GB2247201A

GB2247201A - Rotating disk for floor maintenance

Info

Publication number: GB2247201A
Application number: GB9115078A
Authority: GB
Inventors: Takayasu Hamagaki
Original assignee: Seiken Co Ltd
Current assignee: Seiken Co Ltd
Priority date: 1990-07-20
Filing date: 1991-07-12
Publication date: 1992-02-26
Also published as: CA2046810A1; JPH0482673A; GB9115078D0

Abstract

A rotating disk for floor maintenance has a reinforcing core (1) having opposite sides and being of a material having open spaces through which fibers can pass. A layer (2) of nonwoven fiber material bonded to each of the opposite sides of the reinforcing core (1). The reinforcing core (1) and nonwoven fiber material layers (2) are in the shape of a disk having a hole in the center. Fibers from the layer (2) of nonwoven fiber material bonded to one side of the reinforcing core (1) extend through the reinforcing core (1) and into the layer (2) of nonwoven fiber material bonded to the other side of the reinforcing core (1) and intersect with nonwoven fibers in the layer of nonwoven fiber material bonded to the other side of reinforcing core and are joined thereto at the intersection points for connecting the layers (2) of nonwoven fiber material to each other. Particles of abrasive material may be attached to the nonwoven fiber material layers. <IMAGE>

Description

TITLE OF THE INVENTION ROTATING DISK FOR FLOOR MAINTENANCE BACKGROUND OF THE INVENTION This invention relates to rotating disks for floor maintenance, such as for scrubbing, dirt removal, or polishing floors. In particular, this invention relates to motor driven nonwoven fiber rotating disks for floor maintenance.

Rotating disks ror floor maintenance employing nonwoven fiber material are already used for a variety of applications. These rotating disks have the feature that they can deform to follow the three dimensional protrusions and depressions of somewhat rough surfaced floors so as to carry out thorough abrasive action.

The inventor has previously developed an improved rotating disk for floor maintenance made of nonwoven fiber, as disclosed ill Japanese published application No. 29101/1981. This rotating disk has fibers in loop form which are collected into a solid body, joined together at all fiber crossing points, and coated with abrasive material.

A rotating disk for floor maintenance with this structure has superior abrasive characteristics, but it has the drawback that it easily loses its shal)e. This is caused because it is easily deformed by a pull in the radial direction.

A rotating disk which casily loses its shape cannot stand up to high rotation speeds. This is because the centrifugal force acting on the rotating ci isl < is proportional to tlie sciuare ol' tlu( rotation speed.

and therefore inereases rapidly with rotation speed.

A rotating disk which easily loses its shape can be made to withstand high speed rotation by bonding reinforcing core material to the surface of the nonwoven fiber material. Such a rotating disk having layers of nonwoven fiber and reinforcing core material is described in Japanese patent No. 114670/1981, and No. 68752/1982.

In the rotating disks disclosed in these items and elsewhere, reinforcing core material is bonded to one face of the nonwoven fiber material to make a layered structure of nonwoven fiber and reinforcing core material. The reinforcing core material serves both to reinforce the rotating disk preventing its loss of shape, and to allow application of strong pressure against the surface it is applied to. The abrasive or scrubbing efficiency is improved by the application of strong pressure of the nonwoven fiber through the reinforcing core material.

In other words, the reinforcing core material pushes the nonwoven fiber strongly against the object to be scrubbed, and also prevents the rotating disk from losing its shape. For achieving this effect, it is extremely important that the reinforcing core material and the nonwoven fiber material be strongly bonded together. If bonding between tlie reinforcing core material and the ri()nwoven Ii her material is insufficient, pressure exerted by the nonwoven fiber material will lose its shape by the action of centrifugal force.

Nonwoven fiber material has numerous vacant regions between the fibers This is responsible for reducing the bonding strength between nonwoven fiber material and reinforcing core material. The fibers of nonwoven fiber material with many vacancies can only adhere to reinforcing core material at sparse points. In order to more strongly bond nonwoven fiber material and reinforcing core material, that is in order to join many li hers over a wider area of' reinforcing core material, rotating disks for floor maintenance have heretofore bonded nonwoven fiber material and reinforcing core material together by thick application of a rubber based cement.The thickly applied cement bonds fibers of the nonwoven fiber material to a wider area of the reinforcing core material. This type of rotating disk is made by the following process.

(1) The nonwoven fiber material is Immersed in liquid adhesive. Excess adhesive Is removed by compressing the nonwoven fiber by passing it between two rollers. By this step, the fiber surfaces are coated with adhesive.

