U.S. patent application number 10/877593 was filed with the patent office on 2005-01-06 for fabric article treating system.
This patent application is currently assigned to The Procter & Gamble Company. Invention is credited to Gustwiller, Mark Eric, Price, Kenneth Nathan, Zhang, Shulin Larry.
Application Number | 20050000031 10/877593 |
Document ID | / |
Family ID | 33567672 |
Filed Date | 2005-01-06 |
United States Patent
Application |
20050000031 |
Kind Code |
A1 |
Price, Kenneth Nathan ; et
al. |
January 6, 2005 |
Fabric article treating system
Abstract
A fabric article treating system, including the apparatus and
the process, to provide improved fabric cleaning, fabric appearance
and/or fabric care benefits. More particularly, the present system
provides an effective delivery of detergent actives and rinse
actives by depositing the actives directly upon a fabric article
being treated. The detergent composition and fabric care
composition suitable for use in such apparatus and process are also
provided. The system is water-saving and energy efficient, compared
to conventional immersive aqueous laundry system.
Inventors: |
Price, Kenneth Nathan;
(Wyoming, OH) ; Zhang, Shulin Larry; (West
Chester, OH) ; Gustwiller, Mark Eric; (Cincinnati,
OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY
INTELLECTUAL PROPERTY DIVISION
WINTON HILL TECHNICAL CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
33567672 |
Appl. No.: |
10/877593 |
Filed: |
June 25, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60483153 |
Jun 27, 2003 |
|
|
|
60483155 |
Jun 27, 2003 |
|
|
|
Current U.S.
Class: |
8/142 |
Current CPC
Class: |
Y02B 40/00 20130101;
C11D 11/0064 20130101; C11D 3/0015 20130101; C11D 11/0017 20130101;
D06F 35/006 20130101 |
Class at
Publication: |
008/142 |
International
Class: |
D06L 001/00 |
Claims
What is claimed is:
1. A process for cleaning fabric articles in a laundering apparatus
comprising: a. placing fabric articles comprising soils inside a
treatment chamber of the laundering apparatus; b. dispensing into
the treatment chamber a wash liquor such that the fabric articles
are substantially uniformly contacted by the wash liquor, wherein
the wash liquor comprises water and a detergent active; c. allowing
the wash liquor to remain in contact with the fabric articles for a
period of time while the fabric article is in motion, continuously
or intermittently; d. dispensing into the laundering apparatus a
first rinse liquor comprising water such that the first rinse
liquor directly or indirectly contacts the fabric articles, wherein
quantity of the first rinse liquor is sufficient to produce enough
free water to adequately suspend the detergent active and soils,
and the first rinse liquor is thereby converted into a first rinse
liquor mixture comprising water, detergent active and soils; e.
removing at least part of the first rinse liquor mixture from the
treatment chamber; and f. optionally, steps (d) and (e) are
repeated such that one or more subsequent rinse liquors are applied
to the fabric articles, converted to subsequent rinse liquor
mixtures, which are at least partially removed from the treatment
chamber; g. optionally, dispensing into the treatment chamber a
finishing liquor such that the fabric articles are substantially
uniformly contacted by the finishing liquor; wherein the first
rinse liquor comprises a rinse active and a subsequent rinse liquor
or the finishing liquor comprises a fabric care active.
2. The process of claim 1 wherein the rinse liquor contacts the
fabric articles by an indirect method comprising the steps of: a.
introducing the rinse liquor to outside of the treatment chamber;
and b. tumbling the chamber such that the rinse liquor passes
through perforations in the treatment chamber to contact the fabric
articles.
3. The process of claim 1 wherein quantity of the first rinse
liquor in step (d) is from about 5 to about 20 times of the dry
weight of the fabric articles.
4. The process of claim 1 wherein quantity of each subsequent-rinse
liquor in step (f) is from about 1 to about 10 times of the dry
weight of the fabric articles.
5. The process of claim 1 wherein the rinse liquor mixture in step
(d) or step (f) is removed from the treatment chamber by a
non-centrifugal method.
6. The process of claim 1 wherein the first rinse liquor in step
(d) comprises a rinse active selected from the group consisting of
soil suspending agents, hydrotropes, rinse activators, dye transfer
inhibition polymers, pH modifiers, and mixtures thereof.
7. The process of claim 6 wherein the soil suspending agent is
selected from the group consisting of ethoxylated amines,
zwitterionic polymers, polycarboxylates, polyalkyleneglycols,
polyaminoacids, and combinations thereof.
8. The process of claim 7 wherein the soil suspending agent is an
ethoxylated amine selected from the group consisting of (a) a
polyethyleneimine having an average molecular weight of about 189
to about 1800 daltons, each nitrogen in the backbone has a
substituent (EO).sub.x wherein x is an integer from 7 to 30, and
some or all of the terminal OH groups have been substituted with
sulfate groups and/or some or all of the amine groups have been
quaternized with methyl, ethyl, or benzyl groups; (b) a
polyhexamethyleneimine having an average molecular weight of about
116 to about 550 daltons, each nitrogen in the backbone has a
substituent (EO).sub.x wherein x is an integer from 7 to 30, and
some or all of the terminal OH groups have been substituted with
sulfate groups and/or some or all of the amine groups have been
quaternized with methyl, ethyl, or benzyl groups; and (c) mixtures
thereof.
9. The process of claim 7 wherein the soil suspending agent is a
polycarboxylate selected from the group consisting of water-soluble
salts of polyacrylic acid, water soluble salts of poly(maleic
acid)-co-poly(acrylic acid), carboxymethylcellulose, and mixtures
thereof.
10. The process of claim 6 wherein the hydrotrope is selected from
the group consisting of metal salts of cumene sufonic acids,
toluene sulfonic acid, or xylene sulfonic acid, and mixtures
thereof.
11. The process of claim 6 wherein the rinse activator is selected
from the group consisting of fatty mono- or oligo- amines, wherein
one or more of the nitrogen in the backbone has backbone has a
substituent (EO).sub.x wherein x is an integer from 7 to 30, and
some or all of the ternminal OH groups have been substituted with
sulfate groups and/or some or all of the amine groups have been
quaternized with methyl, ethyl, or benzyl groups; analogs of the
ethoxylated fatty amines or quaternized fatty ethoxylated; and
mixtures thereof.
12. A process of claim 6 wherein the dye transfer inhibition
polymers are selected from the group consisting of
polyvinylpyrrolidone, polyvinylpyridine-N-oxide,
poly(vinylpyrrolidone)-co-poly(vinylimidazole)- , manganese
phthalocyanine, peroxidases, and mixtures thereof.
13. The process of claim 1 wherein the subsequent rinse liquor
and/or the finishing liquor comprises fabric care actives selected
from the group consisting of dye transfer inhibition polymers,
anti-abrasion agents, fabric enhancement agents, crystal growth
inhibitors, dye fixative agents, fabric softening agents, fabric
rejuvenating agents, fiber/water protection agents, and mixtures
thereof.
14. A process of claim 13 wherein the anti-abrasion agents are
selected from the group consisting of homo or copolymers containing
one or more of the following monomers: acrylamide, vinylamine,
3-trimethylammoniopropyl acrylate, N-alkylvinylpyridine,
N-oxide-vinylpyridine, vinylalcohol, dialkyldiallylammonium
chloride, N,N-dialkylaminoalkyl(meth)acrylate,
N,N-dialkylaminoalkylacrylate, N,N-dialkylaminoalkylacrylamide,
N,N-dialkylaminoalkyl(meth)acrylamide, and the quaternized
derivatives thereof.
15. A process of claim 13 wherein the dye fixative agents are
selected from the group consisting of the amines; quaternized
amines; polydiallyl dimethyl ammonium chloride; copolymers of
epichlorohydrin and amines such as imidazole,
dimethylaminopropylamine; polyvinylamine; water soluble salts of
magnesium(II) and zinc(II), and aluminum (III); the hydrochloride,
acetate, metosulphate and benzyl hydrochloride salts of diamine
esters, the N-oxides of tertiary amines; derivatives of polymeric
alkyldiamines, polyamine-cyanuric chloride condensates, and
aminated glycerol dichlorohydrins.
16. A process pf claim 13 wherein the fabric enhancement agents are
selected from the group consisting of triethanolamine;
monoethanolamine; N,N'-bis(3-aminopropyl)-1,3 -propylenediamine
(TPTA), dipropylenetriamine (5-N'-methyl dipropylenetriamine),
1,4-piperazines, their N-alkylated and N-hydroxyalylated
derivatives, and mixtures thereof.
17. A process of claim 13 wherein the fabric rejuvenating agents
are selected from the group consisting of aminopropylated
polydimethylsiloxane, aminopropyl-aminoethylated
polydimethylsiloxane, aminosilicones, cationic aminosilicones,
polydimethylsiloxanes; polydimethylsiloxanes or trisiloxanes with
pendant polyethylene or polyethylene/polypropylene sidechains,
alkylated or hydroxyalkylated celluloses.
