Patent Application
20070259580
The present invention relates to the commercial laundry industry, and specifically to an improved cleaning pad for flatwork ironers used in establishments such as hotels, hospitals, nursing homes and other commercial laundry facilities.
Commercial flatwork ironers include padded rolls carrying the sheets or flatwork against a heated chest which performs the pressing action. During prolonged use, the sheets deposit residual detergents and other additives upon the chest which reduces the efficiency of the ironer. More specifically, when the chest becomes coated with residue, the residue interferes with the passage of the sheets through the ironer. In some cases, the flatwork pieces become distorted.
To address this problem, it is known to place flatwork ironer cleaning pads into the ironers to clean the chest. Conventional flatwork ironer cleaning pads, notably the KLEENO-PAD® pad manufactured by the present Assignee, the Resillo Press Pad Co. in Lincolnwood, Ill., include a carrier layer of cotton duck or spun polyester having a leading edge portion, a cleaning portion and a trailing edge portion. The cleaning portion includes several spaced parallel rows of braided steel wool cloth running transverse to the direction of travel of the pad through the rollers, or parallel with the longitudinal axis of the rollers. The rows of braided steel wool are welded to a sheet of metal stainless steel mesh, which in turn is secured to the carrier layer with staples. Next, the trailing edge portion is provided with several spaced parallel rows of polishing felt. In the case of both the braided steel wool and the polishing felt, the respective cleaning and polishing materials project above the carrier layer approximately 1 inch. In some cases, the use of the cleaning pad is followed by the insertion of a waxing pad to wax the chest.
It has been found that newer model flatwork ironers have a narrower intake area. As such, when conventional cleaner pads are inserted into the machines, the steel wool braids, among other components, are pulled from the carrier layer. Aside from interfering with the cleaning process, the destruction of the pad leaves residue in the ironer which must be removed.
One attempted solution has been to use sheets of silicate-coated screen cloth or commonly known material referred to as “sand screen”. Such material is thinner than the conventional cleaning pad, and upon insertion into the machine, passes easily between the rollers and the chest. However, after a relatively few passes through the ironer, the sand screen material deteriorates and crumbles in the ironer, leaving excessive amounts of a powdery residue, which, if not removed, will soil the clean linen passed through the ironer. Again, special procedures are required to remove the residue from the decomposed sand screen sheets.
Thus, there is a need for an improved flatwork ironer cleaning pad which overcomes the disadvantages of conventional pads used on newer ironers with narrower insert openings. There is also a need for such an improved pad which can withstand repeated use in newer ironers.
Accordingly, the above-identified drawbacks of conventional flatwork ironer cleaner pads used in contemporary ironers are overcome with the present pad, overcomes production difficulties. The present cleaner pad employs a layer of sand screen cloth secured to a carrier layer of cotton duck or spun polyester, disposed between a leading edge portion and a trailing edge portion. The trailing edge portion is preferably a continuous layer of felt for polishing purposes. An important feature of the present pad is the manner in which the sand screen is secured to the carrier layer, being stitched through an overlying hem or binder. The resulting pad moves through ironers more easily than prior pads, and is significantly more durable. Another feature of the present pad is that a separate application of a waxing pad is eliminated, since cleaning and waxing can be performed simultaneously.
More specifically, a flatwork ironer cleaning pad includes a carrier layer having a leading edge portion, a cleaning portion and a trailing edge portion and a sand screen sheet secured to the cleaning portion.
In another embodiment, a flatwork ironer cleaning pad includes a carrier layer having a leading edge portion, a cleaning portion and a trailing edge portion, a sand screen sheet disposed on the cleaning portion, a hem enveloping each side edge of the sand screen sheet and being stitched to both the sand screen sheet and the cleaning portion, and a felt layer secured to the trailing edge portion.
In still another embodiment, a flatwork ironer cleaning pad includes a carrier layer having a leading edge portion, a cleaning portion and a trailing edge portion, the leading edge portion having a pocket formed at a front edge, and a sand screen sheet disposed on the cleaning portion so that a substantial portion of the sand screen sheet lays directly upon the cleaning portion. A hem envelops each side edge of the sand screen sheet and is stitched to both the sand screen sheet and the cleaning portion. A continuous felt layer covers the trailing edge portion.