(2) Before the adhesive hardens, abrasive particles are sprayed onto the nonwoven fiber material. 13y this step, abrasive particles are attached to the fiber surfaces. The adhesive is then dried.

(3) The surfaces of reinforcing core material to be layered with the nonwoven fiber material are thickly coated with a rubber based cement.

(4) Before the cement hardens, nonwoven fiber material is bonded to both sides of the reinforcing core material.

(5) After the cement hardens, the layered piece of nonwoven fiber and reinforcing core material is cut to a disk shape.

(6) Because the rubber based cement has flexibility in the solidified state, t!ie rubber based cement cannot make the center portion or the rotating disk sufficiently hard. Therefore, a rcin forcing adhesive is is app 1 led to stiffen the center portion of the rotat irig disk.

(7) If necessary the center portion is compressed in a prcss, and the adhesive is dried in a kill).

Rotating disks for floor maintenance made by the above e process have the drawback that they have a maximum Rl'i (revolution per minute) operating limit, and therefore cannot scrub floors uith high efficiency. The reason for tnis is that regardless of ()". mu(lI rubber based cement is used, the strength of the bond between the nonwoven fiber material and the reinforcing core material is insufficient.

Further, previously known nonwoven fiber rotating disks for floor maintenance have the feature that they can deform to follow three dimensional protrusions and depressions to uniformly scrub the entire floor surface, but because nonwoven fibers are used, they have the drawback that some fibers detach during use, and durability is degraded. In particular, when scrubbing floors which have protrusions, fibers catch on the protrusions and a portion of nonwoven fiber becomes detaches. Detachment of nonwoven fibers does not depend on whether the rotating disk is new or old. Even fibers from a new rotating disk are pulled oft' wheii caught or a protrusion from the floor. Consequently, depending on where the rotating disk is used, partial detachment has the deleterious eflect of drastically reducing disk lifetime.

The cause of nonwoven fiber detachment during use lies in the method of nonwoven fiber manufacture. Namely, since nonwoven fiber is made by piling up randomly oriented fibers to a given thickness then joining those fibers at their crossing points with adhesive bonding material, when one part gets caught on something, and entire section of layered fibers detaches.

When the quantity of adhesive bonding material used is itereased to prevent fiber layer detachment arid increase bonding st rengtti between tlie nonwoven fiber and reinforci rig core mat serial , the excellent cushioning property instrinsic to nonwoven í'ii)er arid indispensable to rotating disks for floor maintenance is lost. This is because the vacant regions within the nonwoven fiber become 'i II ed arid the fiber surfaces become covered with thick layers ()l' adliesi v( bonding material.

Further, when large quantities of adhesive bonding material are used, the rotating disk cannot be used until it becomes sufficientl' abrasive, and its lifetime is reduced. This is because large quantities of adhesive bonding material seep between the nonwoven fibers and the fibers burled in bonding material.

Still further, former rotating disks for floor maintenance require extensive processing, and manufacturing costs increase with an increase In the amount of adhesive bonding material used. This is because during the fabrication process, adhesive bonding material is applied repeatedly and must be repeatedly dried.

In previously known rotating disks for floor maintenance using a single application adhesive bonding material, the center portion of the rotating disk could not be stiffened after abrasive particles were attached to the nonwoven fi hers, and the nonwoven l'i her anci reinforcing core material were joined in layers. This is because of restriction in the order in which adhesive bonding material was used.

It was necessary to first attach abrasive particles to the nonwoven fiber, and then bond the nonwoven fiber and reinforcing core material. The opposite operation of first bonding the noriwoven fiber and reinforcing core material, and then attaching abrasive particles to the nonwoven fiber can not be used. If abrasive particles are attached to the nonwoven fibers after layering together the nonwoven fiber arid reinforcing core material, the rubber based cement will soften and the nonwoven fiber material will separate from the reinforcing core material.

This invention was developed to eliminate these and outher drawbacks of previous rotating disks for floor maintenance.

Accordingly, one ol' the primary objects Or this is invention is t to provide a rotating disk which can effciently abrade a floor at high rotational speeds, which has a long lifetime, and which can be manufactured in quantity a simple process for a low price. Another one of the prImary objects is to provide a rotating disk which can be pushed against the floor with strong pressure without losing its shape.

