts of the floor-care system 50 that a user encounters and can also facilitate easy attachment and removal of the rotary head 10 from the floor-care system 50.

[0037] The housing 52 can include an extraction structure such as a doctor blade 58 that can be configured to extract a floor-treatment agent 72 from the nap 34 when the nap 34 contacts part of the doctor blade 58. FIGS. 5A-5D depict a scalloped doctor blade 58, however any extraction structure configured to remove floor-treatment agent 72 from the nap 34 can be employed. The extraction structure can be configured to be tangential to the nap 34, for example as illustrated by the doctor blade 58 in FIGS. 5A-5D. In configurations, the extraction structure can be angled, or a portion of the extraction structure can be angled, for example to enhance collection of the floor-treatment agent 72 from the nap 34. An example extraction structure is described in U.S. Patent No. 4,573,235, which is hereby incorporated by reference in its entirety (see, for example callout number 102 in FIG. 3, and accompanying description in Col. 4, lines 31 - 68). The dimensions of the housing 52 and additional internal structures, such as the doctor blade 58, can therefore also influence the dimensions of the rotary head 10.

[0038] The intended application for the rotary head 10 can also affect the dimensions of the rotary head 10, and more specifically, the height of the nap 34. For example in a mopping or scrubbing application, as the rotary head 10 rotates, the nap 34 contacts the floor 70 and performs a mopping or scrubbing action. At least one of a floor-treatment agent 72 such as water, soaps, perfumes, disinfectants, cleaners, antistatic agents, polishing and buffing compounds can be applied to the floor 70 to aid in the mopping and scrubbing. As the rotary head 10 rotates, floor-treatment agent 72 containing dirt and debris is picked up by the centrifugal force of the rotary head 10 as well as being absorbed by the nap 34. The rotary head 10 can be positioned within the housing 52 so that a portion of the nap 34 contacts the doctor blade 58 as shown in FIGS. 5A and 5B. Contact with the doctor blade 58 extracts floor- treatment agent 72 containing dirt and debris from the nap 34 and deposits it in a trough portion 60 of floor-care system 50. In one embodiment, the nap 34 extends approximately 9 mm from the outer surface 28 of the core 20. Any portion of the nap 34 longer than 9 mm can contact the doctor blade 58 resulting in extraction of floor-treatment agent 72 containing dirt and debris as the rotary head 10 rotates. For mopping and or scrubbing, the nap height can be about 12 mm ±1 mm, as measured from the outer surface 28.

[0039] For applications such as polishing or buffing, it can be desirable for at least one floor-treatment agent, and in particular polishing and buffing compounds, to remain substantially in the nap 34 so as to be worked against the hard floor 70 rather than be collected by the doctor blade 58 and deposited in the trough portion 60. Nap 34 that does not contact or only makes light contact with the doctor blade 58 when the rotary head 10 is rotating can therefore be desirable, as is shown in FIGS. 5C-5D. As such, the nap 34 can be shorter and include less absorptive material. For polishing or buffing, the height of the nap 34 can be 9 mm ±1 mm, as measured from the outer surface 28 of the core. In this manner, the height of the nap 34 can minimize the amount of polishing or buffing compound collected by the doctor blade 58 when the rotary head 10 is rotating. A nap height of about 9 mm ±1 mm can also be effective for light cleaning of a soft surface such as carpet as opposed to a hard floor 70. By selecting an appropriate length of the nap 34, the rotary head 10 can perform differently for different applications.

[0040] The length of the nap 34 can also be selected based on the desired amount of contact with the hard floor 70. A longer nap 34 will generally create an increased amount of contact with the surface of the hard floor 70. For example, if a doctor blade is not used or is not present in the housing 52, the length of the nap 34 can be determinative as to how much contact occurs and pressure is applied to the surface by the nap 34 and the effective surface area of the nap 34 that contacts the surface of the hard floor 70. A longer nap 34 will generally create more contact and apply more pressure to the hard floor to be mopped, scrubbed, polished or buffed as compared to a shorter nap. Similarly, the density of the nap 34 and the materials comprising the nap 34 can be selected based on the intended application of the rotary head 10. Further, the housing 52 can be adjustable, as is known to those of skill in the art, so as to raise or lower the rotary head 10 and thereby increase or decrease the amount of contact and pressure the rotary head 10 can apply to the hard floor 70.