18. A process of claim 13 wherein the crystal growth inhibitors are
selected from the group consisting of glycolic acid, phytic acid,
polycarboxylic acids, polymers and co-polymers of carboxylic acids
and polycarboxylic acids, ether hydroxypolycarboxylates,
polyacrylate polymers, copolymers of maleic anhydride and the
ethylene ether or vinyl methyl ethers of acrylic acid, citric acid
and soluble salts thereof, 3,3-dicarboxy-4-oxa-1,6-hexanedioates,
alkyl and alkenyl succinic acid and salts thereof,
organo-diphosphonic acids or salts such as ethylene diphosphonic
acid, alpha-hydroxy-2 phenyl ethyl diphosphonic acid, methylene
diphosphonic acid, vinylidene-1,1-diphosphonic acid,
1,2-dihydroxyethane-1,1-diphosphonic acid, hydroxy-ethane 1,1
diphosphonic acid, the salts thereof, and mixtures thereof.
19. A process of claim 13 wherein the fiber-water protecting agents
are selected from the group consisting of low molecular weight
aliphatic or aromatic alcohols, low molecular weight alkylene
glycols, low molecular weight alkylene glycol ethers, low molecular
weight esters, or low molecular weight alkylene amines or
alkanolamines.
20. A process of claim 13 wherein the fabric softening agents are
cationic dialkyl or diester quaternary ammonium salts.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 60/483,153, filed on Jun. 27, 2003; and U.S.
Provisional Application Ser. No. 60/483,155, filed on Jun. 27,
2003.
FIELD OF THE INVENTION
[0002] The present invention relates to a fabric article treating
system, including the apparatus and the process, to provide
improved fabric cleaning, fabric appearance and/or fabric care
benefits. More particularly, the present invention relates to an
effective and direct delivery system whereby detergent actives and
rinse actives are directly deposited upon a fabric article being
treated. The present invention also relates to novel detergent
composition and fabric care composition for use in such apparatus
and process. The system is water-saving and energy efficient,
compared to conventional immersive aqueous laundry system, while
providing enhanced fabric cleaning and fabric care.
BACKGROUND OF THE INVENTION
[0003] Conventional aqueous-based laundering apparatuses and
processes typically employ the immersive mode of laundering, that
is, the amount of wash medium in the chamber is far above the
absorptive capacity of the fabric load such that the fabric
articles are bathed in "free" or excess wash medium. However,
complete immersion may not be an effective or economical way to
deliver detergent actives or rinse actives. When diluted in large
quantity of aqueous wash medium, only a small percentage of the
actives come into contact with the fabric articles while most of
the actives are lost in the wash and rinse fluids. Moreover,
certain actives have a higher affinity for water than the affinity
for the fabric surface such that these actives fail to partition
out of the aqueous wash medium and onto fabric surface effectively
even when the actives happen to contact fabric surface.
[0004] There has been a long-felt yet unmet need in the fabric
detergent art to be able to deliver highly water-soluble actives
onto the fabric surface without significant waste of actives down
the drain. Delivering certain actives that have high water
solubility to the fabric surface places the laundry detergent
formulator in the unfortunate position of having to work the
paradigm of the required chemistry. On one hand, the high degree of
polarity is what enables the actives to perform and deliver the
desired benefits, such as cleaning or interacting with soils; on
the other hand, these very same features prevent the actives from
efficient partitioning out of solution, and most of the active
"goes down the drain". So far, there are few if any satisfactory
ways to achieve this objective. For example, strategies to enhance
the surface activity of the active usually attenuate the
polar/hydrophilic properties that are desired for performance, and
"delivery enhancement actives" (e.g. high molecular weight
polymers) often result in less effective cleaning or are
expensive.
[0005] In an alternative approach, the actives are delivered via a
low volume of wash medium or delivered to the fabric surface
directly. However, it remains a challenge to distribute the low
volume of actives evenly or substantially evenly over the entire
fabric surfaces in the fabric load in the chamber. For example,
surfactants delivered only to certain areas and not to others would
result in uneven cleaning, or even to unacceptable failure in
cleaning performance. Another example is perfume: perfume is an
expensive and very potent active; therefore, a small volume of
perfume is typically used in a fabric article treating process and
substantially even distribution is necessary. In other words, it is
not desirable to deliver perfume in such a manner that one treated
fabric article is drenched in perfume while another treated fabric
article receives only a drop of perfume in one area.
[0006] Based on the foregoing, it is desirable to have a way of
delivering these actives onto the fabric surface effectively and
economically. This delivery method would make it feasible to treat
fabric articles with currently available or novel actives having a
low partition factor between the aqueous medium and the fabric
surface. This delivery method would also make it feasible to treat
fabric articles with expensive actives.
[0007] Based on the foregoing, it is further desirable to have a
way of achieving even or substantially even distribution of the low
volume of actives over the entire fabric surface such that the
treated fabric articles do not exhibit blotchy or uneven
benefits.
SUMMARY OF THE INVENTION
[0008] The present invention fulfills the need described above by
providing a fabric article treating system that effectively
deposits fabric article actives on fabric articles in need of
treatment.
[0009] In one aspect of the present invention, a fabric article
treating process capable of effectively delivering specific rinse
actives and/or fabric care actives to the fabric articles being
treated is provided. The process comprises the steps of:
[0010] a. placing fabric articles comprising soils inside a
treatment chamber of the laundering apparatus;
[0011] b. dispensing into the treatment chamber a wash liquor such
that the fabric articles are substantially uniformly contacted by
the wash liquor;
[0012] c. allowing the wash liquor to remain in contact with the
fabric articles for a period of time while the fabric article is in
motion, continuously or intermittently;
[0013] d. dispensing into the laundering apparatus a first rinse
liquor comprising water such that the first rinse liquor directly
or indirectly contacts the fabric articles, wherein quantity of the
first rinse liquor is sufficient to produce enough free water to
adequately suspend the detergent active and soils, and the first
rinse liquor is thereby converted into a first rinse liquor mixture
comprising water, detergent active and soils;
[0014] e. removing at least part of the first rinse liquor mixture
from the treatment chamber; and
[0015] f. optionally, steps (d) and (e) are repeated such that one
or more subsequent rinse liquors are applied to the fabric
articles, converted to subsequent rinse liquor mixtures, which are
at least partially removed from the treatment chamber;
[0016] g. optionally, dispensing into the treatment chamber a
finishing liquor such that the fabric articles are substantially
uniformly contacted by the finishing liquor.
[0017] wherein the first rinse liquor comprises a rinse active and
a subsequent rinse liquor or the finishing liquor comprises a
fabric care active.
DETAILED DESCRIPTION OF THE INVENTION
[0018] All ratios are weight ratios unless specifically stated
otherwise.
[0019] Except as otherwise noted, all amounts including quantities,
percentages, portions, and proportions, are understood to be
modified by the word "about", and amounts are not intended to
indicate significant digits.
[0020] Except as otherwise noted, the articles "a", "an", and "the"
mean "one or more"
[0021] As used herein, "and/or" means subject X or subject Y or
both.
[0022] As used herein, "fabric article" means any article, composed
of fabrics and/or fibers, that is customarily cleaned in a
conventional laundry process or in a dry cleaning process. As such
the term encompasses articles of clothing, bed linens, bath linens,
table linens, drapery, furniture covers, carpets, and clothing
accessories. The term also encompasses other items made in whole or
in part of fabric, such as tote bags, sleeping bags, tarpaulins,
tents, and the like.
[0023] As used herein, "non-immersive" means that essentially all
of the wash fluid is in intimate contact with the fabric articles.
There is at most minimal amounts of "free" wash fluid. It is unlike
an "immersive" process where excess wash fluid forms a bath in
which the fabric articles are submerged. A process is non-immersive
if the fluid applied is less than about 100% of the dry weight of
the fabric article; at this applied fluid level, the fluids are
substantially absorbed by the fabric articles and there is minimal
amount of free fluid. However, it should be noted that different
fabric types and weaves can vary greatly in their degree of water
absorptiveness, hence, some thin fabrics made from artificial
fibers will only absorb substantially less than 100% of their dry
weight before additional water becomes "free wash fluid", whereas
some thick cotton fabrics may absorb substantially more than 100%
(e.g. sometimes more than 200%) of their dry weight before
additional water becomes "free wash fluid". Thus, in an average
load of household laundry, a process is non-immersive if the fluid
applied in the process is less than about 80% of the dry weight of
the fabric article load. As used herein, "dry weight of a fabric
article" means the weight of a fabric article that has no
intentionally added fluid weight.
[0024] As used herein, "fabric article treating/treatment
composition" or "treating liquor" means a composition that
comprises one or more fabric treating actives, including detergent
actives, rinse actives or combinations thereof, and optionally, a
polar solvent. Thus, the fabric article treating composition may be
a detergent composition, a rinse composition or a rinse liquor.