SUMMARY OF THE INVENTION In one preferred embodiment, the rotating disk for floor maintenance according to this invention has the overall shape of a disk with a hole through the center. The rotating disk has a layered structure with nonwoven fiber material bonded to both sides of a reinforcing core material. The reinforcing core material has the property that fibers of the nonwoven fiber material can pass through it. The fibers of nonwoven fiber material bonded to one side of the reinforcing core material pass through the reinforcing core material and extend into the nonwoven fiber material bonded to the other side of the reinforcing core material.Fibers which pass vertically through the reinforcing core material connect the nonwoven fiber material on both sides of the reinforcing core material. Fibers passing through the reinforcing core material cross with fibers of nonwoven filter material layered on the opposite side of the reinforcing core material, and are joined at those crossing points.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional drawing of one embodiment Of the rotating disk floor maintenance according to this invention; and FIG. 2 is a side view of a barbed needle used in forming the rotating disk of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION There is described hereinafter an embodiment of the present invention based on illustrations. however, the described embodiment is only intended as a specific example illustrative of the technology Involved In the rotating disk for floor maintenance according to this invention and consequently, the rotating disk of this invention is in no way restricted to the materials, form, construction, or placement of structural in the parts described embodiment. It is therefore to be understood that, in the scope of the appended claims, the invention may be practiced other than specifically described.

Turning to FIG. 1, the rotating disk shown has a reinforcing core material 1 having opposite surfaces and a layer nonwoven fiter material 2 bonded to each of its opposite surfaces. The nonwoven fiber materials 2 bonded to both sides of' title reinforcing core materia I become the floor abrading surfaces (in t he position shown in FIG. 1 t lie lower surfaces is the abrading surface).Consquently, by the disk, first the lower and then the upper surface of the rotating disli with this structure can be used as ah rad i ng surfaces The rotat i jig disk for floor mii ri teriance is used by attachment to a rotary tool. 'Ilierefore, it is cut in a disk shape and has an insertion hole 3 cut through the center for attchment to the toll.

Tite nonwoven fiber material 2 is a collection of randomly oriented nonwoven fibers 4 joined together such that vacant regions exist between fibers. The thickness of the fibers in the nonwoven fiber material 2 is selected depending on the application. Nonwoven fiber material 2 with thick fibers is rigid and has exceptional abrasive strength. Nonwoven fiber material 2 with thin fibers can smoothly polish surfaces. Therefore, nonwoven fiber material 2 used for rough abrasion has thick fibers, and nonwoven fiber material 2 used for finishing or polishing has thin fibers.

The rotating disk is used for abrading floors, for removing dirt from floors, or for polishing floors to a luster. A rotating disk for abrading floors uses nonwoven fiber material which has abrasive particles attached to the surfaces of its fibers. A rotating disk for removing dirt from floors or for polishing floors to a luster uses nonwoven fiber material which has particles that are pliable compared with abrasive particles, such as a powder having plasticity attached to the surfaces of its fibers. Moreover a nonwoven fiber rotating disk with no abrasive particles or powder attached to its fibers polishes floors directly with the nonwoven fiber.

The abrasive particles attached to the nonwoven fibers 4 are selected based on the fiber thickness and the use of the disk. In general, large diameter abrasive particles are attached to thick fibers and small diameter abrasive particles are attached to thin fibers. Carborundum, alundum, silica, alumina, eIc. can be used as materials for the abrasive particles. Aithouglt the thickness of the fiber 4 of the nonwoven fiber material and the abrasive particle diameter vary depending on the use of the disk, -40 to .3000 size particles are, for example, used with 3 to 200 denier fibers (a 450 meter length of 1 denier fiber weighs 0.05 gram).

The reinforcing core material I can be sflcct material with open regions that allow nonwoven fibers to pass through. For example, solid conglomerates of randomly oriented L'ibers such as felt or thin fiber nonwoven fiber material in sheet flrm, or woven net in sheet form made by weaving thread can be used.

The nonwoven fiber material 2 bonded to both sides of the reinforcing core material 1 is in terconnecteci by vertically orient ed fibers 5. As shown in FIG. 1, fibers 5 from 1 lie nonwoven fiber material 2, bonded to the upper surface of the reinforcing core material 1, pass downwards through the reinforcing core material 1. These vertical fibers 5 that pass through the reinforcing core material 1 extend into the nonwoven fiber material 2 bonded to the lower surface of the reinforcing core material 1 where they are joined by adhesive at all crossing points to interconnect with the fibers 4 of the lower nonwoven fiber material.

Conversely, fibers from the nonwoven fiber material 2, bonded to the lower surface of the reinforcing core material 1, pass upwards through the reinforcing core material 1. Vertical fibers 5 that pass upwards through the rein forcing core mater a 1 1 extend into the nonwoven fiber material 2 bonded to the upper surface of the reinforcing core material 1 where they are joined by adhesive at all crossing points to interconnect with the nonwoven fibers 4 of the upper nonwoven fiber material.