Referring now to
At the leading edge portion 14, in the preferred embodiment a front edge 20 is folded back to form a pocket 22, which is then secured by being secured along side edges 24, preferably by stitching. The pocket is used to hold solvents as are known in the art for facilitating the breakdown of baked on deposits on the ironer rollers.
Referring now to the cleaning portion 16, as described above, an important factor in developing a flatwork ironer cleaning pad which is suitable for use in ironers is that the overall height or thickness “T” be thin enough to pass through the ironer without becoming damaged. For best results, it is preferred that the thickness “T” be less than or equal to 0.5 inch.
In the industry, it was known to use sand screen material to clean ironers, however the material was inserted in sheet form directly into the ironer after being cut to suitable size. Such material was made of a polymeric or fiberglass screen material, similar in construction to that used for window screens, and was coated with an abrasive particulate material to provide cleaning action. While silicon carbide is the preferred particulate abrasive, it is contemplated that other mineral abrasive-coated sheet materials may be used, such as aluminum oxide or synthetic minerals, as are well known in the abrasive materials art. For the purposes of this application, “sand screen” will refer to all such sheet materials coated or embedded with abrasive minerals for cleaning and/or polishing. Also, while screen material is preferred as the base for such cleaning sheets, it is contemplated that the mesh size of the material may vary to suit the application, and alternatives to screen material are also contemplated, provided that the material has sufficient abrasive action. Such sand screen material is commercially available from 3M Company, St. Paul, Minn., among others.
While effective in cleaning the rolls, the sand screen material used alone broke down or decomposed after only a few uses. In addition to adding to maintenance costs due to the more frequent required replacement of pads, the material also increased maintenance costs by requiring the removal of the residual powder formed by the decomposing pads. If not removed, the powder was deposited on laundry passing through the ironer.
To maintain a relatively thin profile, and keep the thickness “T” within desired parameters, it is preferred that a sheet of sand screen 26 is attached to the carrier layer 12 so that a majority of the sheet of silicate material is in direct contact with an inner surface 27 of the carrier layer. However it was found that securing the silicate material to the carrier layer 26 was not easily accomplished. Adhesives would break down under the hot damp working environment of the ironers and might stain the linen. Staples would have a relatively thick profile and might scratch the surface of the ironer's chests. Further, staples might fracture the silicate material.
While stitching with thread using industrial sewing machines is known in the manufacture of other types of laundry cleaning and pressing pads, it was found that sewing sand screen sheets to the carrier layer 12 caused the sewing needles to heat up and eventually disintegrate through exposure to the abrasive minerals. It was found that using a hem or binder of fabric 28 enveloping an edge 30 of the sand screen material 26 enabled the stitching to proceed without needle degradation. While other materials are contemplated, the hem 28 is preferably made of No. 12 cotton duck, which is also a desired material for the carrier layer 12.
Referring now to
Referring now to
It is also contemplated that optional strips of binder material 46 be stitched along forward and rear edges 48, 50 (shown hidden) of the sand screen sheet 26 to further secure it to the carrier layer 12. These optional binder strips 46 may be used in either embodiment 10 or 40, and are preferably made of the same material as the hem 28; however other suitable materials used in cleaning pads are contemplated.
Referring again to
Accordingly, to provide the desired cleaning and polishing of the ironer chests after the cleaning by the sand screen sheet 26, the felt layer 52 on the present pad 10, 40 is preferably continuous across and covers the entire trailing edge portion 18. This arrangement also helps maintain the thickness “T” of the pad 10 within the desired parameters for use in ironers, including newer model machines. Also, as is known in the art, it is preferable to add a coating of powdered wax 54 to the felt layer 52 to enhance the polishing action. Thus, by using the present pad 10, cleaning and waxing can be accomplished in a single application. Previously, users were forced to first insert a cleaning pad, then a waxing or polishing pad.
Referring now to
It will be seen that the present pads 10, 40, 60 provide an effective and durable solution to the implementation of newer design ironers. By employing the hem 28, the sand screen sheets 26 may be readily secured to the carrier layer 12 without causing sewing needle deterioration. Further, the addition of solvent in the pocket 22 and powdered wax 54 on the trailing edge portion 18 results in a flatwork ironer cleaning system which is superior to conventional cleaning techniques.
While specific embodiments of the flatwork ironer cleaning pad of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