Suitable forms of the treatment compositions include, but are not
limited to, liquids, gels, pastes, particles or powders. The
composition may be mixed with a polar solvent, such as water, to
form the liquors used in various steps of the fabric article
treating process.
[0025] As used herein, "detergent active" or "detergent adjunct"
means a material or combination of materials that can deliver
cleaning, soil/stain removal or soil/stain masking benefits to a
fabric article.
[0026] As used herein, "rinse active" or "rinse adjunct" means a
material or combination of materials that can deliver one or more
of the following fabric care or fabric finishing benefits to a
fabric article: softening, crispness, water and/or stain
repellency, refreshing, antistatic, anti-shrinkage, anti-microbial,
durable press, wrinkle resistance, odor resistance, abrasion
resistance, anti-felting, anti-pilling, appearance enhancement, and
mixtures thereof.
[0027] "Average molecular weight" as used herein means the
weight-average molecular weight of a polymer, as determined by gel
permeation chromatography.
[0028] As used herein, "fabric article treating apparatus" means
any apparatus designed to treat fabric articles, such as an
automatic washing machine, horizontal-axis or vertical-axis,
preferably horizontal-axis. Further, the fabric article treating
apparatus is preferably a polar solvent-based fabric article
treating apparatus, wherein a polar solvent is the primary liquid
for rinsing the fabric articles after the cleaning and/or care step
has occurred.
[0029] The fabric article treating apparatus may comprise a source
of the fabric article treatment composition comprising a reservoir
for storing the fabric article treatment composition and an
applicator for applying the fabric article treatment composition
from the reservoir to the fabric article.
[0030] Further, the fabric article treating apparatus preferably
comprises a nozzle, more preferably a plurality of nozzles,
suitable for delivering a fabric article treatment composition.
[0031] Fabric Article Treating Apparatus
[0032] An apparatus of the present invention can be built or
modified from a conventional aqueous based laundering machine such
that the modified apparatus is capable of applying a very low
volume of a treating liquor (e.g., a neat detergent composition or
a neat rinse composition) into a fabric treating chamber and onto
fabric articles in the treating chamber. Specifically, the
apparatus of the present invention is designed to provide uniform
or substantially uniform treatment of the fabric articles. In one
embodiment, laundering apparatus that guarantee homogeneous
coverage of the fabric articles with the neat composition by
intermittent spin and spray, concurrently with or followed by
random tumbling until all the wash medium has been sprayed. For
example, modifications of conventional low water wash appliances to
deliver low levels of a treating liquor should be considered; such
conventional water wash appliances are described in U.S. Pat. Nos.:
4,489,574; 4,489,455; 5,191,669; 5,191,668; 5,233,718; and
5,671,494. Another example of automatic washing machine useful for
such low volume treating process is described in detail in U.S.
Pat. No. 6,691,536.
[0033] FIG. 1 is a schematic illustration of an embodiment of
apparatus for carrying out the fabric article treating process in
accordance with the present invention.
[0034] The apparatus 70 comprises a fabric article treating chamber
1 capable of receiving a fabric article to be treated directly with
a detergent composition, or with a wash or rinse liquor comprising
water. When a fabric article to be treated is present in the
chamber and a wash liquor is introduced into the fabric treating
chamber 1, the treating chamber 1 retains an amount of the wash
liquor up to the non-immersive level of the fabric articles
contained therein. Additionally, the treating chamber 1 can be a
fluid pervious (e.g., via perforations in the side wall)
chamber.
[0035] The apparatus 70 may optionally comprises an outer chamber 2
capable of receiving the wash or rinse liquor from the fabric
article treating chamber 1 that is not retained in said
fabric-treating chamber. The outer chamber 2 is configured to house
the chamber 1. The outer chamber 2 typically comprises an exit port
or drain 7 through which the fluid received by the outer chamber 2
exits the outer chamber 2. It is desirable that the exit of the
fluid from the outer chamber 2 is at a rate such that the amount of
wash liquor in the fabric treating chamber 1 does not exceed the
non-immersive level of the fabrics contained within the fabric
article treating chamber 1.
[0036] In some embodiments, treating chamber 1 and outer chamber 2
are of cylindrical construction and have a horizontal access
opening 58, as shown in FIG. 2. The horizontal center line of the
outer chamber, which is typically stationary with respect to the
chamber 1 coincides with the axis of rotation 100 of chamber 1
movably mounted within the outer chamber 2. The chamber 1 can in
general have any suitable pattern of perforations or openings and
is designed consistently with design principles for maximizing
fluid flow through its perforated surface without weakening it to
an unacceptable extent. The chamber 1 is designed to remain fully
rigid when rotated at a high speed in the presence of a load of
fluid-containing fabric articles. Chamber 1 may contain
strengthening elements, such as struts, not shown, and has a back
face not visible in FIG. 1, which is typically flat, and may be
perforated or non-perforated. The appliance is configured to
preferentially direct at least the wash liquor toward the
fluid-pervious surfaces of chamber 1, rather than toward the back
face of the chamber 1.
[0037] In another embodiment, the rinse liquor contacts the fabric
articles being treated by an indirect method, wherein the rinse
liquor is first introduced into chamber 2, which is located outside
the fabric article treating chamber 1, then the chambers are
rotated such that the rinse liquor passes through the perforations
and contacts the fabric articles inside the treating chamber 1.
[0038] As is more clearly illustrated in the cross-sectional views
of FIG. 2, outer chamber 2 comprises a peripheral wall 62, a back
wall 63 secured to one edge of the peripheral wall, a front wall 64
secured to the opposite edge of the peripheral wall; said front
wall has a tubular-shaped extension 55 having an access opening 58
used to load and unload laundry from the apparatus 70. This
flexible tubular-shaped extension 55 minimizes transmission of
vibrations which occur during operation of the machine. Access
opening 58, forms a gas seal with front door 59 which is secured
about its outermost periphery to the front wall 56 of the washing
machine cabinet. Front door 59 optionally includes additional means
for assuring a good seal, such as rubber, synthetic rubber, or
elastomeric sealing material formed into any suitable shape for
assuring the seal. When the fabric treating apparatus 70 is in
operation, the access door 59 is in the closed position shown in
FIG. 2 and forms a "gas-tight" seal against the outermost portion
of flexible tubular-shaped extension 55. The quality of the seal is
sufficient to permit overpressures or reduced pressures in the
appliance, but need not be of the quality required for extreme
pressure, e.g., supercritical carbon dioxide operation. These
latter elements are illustrated only in the cross-section of FIG. 2
to ensure maximum clarity in the remaining drawing figures.
[0039] As can be seen in FIG. 2, outer chamber 2 is supported by
means of four suspension springs 47 (only two of which are shown)
which are connected at one end to the uppermost portion of the
outer chamber 2 and at their other end are secured to the fabric
treating apparatus cabinet. The top spring 47a is connected to a
load sensor 48 interfaced with controller. In variations of the
appliance not shown, any desirable high-speed suspension, load
balancing or stabilizer system, for example of types known or
disclosed for modern European front-loader washing machines, can be
adapted for use in the present apparatus.
[0040] In one embodiment, chamber 1 comprises a fluid-pervious
(e.g., perforated) peripheral wall 65, a substantially imperforate
back wall 66 secured to said peripheral wall and a substantially
imperforate front wall 67, secured to the opposite edge of said
peripheral wall.
[0041] Chamber 1 is rotatably secured to outer chamber 2 by means
of drive shaft 49. Power to rotate chamber 1 is transmitted by
means of a concentrically mounted drive pulley 50. The drive system
comprises a variable speed drive motor 54 secured to peripheral
wall 62 of outer chamber 2. Any movement of outer chamber 2 does
not affect the speed of rotation of chamber 1. The output shaft 53
of drive motor 54 has a secured drive pulley 52. Pulley 52 is
connected to pulley 50 by means of conventional drive belt 51. A
possible alternative drive system, not shown in the figures, has
instead of a single drive pulley 52, two drive pulleys, one
eccentrically mounted and one concentrically mounted. In this
alternative drive system power to rotate chamber 1 is transmitted
to the external portion of drive shaft 49 either by means of an
eccentrically mounted driven pulley or by means of a concentrically
mounted driven pulley which are both secured in fixed relation to
drive shaft. The eccentrically mounted driven pulley would be used
to vary the speed of rotation of the chamber 1 throughout each
revolution of the chamber, while the concentrically mounted driven
pulley would be used to drive the chamber 1 at a constant speed of
rotation throughout each revolution.
[0042] In one embodiment of the present invention, drive motor 54
is not only variable speed, but is also reversible so that chamber
1 may be rotated first in one direction and then in the opposite
direction during specific portions of the laundering cycle.