[0041] A rotary head 110 can be provided in any of a variety of other suitable configurations, such as for example rotary head 110 as shown in FIG. 6, wherein the rotary head

110 includes a reinforcement layer 140 disposed between a core 120 and a covering 130.

Reinforcement layer 140 can optionally be included to provide improved structural integrity and hoop strength of the rotary head 110 to withstand internal stresses exerted by the core 120 and external forces such as those applied by a drive belt 62 (not shown). Reinforcement layer 140 can also protect the core 120 from deterioration resulting from contact with solvents and other chemicals used for mopping, scrubbing, polishing and buffing. The material comprising the core 20, 120 can also be selected to withstand external forces such as those applied by the drive belt 62.

[0042] Belt 62 can engage rotary head 10 and couple rotary head 10 to a motorized or non-motorized rotatable shaft (not shown) as part of the floor-care system 50. Belt 62 can engage the rotary head 10 such that there is suitable friction between the belt 62 and rotary head 10, thus allowing the belt 62 to rotate the rotary head 10 without substantial slipping during operation of the floor-care system 50. In the embodiment shown in FIG. 7 A, the belt 62 engages the nap 34 in the middle of the rotary head 10 for rotation of the rotary head 10 about the longitudinal centerline axis 21. In such a configuration, the materials comprising the belt 62 and the nap 34 can be similarly configured to provide coupling without slipping in the presence of floor-treatment agents 72 such as, for example, water, soaps, perfumes, disinfectants, cleaners, antistatic agents, polishing and buffing compounds.

[0043] In another configuration shown in FIG. 7B, the belt 62 can contact the core 20 directly, for example if the backing layer 32 and nap 34 are absent from the core 20 at the position of the belt 62. The materials of the belt 62 and core 20 can be selected to provide sufficient friction for coupling belt 62 to the core 20, even when an amount of fluid such as water, soaps, perfumes, disinfectants, cleaners, antistatic agents, polishing and buffing compounds are present. [0044] In an additional configuration shown in FIG. 7C, the rotary head 10 can include an indentation in the core 20 that can help to maintain the position of the belt 62 when the belt 62 directly contacts the core 20 for rotation. In each of the embodiments 7A-7C, the belt 62 is shown as engaging approximately the middle of the rotary head 10; however, the rotary head 10 can be engaged at or near the first end 22 or second end 24. After the rotary head 10 is rotatably positioned in the housing 52, the floor-care system 50 can be operated.

[0045] The present use of a rotary head (e.g. 10, 110) can result in various advantages such as, for example, making mopping, scrubbing, polishing and buffing efficient and easy for household as well as commercial use. The rotary head (e.g. 10, 110) is portable, easy to operate, and when used in place of a vacuum cleaner brushroll (not shown), can provide a vacuum cleaner with the additional functionalities such as mopping, scrubbing, polishing and brushing. The rotary head (e.g. 10, 110) is easily detachable and can therefore be removed for rinsing and cleaning after use. Alternatively, the rotary head 20 can be disposable. Additionally, because fresh water is supplied and dirty water is removed, the quality of cleaning and sanitation is enhanced. Further, a lower quantity of water is required for cleaning compared to traditional mop-and-bucket mopping.

[0046] It is understood that the described embodiments of the rotary head are merely examples of the many suitable varieties of rotary heads that are capable of manufacture and use in accordance with the teachings herein. [0047] The foregoing description of embodiments and examples have been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described for illustration of various embodiments. The scope is, of course, not limited to the examples or embodiments set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather it is hereby intended the scope be defined by the claims appended hereto.