In the rotating disk for floor maintenance shown in FIG. 1, fibers from the upper nonwoven fi ber material extend into the lower nonwoven fiber material 2. fibers from the lower nonwoven fiber material extend into the upper nonwoven fiber material 2, and the nonwoveri fibers 4 are joined at- crossing points with the vertical fi hers 5.In this rrianner, fibers from nonwoven fiber material 2 adhesive bonded to both sides of the reinforcing core material I are joined together after mutual liy passing through the reinforcing core material 1. This type of rotating disk has the feature that the nonwoven fiber material 2 on both surfaces can be more solidly joined toget tier.

However, in the rotating disk for floor meintenance of this invention, it is not always necessary that fibers from the nonwoven fiber material on both surfaces pass through the reinforcing core material to the other side. For example, awl though it is not illustrated. it is also possible for fibers to pass from the nonwoven fiber material on only one side, through the reinforcing core material to be joined with nonwoven fibers on the other side.

Further, in the case where felt or thin fiber nonwoven fiber material is used as the reinforcing core material 1, thin fibers 6 from the reinforcing core material 1 can also be joined at crossing points with the nonwoven fibers 4. In this fashion by joining the thin fibers 6 of the reinforcing core material and the fibers 4 of the nonwoven fiber material at all crossing points, increased bonding strength between the reinforcing core material 1 and the nonwoven fiber material 2 can be achieved.

One method of obtaining the fiber arrangement comprises inserting a barbed needle 7 as shown in FIG. 2 into the nonwoven fiber material 2 towards the reiforcing core material 1 to pass fibers of the nonwoven fiber material through the reinforcing core material 1, and to cause thin fibers 6 of' the reinI'orcing core material 1 to extend into the nonwoven fiber material 2. Barbs 8 are provided on the surface of the barbed needle 7 so that fibers will catch on the barbs as the needle moves in the direction of insertion but not when the needle moves in the direction of extraction.When a barbed needle with this structure is inserted through the nonwoven fiber material 2, the barbs 8 On the needle surface catch nonwoven fibers and push them through ttte reinforcing core material 1. Furthermore, thin fibers ol' the reinforcing core material also catch on the barbs 8, and are pushed into the nonwoven fiber material.

When the barbed needle 7 is removed from the nonwoven fiber material 2 and the reinforcing core material 1, the barbs 8 release fibers caught on tit em, arid oil ly the barbed needle is removed Consequently, by repeated insertion of a barbed needle with this structure into the nonwoven fiber material 2 and through ttic reinforcing core material 1, fibers of the nonwoven fiber material can be. passed through the reinforcing core material 1. The number of fibers passing through the reinforcing core material can be increased by increasing the number of times the barbed needle is inserted, or by simultaneously inserting a large number of barbed needles.

After layering or sandwiching the reinforcing core material 1 with nonwoven fiber material 2, passing fibers of the nonwoven fiber material 2 through the reinforcing core material 1, and entangling the vertical fibers 5 passed through the reinforcing core material 1 with the fibers 4 of the nonwoven fiber material on the opposite side, tiIe rotating disk shown is FIG. 1 is cut in a circular shape. The cut layered material is coated with adhesive cement, sprayed with abrasive particles, its center region is compressed, and it is then delivered into a kiln to dry and harden the adhesive cement.

In a rotating disk fabricated in this fashion the adhesive cemeri t bonds the nonwoven fiber material 2 to the rei Ir to rc'i rrg core material attaches abrasive particles to the surfaces of the nonwoven fibers 4, and hardens the center of' the rotating ci isk in the compressed state.

However, tire rotating disk of this invention is not always necessarily fabricated with only one application of adhesive cement or bond agent. It is also possible to first entangle the fibers arid tack the layers of nonwoven fiber material and reinforcing core material together with an adhesive cement, then attach abrasive partic'Ies to the nonwoven fibers by coating the nonwoven fiber material with another adhesive cement for that purpose.In addition, in I he case where the center region of the rotating disk is further stiffened, the center of the rotating disk can be compressed after coating that region with still another adhesive cement.

In the rotating disk for floor maintenance shown in FIG. 1 nonwoven fibers pass vertically through the reinforcing core material and those vertical fibers interconnect with fibers of. the nonwoven fiber material located on both sides of the reinforcing core material. Consequently, by virtue of the fibers passing vertically through the reinforcing core material, the nonwoven fiber materials on both sides of the reinforcing core material are joined together in a sturdy fashion which avoids any shift in position with respect to the reinforcing core material during use.In other words, in a rotating disk for floor maintenance having this structure, the nonwoven fiber material and the reinforcing core material are integrated more nearly as a single structure, and that structure is robustly reinforced by the reinforcing core material.