Reversing the direction of chamber rotation several times during
stages of fluid application/removal provide more uniform agitation
to the fabric articles being treated, hence more uniform
application of the wash or rinse liquor, thereby providing more
effective removal of soil and/or more uniform fabric care benefits.
Conversions between rotation speed and G-force of any particular
chamber can be calculated using the following formula 1 v = 2 r t
a.sub.c=v.sup.2/r
F.sub.g=a.sub.c/g
[0043] Where r is the radius of the drum;
[0044] t is the time in minutes of one revolution;
[0045] v is the velocity of rotation;
[0046] a.sub.c is the centripetal acceleration;
[0047] g is 9.8 m/S.sup.-2(acceleration of earth's gravity);
and
[0048] F.sub.g is the G force.
[0049] For example a drum with a radius of 10.5' would need to be
rotated at 40 revolutions per minute (rpm) to generate a force of
0.5 G. Rotating the same drum at 55 rpm would generate a force of
0.9 G. These illustrative examples have no particular significance
other than to illustrate the calculation, do not relate to any
critical ranges of operation (these are given elsewhere herein) and
cannot be construed as limiting of the scope of the present
invention.
[0050] The apparatus of the present invention is configured to
provide chamber 1 with more than one rotation speed with respect to
the outer chamber 2. The variable rotation speed of treatment
chamber 1 can be selected to achieve specific benefits during
different stages of the wash/rinse cycle. In one embodiment, the
treating chamber 1 is rotated at a speed of to generate a force of
up to about 1 G, or from about 0.7 G to about 1 G, or from about
0.5 G to about 3 G, to tumble the fabric articles while the
treating liquor is being applied such that more uniform deposition
of the treating liquor on the fabric surface is achieved. Low speed
rotation also causes agitation of the fabric articles inside the
chamber 1. The chamber 1 can be rotated to generate a centrifugal
force of from about 50 G to about 450 G, or from about 150 G to
about 400 G, such that the fabric articles are "spun" or pressed
against the walls to effectively remove treating liquors from the
fabric articles and/or the chamber.
[0051] In another embodiment, the front wall 67 has a
tubular-shaped extension 55 with an access opening 58, which is
used to load and unload laundry from the fabric treating apparatus
70, and is concentrically aligned with the access opening 58 in
outer chamber 2. Equally spaced on the inner circumference of
peripheral wall 65 are three lifting vanes 60, having cross-section
that are substantially triangular or other shapes. In a specific
embodiment, each of the vanes is symmetrically-shaped about a
radially extending line originating at the axis of rotation 100 of
chamber 1 and passing through its altitude. This permits rotation
of chamber 1 in opposite directions with equal lifting effect on
the articles being laundered. It should be understood and
appreciated that most conventional laundering machines do not have
lifting vanes, while tumble-dryers have lifting vanes designed for
low-speed and/or unidirectional "tumbling" operation. Further, the
chamber 1 may comprise baffles or other structures a long its
interior surface to aid in repositioning the fabrics contained
therein.
[0052] In still another embodiment of the present invention, the
treating chamber 1 comprises at least two rotatable portions (not
shown) and the drive system is capable of rotating the treating
chamber 1 in such a manner that relative rotation is produces
between adjacent rotatable portions. This allows the fabric
articles inside chamber 1 to be agitated at a higher rate than in a
single portion, unitary chamber typically found in a conventional
laundering machine. An example of such contra-rotation treating
chamber is described in PCT publication WO 99/58753.
[0053] Pump 24 is connected to applicator 26 via conduit 25 in
order to introduce fluids into interior of chamber 1. The
applicator 26 may be a spray nozzle, an atomizer, a nebulizer or
like device, of any suitable configuration.
[0054] Spray technology including spray qualities and nozzle types
is well described in the reference Atomization and Sprays, by A. H.
Lefebvre, Hemisphere Publishing Company, USA, 1989. There are many
ways to apply the treatment fluids via spray applicators in
accordance with the present invention.
[0055] Sprays vary in pattern, penetration length, shape, and
droplet size among others. In one embodiment, applicator 26 is
configured to deliver a flat fan spray and/or a cone spray. A solid
cone spray is one wherein the droplets are fairly uniformly
distributed throughout a solid conical spray volume. A hollow cone
spray is one wherein the droplets are concentrated at the outer
edge of a conical spray pattern. A fan spray or flat spray or flat
fan spray produces a liquid sheet parallel to the major axis of the
orifice, the spray pattern is in the shape of a sector of a circle
of about a 75-degree angle and is elliptical in cross section.
[0056] A spray nozzle typically provides an average droplet size
that is less than about 1200 microns, typically from about 100 to
about 1000 microns, or from about 120 to about 500 microns, or from
about 150 to about 300 microns. This average droplet size is
measured by either a Malvern particle analyzer or high speed
photography. When a spray nozzle is covered with a fine grid or a
membrane to produce a finer mist of droplets with an average
particle size of less than 100 microns, the spray pattern is
typically disturbed by air movement in chamber 1. Higher rotation
speed of the chamber 1, typically above 735 m/s.sup.2, requires
larger droplets in spray pattern.
[0057] The pressure in the delivery conduit 25 may be adjusted and
optionally, be accompanied with a heater for adjusting the
temperature, the present apparatus is capable of applying all types
of fluids, gels, pastes and other materials, including Newtonian
and non-Newtonian fluids, shear-thinning and non-shear thinning
fluids, multiphase mixtures, emulsions, microemulsions, and
dynamically changing emulsion systems.
[0058] In one embodiment of the present invention, a suitable spray
nozzle is rated to deliver 0.5 gallons per minute (about 1.87
liters per minute) at 40 psi (about 275 kPa) fluid pressure,
maximum pressure 100 psi (about 690 kPa), and forms a spray angle
of 80.degree..
[0059] In another embodiment, the treating liquor is delivered via
multiple spray nozzles; each spray nozzle is positioned such that
the liquor is sprayed from the multiple spray nozzles in a fashion
to evenly distribute the fluid on the fabric articles being
treated. In another embodiment, the apparatus has one nozzle for
delivering the wash liquor and other nozzles for delivering the
rinse liquor. Such other spray nozzles can operate at any suitable
cycle (such as washing, rinsing, or extracting) in a fabric
treating process and can be sequential with or concurrent with
application and/or removal or the treating liquors.
[0060] In another embodiment, other applicators or dispensing
devices, for example, atomizers, nebulizers, and like devices, are
used. Nebulizers, atomizers or like devices are well known to those
skilled in the art. These devices are capable of disintegrating a
quantity of fluid into fine droplets. A typical applicator of this
type is capable of providing droplets having average particle size
less than about 100 microns, typically from about 0.1 to about 60
microns, or from about 0.5 to about 40 microns, or from about 1 to
about 20 microns. Due to the small particle size, the droplets are
more susceptible to air movement in the chamber 1. An air
circulation device, such as a fan, may be used to direct the
droplets towards the walls 65, 66, 67.
[0061] Some well known atomizers include orifice atomizers which
employ high speed ejection to produce droplets, pressure atomizers
which convert pressure into kinetic energy to produce droplets, and
ultrasonic atomizers which employ high frequency vibration to
release fine droplets from the fluid surface. A suitable ultrasonic
atomizer is commercially available under the tradename Acu
Mist.RTM. from Sono Tek Corporation, Milton, N.Y. Still other
examples of such devices are available from Omron Health Care,
GmbH, Germany; and from Flaem Nuove, S.P.A, Italy. Likewise,
aerosol delivery systems, which are well known to the art, can be
used to deliver the detergent and/or finishing compositions.
Electrostatic dispensing devices can also be used to dispense the
compositions to the chamber 1. Exemplary of such electrostatic
dispensing devices are described in U.S. patent application Ser.
No. 10/418,595 (P&G Case 8903) and PCT Publication WO
03/02291.
[0062] Other dispensing devices can be removably attached to the
front door 59 are described in U.S. patent application Ser. No.
10/697,735; 10/697,685; and 10/697,736 (P&G Cases 9397, 9398,
and 9400); U.S. patent application No. 2003/0200674A1; PCT
publications WO 03/087285 and WO 03/087461. It is understood that
these dispensing devices can be used to deliver the detergent
composition, the finishing composition, and even the liphophilic
fluid.
[0063] FIG. 2 shows an example of the internal configuration of
applicator 26, as a spray nozzle in the following embodiments. The
applicator 26 is shown in FIG. 2 as parallel to the axis of
rotation 100 of the chamber 1. In another embodiment the applicator
26 is located on the axis of rotation 100 of the chamber 1. The
applicator 26 is supported by a spraying arm 57 secured to the
front door 59. The fluids are delivered to the nozzle 26 via duct
61 connecting fluid delivery conduit 25 to the nozzle 26.
Applicator 26 is located parallel to the axis of rotation 100, so
that it directs a flat, fan-shaped spray to strike peripheral wall
65, front wall 67, and back wall 66 of the chamber 1. Spray arm 57
allows spraying onto the front wall of the chamber 1 without any of
the garments in the discrete fabric articles been wrapped around
the spray arm 57 during tumbling cycle and consequently inhibit or
possibly even prevent efficient cleaning of the discrete fabric
articles.
[0064] In an alternative embodiment, not illustrated in the FIG. 2,
the applicator 26 can be directly secured to flexible
tubular-shaped extension 55, eliminating the need for spray arm 57
and duct 61. Thus, applicator 26 can be directly linked to fluid
delivery conduit 25. Applicator 26 can be located in a position on
the flexible tubular-shaped extension 55 which can allow it to
direct a flat, fan-shaped spray to strike peripheral wall 65, front
wall 67, and back wall 66 of the chamber 1. Different location
and/or configuration of the applicator 26 and/or the spray arm 57
are also suitable so long as the applicator nozzle or plurality of
nozzles is not located where the fabric articles in the chamber can
get tangled with or wrapped around the spray arm 57, applicator 26,
or any other structure associated with the applicator 26, during an
operating cycle (e.g., a tumbling cycle). In one embodiment of the
invention, the location and/or configuration of the applicator 26
(in the form of a spray nozzle or a plurality of such nozzles) is
selected such that the applicator 26 directs a flat, fan-shaped
spray to strike preferentially at the fluid-pervious peripheral
wall 65, and optionally, to the front wall 67 and/or the back wall
66 as well.
[0065] In another embodiment of the present invention, the treating
composition is delivered to the outer chamber 2 such that the fluid
level in the outer chamber 2 is below the bottom of the fabric
article inside treating chamber 1. During the treating process, the
treating chamber 1 can rotate such that centrifugal forces and/or
gravity pulls the treating composition through the perforations 46
of chamber 1 to come into contact with fabric articles inside
chamber 1. Similarly, in an extracting or removing fluids step, the
treating composition from chamber 1 can pass through the
perforations 46 of chamber 1, and down the outer surface of the
chamber 1 until they reach the bottom (i.e., the lowest point) of
the outer surface of the chamber 1, pass through the perforations
in chamber walls, then to the bottom of the inner surface of the
outer chamber 2. Conduit 7 is located at this bottom (i.e., lowest
point). The inner surface of the outer chamber is designed to
direct all fluids/droplets into conduit 7. Fluids in conduit 7, as
well as those from conduit 37, described in more detail
hereinafter, are then fed into the filter 6 and tank 8 by means of
a pump 3 having a maximum rated capacity of 3 gallons per minute
and maximum pressure 50 psi (345 kPa). The delivery conduit 7
typically has a diameter of 1/2' (127 mm).
[0066] Fabric Article Treating Process
[0067] Another aspect of the present invention provides a fabric
article treating process. The process comprises the step of
applying a low volume of detergent composition to the fabric
articles such that the composition is substantially evenly
distributed onto all portions of the fabric articles being treated
and the subsequent steps of applying and extracting one or more
rinse liquors sufficient to remove the detergent composition and/or
soils, and to substantially evenly distribute rinse actives to all
portions of the fabric articles being treated. Optionally, a
finishing liquor comprising fabric care actives is applied to the
fabric articles.
[0068] It is desirable that the fabric article is uniformly or
substantially uniformly treated with the fabric article treatment
composition such that the desired benefit is recognizable by a
consumer. The extent of uniformity can vary depending upon the
fabric article actives present in the fabric article treatment
composition. For example, a perfume may not need to be entirely
uniformly applied if its benefit is recognizable by a consumer
without being entirely uniformly applied. Other the other hand, an
anti-wrinkle agent may need to be applied uniformly in order for
its benefit to be recognized by a consumer.
[0069] (A) Wash Liquor Application Step
[0070] The wash liquor for the present process can be a
concentrated detergent composition applied to the fabric article
"as is" or in its "neat form". In this aspect of the present
invention, the detergent composition is not diluted by any
additional diluent, such as a polar solvent, prior to contacting
the fabric article. In other words, the fabric article treatment
composition, in neat form, contacts the fabric article prior to
contacting any discrete diluent or other solution. This is unlike
conventional washing systems where the fabric article treatment
composition, such as a detergent, is added to an excessive amount
of a diluent and/or other solution, such as water, to form a
mixture which then contacts, or more typically bathes, the fabric
article. "Neat form" refers to the detergent composition that a
user obtained from a vendor of the composition, thus, the neat form
can include water, in combination with fabric article actives.
Water is typically present in liquid or paste detergent
compositions in their neat forms.
[0071] In another aspect of the present invention, the wash liquor
can also be prepared by mixing the paste or liquid concentrate
detergent composition with water or dissolving/suspending the
granular detergent composition in water to form a wash liquor,
which is applied to the fabric article. The mixing or dissolving
can be done outside of the apparatus, or can be done by placing the
detergent composition in a wash liquor reservoir and fill it from a
water supply line or in the case of a liquid concentrate, a flow
through cell can be used to mix and prepare the wash liquor. As
used herein, the term "wash liquor" is meant to encompass both the
embodiment wherein the detergent composition is applied to the
fabric article in its neat form, and the embodiment that a
pre-dilute or pre-dissolved a detergent composition (e.g., liquid
concentrate, paste, granules) is applied to the fabric article.
[0072] The wash liquor is applied to the fabric article being
treated to achieve substantially uniform distribution over all
portions of the fabric article. Non-uniform distribution of the
wash liquor tends to create clean spots where disproportionate
amount of the wash liquor contacts the fabric article and leaves
the non-contacted portions or the less saturated portions of the
fabric articles untreated or not as well cleaned. This is
especially true where the amount of the wash liquor is about or
below non-immersive level.
[0073] A combination of factors are employed in the system of the
present invention to better achieve the substantially uniform
distribution of the wash liquor to the fabric article, including,
but not limited to, applying the wash liquor in fine droplets forms
in a continuous manner or an intermittent/pulsed manner; moving or
tumbling the fabric articles while the wash liquor is being applied
such that all portion of the fabric article is exposed, wherein the
moving or tumbling mode can be continuous or intermittent, forward
or reverse, uni-, bi- or multi-directional; incorporating and/or
using additional structural elements, such as lifting vanes, spray
arms, contrarotating chamber sections, such that bundling of fabric
articles during treatment is prevented or minimized.
[0074] The uniformity of the applied wash liquor, expressed as a
Spray Uniformity Index, can be determined by the following method.
A representative load of fabric articles (such as the mixed fabric
load described in ASTM test D2960-98) is placed into the apparatus.
Also included in the load are eight tracers comprising 25
cm.times.25 cm squares of white cotton fabric; each tracer is then
marked with a wash-safe marker to subdivide the tracer into a grid
of twenty-five 5 cm.times.5 cm squares. A wash liquor which has
been spiked with 1% of a standard red dye solution is applied via
the applicator to the amount of about 50% of the dry weight of the
load. The swatches are then removed, air-dried, and the color
intensities of the tracers' 5 cm.times.5 cm square regions are each
graded visually on a scale of 0-10 where a grade of 0 corresponds
to a reference cotton swatch, and a grade of 10 corresponds to a
white cotton reference swatch totally submerged in the dye-spiked
wash liquor solution for 10 seconds and then dried. From the 200
grades obtained from the tracers, an average grade and standard
deviation are calculated. The Spray Uniformity Index is the
percentage of swatches whose grades fall within 0.5 standard
deviation of the average grade. The process of the present
invention is capable of delivering a Spray Uniformity Index of
greater than about 90.
[0075] Thus, the process is extremely efficient because the
quantity of wash liquor used can be as low as about 0.25 times of
the dry weight of the fabric articles. The process also permits
very effective detergent/soil interactions because no excess water
is present to dilute the interactions. Furthermore, the process
permits the use of certain hydrophilic detergent actives that are
not effective in conventional immersive aqueous wash system because
such detergent actives have relatively poor fabric affinity and
would prefer to remain in the aqueous bath rather than being
deposited onto the fabric surface and interacting with the
fabric/soil. Specifically, the present process can employ actives
having an in-wash fabric-water partition ratio (Q.sub.i) of less
than about 0.3 as described below.
[0076] In the process of the present invention, the amount of wash
liquor used in the wash step is extremely low. By application of a
low volume of the wash liquor directly onto the fabric articles in
a substantially uniform manner, the resulting fabric articles are
coated with a thin film of the wash liquor. Within such a thin
film, the detergent actives are in intimate contact with the fabric
surface and are able to suspend and/or remove soils from fabric
surface. Moreover, errand dye molecules are confined by the thin
film and is less prone to transfer to another fabric surface.
[0077] In one embodiment, the volume of the wash liquor applied
during of the thin film wash step is less than about 75%, or less
than about 50%, or less than about 25%, of the dry weight of the
fabrics being treated. In another embodiment, the volume of the
wash liquor applied is from about 50% to about 200%, or from about
75% to about 150%, of the dry weight of the fabrics being
treated.