Further, a rotating disk with this structure has the feature that separation of a fiber layer from the nonwoven fiber material is prevented. This is because, as shown in FIG. 1, the vertical fibers that pass through the reinforcing core material extend towards the surface of the nonwoven fiber material perpendicular to or at an angle to ttie surface thereof, and are joined with nonwoven fi hers at al I intersection points.In other words, since the vertical fibers that pass through the reinforcing core material extend into the nonwoven fi her material on tlic opposite sides in a Cii rection which extend through the stack of nonwoven fibers created during nonwoven fiber material manufacture, and since those vertical fibers and nonwoven fibers are interconnected. the vertical fibers can prevent detachment of layers of nonwoven fiber. Consequently, a rotating disk f'or floor maintenance with this structure has the feature that detachment of' layers of disk material, brought about when floors with protrusions are abraded or polished, can be prevented.

Therefore, a rotating disk with this structure has the features that it can endure strong centrifugal forces resulting from high rotational speeds and strong deformation forces resulting from being pushed against the surface being abraded. Further, it has the feature of strength with respect to fiber layer detachment caused by protrusions from the floor. It can scrub floors efficiently by attachment to a high speed rotary tool.

Further, a rotating disk for floor maintenance with this structure also has good durability and long lifetime. The reasons for this are that it can be used for long periods without losing its shape, fiber layer detachment from the nonwoven fiber material is prevented and there is no need for a thick adhesive layer between the reinforcing core material and the nonwoven fiber material Still further. since a rotating disk for floor maintenance with this structure has layered nonwoven fiber material and reinforcing core material connected by entangled fibers, the adhesive cement used to attach abrasive particles to fiber surfaces can also be used to bond the nonwoven fiber material and reinforcing core material together, as well as to stiffen the center region of the rotating disk if required. Consequently a rotating disk with this structure makes it.

possible to reduce the number of' applications of adhesive and the number of drying steps from many, in heretofore used processes, to one single process step.

A rotating disk for floor maintenance with this structure, which can be made by a simplified adhesive application and drying process.

cart reduce fabrication and materials costs, rnd t)e man ri I'actu reci inexpensively in quantity. The feature of easy and efficient manufacture by simplification of the fabrication p process is I lie tilerel)y achieved.

Claims

We claim:

1. A rotating disk for floor maintenance, comprising: a reinforcing core having opposite sides and being of a material having open spaces through which fibers can pass; a layer of nonwoven fiber material bonded to each of the opposite sides of said reinforcing core material; said reinforcing core and nonwoven fiber material layers being in the shape of a disk having a hole in the center;; fibers from the layer of nonwoven fiber material bonded to orate side of said reinforcing core extending through said reinforcing core and into the layer of nonwoven fiber material bonded to the other side of said reinfl)rcing core and intersecting with nonwoven fibers in the layer of nonwoven fiber material bonded to the other side of said reinforcing core and joined thereto at the intersection points for connecting the layers of nonwoven fiber material to each other.

2. A rotating disk as claimed in claim 1 in which fibers from the layer of nonwoven fiber material bonded the other side of said reinforcing core extending through said reinforcing core and into the layer of nonwoven fiber material bonded to the one side of said reinforcing core and intersecting with nonwoven fibers in the layer of' nonwoven fiber material bonded to the one side of said reinforcing core and joined thereto at the intersection points.

3. A rotating disk as claimed iii claim I or 2 in which tite fibers I'rc)rri the nonwoven íiL)er material are bonded to title material oí' said reinforcirig core.

4. A rotating disk as claimed in claim ] or 2 in which the material ot' said reinforcing core is a sheet of felt which is a conglomerate of' randomly oriented fibers.

5. A rotating disk as claimed in claim 1 or 2 in which the material of said reinforcing core is a sheet of fine nonwoven fiber material that Is a conglomerate of randomly oriented thin fibers.

6. A rotating disk as claimed in claim 1 or 2 In which the material of said reinforcing core is a woven sheet made of weaving thread.

7. A rotating disk as claimed in claim 1 or 2 in which the fibers of the layers of nonwoven fiber material bonded to the opposite surfaces of said reinforcing core are fibers having a denier of from 3 to 200.

8. A rotating disk as claimed in claim 1 or 2 further comprising abrasive material attached to the surfaces of. the nonwoven fiber material of the layers of nonwoven fiber material attached to the opposite surfaces of said reinforcing layer.

9. A rotating disk as claimed in claim 8 in which the abrasive material is in the form of particles having a particle size of from =40 to t3000.