[0078] As the amount of wash liquor applied is reduced, it becomes
more important to distribute the wash liquor uniformly over the
fabric article surface so as to minimize spotty results from the
low volume, thin film fabric treating process. To achieve uniform
distribution, suitable applicator must be capable of producing an
acceptable spray pattern that results in a uniform spray coverage,
for example, having a Spray Uniformity Index of greater than 90, as
described above.
[0079] The wash liquor may be applied in the form of a fog or a
mist comprising droplets of the wash liquor, wherein at least 80%
(D.sub.80), or at least 90% (D.sub.90) of the droplets have a
droplet diameter of less than about 500 microns or less than 350
microns, or less than 200 microns.
[0080] In one embodiment of the present invention, a spray nozzle
is employed, which is capable of delivering a flat fan spray in a
solid cone spray volume wherein the droplet size falls within the
ranges described above. Alternatively, an atomizer is employed,
which is capable of producing a fine mist or fog comprising fine
droplets with droplet size falling well within the ranges described
above. Suitable applicators are described herein above in the
Apparatus Section.
[0081] The wash liquor application process employs an amount of
wash liquor to achieve an optimal wash liquor to fabric ratio,
which is described below. Without being bound by theory, it is
believed that the optimal wash liquor to fabric ratio is useful in
achieving the following: (1) to ensure most of detergent is in
intimate contact with the fabric, (2) to reduce dye transfer, soil
redeposition, and suds, and (3) to preserve the inherent efficiency
of the process. On one hand, if not enough fluid is added, the
garments are not completely contacted with wash liquor; on the
other hand, too much fluid is added, free (mobile) wash liquor is
present, the concentrated wash liquor can migrate from one garment
to another and cause problems such as dye crocking. It is
previously believed that the optimal wash liquor to fabric dry
weight ratio is between 3/4:1 and 1{fraction (1/2)}:1. It has now
been found that a thin film wash process can be improved or refined
by taking into account factors, such as the variety of fabric
materials, their form of weave and thickness, their degree of
soiling, and other unforeseen factors which are beyond control of
the detergent formulator. This is so because different fabric types
and weaves can vary greatly in their degree of water absorptivity.
For example, certain thin fabrics made from synthetic fibers will
only absorb substantially less than 100% of their dry weight before
additional water becomes "free" wash fluid, whereas thick cotton
fabrics may absorb substantially more than 100% (e.g. sometimes
more than 200%) of their dry weight before additional water becomes
"free" wash fluid. If the overall load is skewed toward one or the
other of fabric types, the optimal amount of wash liquor could vary
significantly from the amount determined simply from the dry weight
of the fabrics.
[0082] It has now been found that an improved or refined wash
liquor to fabric ratio, namely the "absorptive capacity-weighted
wash liquor to fabric ratio," can specific the amount of wash
liquor that both enables the abovementioned thin film distribution
while avoiding excess wash liquor. The "absorptive
capacity-weighted wash liquor to fabric ratio" is defined as
follows:
Z: Y
Y=the total mass of the dry fabric load in kg
Z=.SIGMA.A.sub.1B.sub.1B+A.sub.2B.sub.2+A.sub.3B.sub.3+. . .
A.sub.nB.sub.n
[0083] where 1,2,3, . . . n=the number of different types/weaves of
fabrics; Bn is the mass in kilograms of that portion of the fabric
load comprising a given fabric/weave type; An is the absorption
coefficient for a given fabric/weave type, and is equal to [M/100]
where M is the amount of water in g that are absorbed by a 100 g
swatch of said given fabric weave/type after said fabric is
immersed in water and then centrifuged in a perforated basket for 5
minutes at 400 rpm. Thus, the process of the present invention
employs an optimal amount of wash liquor to deliver an improved
fabric cleaning benefit in the range from about 0.25 to about 2, or
from about 0.5 to about 2, or from about 0.75 to about 1.5, based
on the absorptive capacity-weighted wash liquor to fabric
ratio.
[0084] (B) Optional Incubation step
[0085] After the application step, the optional incubation step
allows the fabric articles and the wash liquor to remain in contact
for a period of time sufficient to allow the detergent actives and
water in the wash liquor to interact with soils, stains, fabric
surfaces. The incubation period may last at least about 1 minute,
or at least about 3 minutes, or at least about 5 minutes. On the
other hand, in order to make this process time efficient, the
incubation period may last less than about 30 minutes, or less than
about 15 minutes, or less than about 10 minutes.
[0086] Optionally, the incubation period can involve the thermal or
non-thermal (e.g. by means of non-heated air circulation and/or
venting) evaporative removal of water to further concentrate the
thin film of wash liquor.
[0087] Optionally, after the fabric articles are contacted by the
wash liquor, energy (thermal and/or mechanical energy) is applied
to the fabric articles in the treating chamber. Thermal energy may
be applied as heated air, steams, microwaves and other radiation
energies. Mechanical energy may be applied by rotaing,
countrarotating, tumbling the treatment chamber 1, and enhanced by
vanes 46, fins, or other structures protruding from the walls of
the treatment chamber.
[0088] Not wishing to be bound by theory, it is believed that
thermal energy may enhance the detergency of the wash liquor, in
the following ways. Thermal energy may improve the kinetics of
composition/fabric/soil interactions. Thermal energy may promote
transitioning of the wash liquor into a "liquid crystalline phase",
which exhibits more effective detergency. As used herein, "liquid
crystalline phase" or "middle phase" refers to any organized
micelle structures, including but are not limited to rodlike,
hexagonal, and lamellar arrangements. At an operating temperature
ranging from about 10.degree. C. to about 70.degree. C., the liquid
crystalline phase can be achieved at a surfactant concentration of
about 10% or greater. Thermal energy may raise the temperature
sufficiently to cause the wash liquor on the fabric surface to
partially lose its water content such that the wash liquor becomes
more concentrated to promote interactions at fabric surface,
formation of middle phase, and ultimately, detergency. Thermal
energy may activate the bleach, inorganic peroxide salt activators
or peroxyacids; non-limiting examples of these heat activatable
materials are disclosed in U.S. Pat. No. 4,248,928; U.S. Pat. No.
4,220,562 and U.S. Pat. No. 4,100,095. Thermal energy may also
promote enzyme activity.
[0089] Mechanical energy may help distributing the wash liquor so
that it is more evenly distributed onto the fabric articles.
Mechanical energy may also minimize the time period that the same
fabric article surfaces are in contact with one another, thus,
minimizes dye transfer. Mechanical energy also contributes to
improved cleaning efficiency, for example, by loosening the soils
from the fabric surfaces.
[0090] (C) Rinse Liquor Application Step
[0091] The rinse liquor may comprise pure water and, optionally
rinse actives. Since a low volume of wash liquor is applied to the
fabric surface to perform the thin film wash step, the detergent
actives, the soils, as well as errand dye materials are
concentrated on the fabric surface. Thus, the goal of the rinse
step is to remove the detergent actives, soils and dye materials
thoroughly. Moreover, if the removal of detergent actives, soils
and dyes is done efficiently in the early stage when these
materials are concentrated, soil redeposition and dye transfer can
be minimized. At the same time, the total amount of rinse water
used in the rinse step need to be limited in order to reduce water
consumption and to minimize water-induced shrinkage in the treated
fabric article.
[0092] Based on the above, an effective rinse can be accomplished
by flushing the system with a large quantity of a first rinse
liquor to produce enough free water on the fabric surface to
adequately suspend the detergent actives, soils and dyes so that
these materials are substantially removed by the first rinse.
Generally, more than one rinse liquors are needed to remove all of
the detergent actives, soils and dyes. The subsequent rinses need
not use as much water as the first rinse liquor. In a typical
embodiment, the amount of the first rinse liquor is from about 5 to
about 20 times the dry weight of the fabric articles, and the
amount of the subsequent rinse liquor is from about 1 to about 10
times of the dry weight of the fabric articles, or about 1/5 to
about 1/2 of the first rinse liquor; and the total amount of water
used in the rinse step(s) is from about 5 to about 50 liters, or
from about 5 to about 20 liters.
[0093] In one embodiment, the complete rinse step comprises two to
five cycles, or frequently, two to three cycles. The first rinse
liquor is typically of pure water and the last rinse liquor may
comprise water and optionally, rinse actives. Each cycle lasts
about 1 to about 15 minutes, or about 3 to about 10 minutes, and
each cycle need not be of the same length of time. In between rinse
cycles, the rinse liquor is removed. Removal or extraction of rinse
liquor can be achieved by rotating or spinning the treating chamber
1 at high speed to produce a centrifugal force of from about 50 G
to about 450 G, or from about 150 to about 400 G. Other ways to
remove the rinse liquor include, but are not limited to, using an
inflatable bladder to squeeze out the rinse liquor, contacting
sponge-like material to suck out the rinse liquor, using a vacuum
pump to suck out the rinse liquor.
[0094] The rinse liquor may be applied in the form of droplets by
the same or similar applicators used to apply the wash liquor,
combined with tumbling to distribute the rinse liquor evenly, to
promote intimate contact between rinse liquor and fabric articles,
or to reduce the contact time between fabric surfaces such that
soil redeposition and/or dye transfer between fabric surfaces are
minimized. In one embodiment, due to the quantity of the rinse
liquors applied, especially the first rinse, instead of spraying or
misting, the rinse liquor is pumped into the chamber 1 at a rate of
from about 1 to about 20 liters/minute, or from about 1 to about 10
liters/minute, or about 2-5 liters/minute. In another embodiment,
the first rinse liquor is pumped in and the last rinse liquor is
sprayed or misted.
[0095] In one embodiment, the rinse liquor is applied to the fabric
articles in the treating chamber indirectly. That is, the rinse
liquor is delivered to the outer chamber 2 to a level just below
the bottom of the treating chamber 1, and by rotating or tumbling
the treating chamber 1, the rinse liquor passes through the
perforations on the wall of the treating chamber 1 and contacts the
fabric articles therein. The advantage of the indirect method is
that the fabric articles are not bathed in the rinse liquor and are
in constant motion, thus, soil redeposition and/or dye transfer are
minimized.
[0096] Tumbling, rotating or other movements of the fabric articles
during the rinse step promotes even distribution of the rinse
liquors. However, such movements need not be at high speed (e.g.,
less than 1 G). This is so to minimize the potential of wrinkling
and/or bundling of the fabric articles. Even the removal of rinse
liquors between cycles need not be performed at very high speed
such that the fabric articles are not pinned to the wall of the
treating chamber.
[0097] (D) Optional Steps
[0098] Optionally, a finishing liquor, similar to the subsequent
rinse liquor or having lower water content than the subsequent
rinse liquor, can be applied to the fabric article in the same way
as the rinse liquor application such that the fabric articles are
substantially uniformly contacted by the finishing liquor.
Preferably, the finishing liquor comprises a fabric care active
that is meant to be left on the fabric article. Thus, partial
removal of the finishing liquor is optional, and in some
embodiments, application of the finishing liquor is followed
immediately with the drying step.
[0099] Optionally, the drying step can be conducted in the same
apparatus after the last rinse cycle. The dual mode apparatus (i.e,
washer and dryer in one apparatus) are known in the art. This
option provide the added advantage of enabling the consumer to
perform the entire (dry to dry) laundering process in a single
apparatus and in continuous fashion, thus, a potential time
saver.
[0100] Fabric Article Treatment Composition
[0101] The compositions of the present invention comprise at least
one fabric treating active. The fabric treating actives may include
detergent adjuncts and/or rinse actives.
[0102] The composition may also comprises a polar solvent,
including water.
[0103] The fabric article active may be any suitable fabric article
adjunct for fabric cleaning, fabric finishing, or fabric care.
Thus, the fabric article active may be detergent actives, rinse
actives and mixtures thereof.
[0104] Nonlimiting examples of detergent actives for use in the
wash step include surfactants, bleaching agents, enzymes, optional
builders, and mixtures thereof.
[0105] Nonlimiting examples of finishing actives for use in the
rinse step include softening agents, brighteners, perfumes, soil
release agents, anti-wrinkle agents and mixtures thereof.
[0106] Polar Solvent
[0107] The polar solvents according to the present invention
exhibit at least one of the following Hansen solubility
parameters:
[0108] a fractional polar value (f.sub.p) of greater than 0.02
and/or greater than 0.05; and/or
[0109] a fractional hydrogen bonding value (f.sub.H) of greater
than 0.10 and/or greater than 0.2.
[0110] Nonlimiting examples of polar solvents suitable for use in
the fabric article treatment composition of the present invention
include: water, alcohols, glycols, polyglycols, ethers, carbonates,
dibasic esters, ketones, other oxygenated solvents, and mixutures
thereof. Further examples of alcohols include: C1-C126 alcohols,
such as propanol, ethanol, isopropyl alcohol, etc, benzyl alcohol,
and diols such as 1,2-hexanediol. The Dowanol.RTM. series by Dow
Chemical are examples of glycols and polyglycols useful in the
present invention, such as Dowanol.RTM. TPM, TPnP, DPnB, DPnP,
TPnB, PPh, DPM, DPMA, DB, and others. Further examples include
propylene glycol, butylene glycol, polybutylene glycol and more
hydrophobic glycols. Examples of carbonate solvents are ethylene,
propylene and butylene carbonates such as those available under the
Jeffsol.RTM. tradename. Polar solvents for the present invention
can be further identified through their dispersive (.delta..sub.D),
polar (.delta..sub.p) and hydrogen bonding (.delta..sub.H) Hansen
solubility parameters. Preferred polar solvents or polar solvent
mixtures have fractional polar (f.sub.p) and fractional hydrogen
bonding (f.sub.H) values of f.sub.p>0.02 and f.sub.H>0.10,
where
f.sub.p=.delta..sub.p/(.delta..sub.D+.delta..sub.P+.delta..sub.H)
and
f.sub.H=.delta..sub.H/(.delta..sub.D+.delta..sub.P+.delta..sub.H),
more preferably f.sub.p>0.05 and f.sub.H>0.20, and most
preferably f.sub.p>0.07 and f.sub.H>0.30.
[0111] In one embodiment, the polar solvent is selected from the
group consisting of: water, alcohols, glycols, polyglycols, ethers,
carbonates, esters, ketones, other oxygenated solvents, amines,
amides, ureas, alkanolamines, alkanolamides phosphate esters, alkyl
nitriles and mixtures thereof.
[0112] In one embodiment, the polar solvent comprises from about 0%
to about 50% and/or from about 0.01 to about 20% by weight of
water.
[0113] Detergent Actives
[0114] The present fabric article treating system is unique in that
it permits the use of certain detergent actives that are not
effective in treating fabrics when used in the conventional aqueous
bath treating system. These detergent actives have a relatively low
affinity for fabric surface (i.e., low fabric-water partition
ratio) such that these actives would prefer to remain in the
aqueous bath rather than being deposited onto the fabric surface.
Detergent actives suitable for use herein have low fabric-water
partition ratios, specifically, low "intra-wash fabric-water
partition ratios". The "intra-wash fabric-water partition ratio" is
applicable to those actives whose presence at the fabric surface
are desirable during the washing stage and that may be later rinsed
away (e.g. bleaches, chelators).
[0115] For purposes of the present invention, the term "intra-wash
fabric-water partition ratio" is defined as {(X-Y)/X}, where X is
the mass of the active (which can be present as a component of a
full detergent composition) added to a conventional immersive North
American or European washing machine operating at the recommended
water level and setting and a typical mixed fabric load, and Y is
the mass of said active remaining in the collected effluent wash
solution after the fabrics have been agitated for 10 minutes
followed by removal of the wash liquor by drainage and spinning. A
"mixed fabric load" is of the type described in Test #D2960-98 of
the American Society for Testing and Materials. A Kenmore 3.2 cu.
Ft. super capacity 27 in. top load washer can be used, with the
machine setting at "Heavy Duty" and the water fill to approximately
17 gallons. Alternatively, a Miele Novotronic W918 washer can be
used, with the machine setting at normal cycle (i.e., the short
button) and water fill to about 11 liters for the wash and about 37
liters for 4 rinses.
[0116] Detergent actives suitable for use herein have an intra-wash
fabric-water partition ratio (Q.sub.i) of less than about 0.3, or
less than about 0.2.
[0117] The present process can also employ hydrophilic detergent
actives having an HLB (hydrophilic-lipophilic balance) value of at
least about 8, or at least about 9, or from about 8 to about
12.
[0118] In one embodiment, the composition comprises representative
surfactants having a suitable Q value for use in the present
invention; these include but are not limited to, short (i.e.,
non-fatty) chain surfactants such as C6-C10 alkyl or aryl
sulfonates, C6-C10 alcohols and their sulfonates, ethoxysulfonates,
ethoxycarboxylates, and ethoxylate or alkoxylate derivatives.
Further, the detergent composition comprises from about 1% to about
30%, or from about 3% to about 20%, or from about 5% to about 15%
by weight of the composition of the hydrophilic surfactant.
[0119] Some suitable detergent adjuncts include, but are not
limited to, builders, surfactants, other than those described above
with respect to the surfactant component, enzymes, bleach
activators, bleach catalysts, bleach boosters, bleaches, alkalinity
sources, antibacterial agents, colorants, perfumes, pro-perfumes,
finishing aids, lime soap dispersants, odor control agents, odor
neutralizers, polymeric dye transfer inhibiting agents,
anti-abrasion agents, fabric-enhancement amines, dye-fixative
agents, fabric-rejuvenating agents, fiber-water protection agents,
crystal growth inhibitors, photobleaches, heavy metal ion
sequestrants, anti-tarnishing agents, anti-microbial agents,
anti-oxidants, anti-redeposition agents, polymer dispersants, soil
release polymers, electrolytes, pH modifiers, thickeners,
abrasives, divalent or trivalent ions, metal ion salts, enzyme
stabilizers, corrosion inhibitors, diamines or polyamines and/or
their alkoxylates, suds stabilizing polymers, solvents, process
aids, fabric softening agents, optical brighteners, hydrotropes,
suds or foam suppressors, suds or foam boosters and mixtures
thereof.
[0120] Suitable odor control agents, which may optionally be used
as finishing actives, include cyclodextrins, odor neutralizers,
odor blockers and mixtures thereof. Suitable odor neutralizers
include aldehydes, flavanoids, metallic salts, water-soluble
polymers, zeolites, activated carbon and mixtures thereof.
[0121] Perfumes and perfumery ingredients useful in the
compositions of the present invention comprise a wide variety of
natural and synthetic chemical ingredients, including, but not
limited to, aldehydes, ketones, esters, and the like. Also included
are various natural extracts and essences which can comprise
complex mixtures of ingredients, such as orange oil, lemon oil,
rose extract, lavender, musk, patchouli, balsamic essence,
sandalwood oil, pine oil, cedar, and the like. Finished perfumes
may comprise extremely complex mixtures of such ingredients.
Pro-perfumes are also useful in the present invention. Such
materials are those precursors or mixtures thereof capable of
chemically reacting, e.g., by hydrolysis, to release a perfume, and
are described in patents and/or published patent applications to
Procter and Gamble, Firmenich, Givaudan and others.
[0122] Bleaches, especially oxygen bleaches, are another type of
detergent adjunct suitable for use in the compositions of the
present invention. This is especially the case for the activated
and catalyzed forms with such bleach activators as
nonanoyloxybenzenesulfonate and/or any of its linear or branched
higher or lower homologs, and/or tetraacetylethylenediamine and/or
any of its derivatives or derivatives of
phthaloylimidoperoxycaproic acid (PAP) or other imido- or
amido-substituted bleach activators including the lactam types, or
more generally any mixture of hydrophilic and/or hydrophobic bleach
activators (especially acyl derivatives including those of the
C.sub.6-C.sub.16 substituted oxybenzenesulfonates).
[0123] Also suitable are organic or inorganic peracids both
including PAP and other than PAP. Suitable organic or inorganic
peracids for use herein include, but are not limited to:
percarboxylic acids and salts; percarbonic acids and salts;
perimidic acids and salts; peroxymonosulfuric acids and salts;
persulphates such as monopersulfate; peroxyacids such as
diperoxydodecandioic acid (DPDA); magnesium peroxyphthalic acid;
perlauric acid; perbenzoic and alkylperbenzoic acids; and mixtures
thereof.
[0124] One class of suitable organic peroxycarboxylic acids has the
general formula: 1
[0125] wherein R is an alkylene or substituted alkylene group
containing from 1 to about 22 carbon atoms or a phenylene or
substituted phenylene group, and Y is hydrogen, halogen, alkyl,
aryl, --C(O)OH or --C(O)OOH.
[0126] Particularly preferred peracid compounds are those having
the formula: 2
[0127] wherein R is C.sub.1-4 alkyl and n is an integer of from 1
to 5. A particularly preferred peracid has the formula where R is
CH.sub.2 and n is 5 i.e., phthaloylamino peroxy caproic acid (PAP)
as described in U.S. Pat. Nos. 5,487,818, 5,310,934, 5,246,620,
5,279,757 and 5,132,431. PAP is available from Ausimont SpA under
the tradename Euroco.
[0128] Hydrogen peroxide is a highly useful bleaching agent.
[0129] Other detergent adjuncts suitable for use in the
compositions of the present invention include, but are not limited
to, builders including the insoluble types such as zeolites
including zeolites A, P and the so-called maximum aluminum P as
well as the soluble types such as the phosphates and
polyphosphates, any of the hydrous, water-soluble or
water-insoluble silicates, 2,2'-oxydisuccinates, tartrate
succinates, glycolates, NTA and many other ethercarboxylates or
citrates; chelants including EDTA, S,S'-EDDS, DTPA and
phosphonates; water-soluble polymers, copolymers and terpolymers;
soil release polymers; optical brighteners; processing aids;
fillers; anti-redeposition agents; humectant; other perfumes or
pro-perfumes; photobleaches; thickeners; simple salts; alkalis such
as those based on sodium or potassium including the hydroxides,
carbonates, bicarbonates and sulfates and the like; and
combinations of one or more of these detergent adjuncts.
[0130] Another class of detergent adjuncts suitable for use herein
are called "detergent-soil mixing promoting agents". Without
wishing to be bound by theory, it is believed that such agents
assist the wash process in the following manner. Whereas shear
mixing normally takes place in conventional aqueous washing
processes, in the presence of a bath of free wash liquor, the
extremely low wash liquor to fabric ratio in the thin film wash
step of the present invention prevents a favorable degree of fluid
shear at the fabric surface, resulting in a less than optimal
degree of soil-detergent mixing. The "detergent soil mixing
promoting agents" compensate for this deficiency by chemically
promoting the mixture of soils with the aqueous detergent liquor
within the thin film. Such agents include but are not limited to
so-called "chelating surfactants" such as oleoyl sarcosinates;
"solid-oil liquefying surfactants" such as lauryl amine oxide;
hydrotropes such as sodium or calcium xylenesulfonate; and `short
chain surfactants` such as C6-C10 alcohols and their sulfate,
ethoxysulfate, ethoxycarboxylate, and ethoxylate derivatives. In
addition, another class of soil-detergent mixing promoting agent
comprises lipases and esterases.
[0131] Another class of detergent adjuncts suitable for use herein
are soil repleent agents, such as inorganic nanoparticles or
polymers. Nonlimiting examples for nanoparticles include
nanoparticles and/or functional colloidal particles selected from
the group consisting of (a) inorganic metal oxides, natural clays,
synthetic clays and mixtures thereof; (b) synthetic clays selected
from the group consisting of kaolinite, montmorillinite/smectite,
hectorite, synthetic fluorohectorite, illite, variants and
isomorphous substitutions of the synthetic clay groups, and
mixtures thereof; and (c) synthetic clays selected from the group
consisting of layered hydrous silicate, layered hydrous aluminum
silicate, fluorosilicate, mica-montmorillonite, hydrotalcite,
lithium magnesium silicate, lithium magnesium fluorosilicate, and
mixtures thereof. A suitable naoaparticle material is commercially
available as LAPONITE.RTM. from Southern Clay Products, Inc,
Austin, Tex. Nonlimiting examples of polymers suitable for use as
the soil repellent agent include polyethylene glycols having a
weight average molecular weight from about 1,000 to about 5,000,000
Daltons, polyacrylates having a weight average molecular weight
from about 1,000 to about 5,000,000 Daltons, and
carboxymethylcellulose having a weight average molecular weight
from about 1,000 to about 5,000,000 Daltons.
[0132] In a typical embodiment, each detergent active comprises at
least about 0.01%, or at least 0.1% or at least 1%, by weight of
the detergent composition; and less than 99%, or less than 50% or
less than 10%, by weight of the detergent composition.
[0133] Rinse Actives
[0134] Rinse actives suitable for use in the first rinse liquor
include but are not limited to soil suspednig agents, hydrotropes,
rinse activators, pH modifiers, and mixtures thereof.
[0135] Nonlimiting examples of soil suspending agents are selected
from the group consisting of ethoxylated amines, zwitterionic
polymers, polycarboxylates, polyalkyleneglycols, polyaminoacids,
and combinations thereof.
[0136] One class of the the soil suspending agent is an ethoxylated
amine selected from the group consisting of (a) a polyethyleneimine
having an average molecular weight of about 189 to about 1800
daltons, each nitrogen in the backbone has a substituent (EO).sub.x
wherein x is an integer from 7 to 30, and some or all of the
terminal OH groups have been substituted with sulfate groups and/or
some or all of the amine groups have been quaternized with methyl,
ethyl, or benzyl groups; (b) a polyhexamethyleneimine having an
average molecular weight of about 116 to about 550 daltons, each
nitrogen in the backbone has a substituent (EO).sub.x wherein x is
an integer from 7 to 30, and some or all of the terminal OH groups
have been substituted with sulfate groups and/or some or all of the
amine groups have been quaternized with methyl, ethyl, or benzyl
groups; and (c) mixtures thereof.
[0137] Another class of the soil suspending agent is a
polycarboxylate selected from the group consisting of water-soluble
salts of polyacrylic acid, water soluble salts of poly(maleic
acid)-co-poly(acrylic acid), carboxymethylcellulose, and mixtures
thereof.
[0138] Nonlimiting examples of the hydrotrope is selected from the
group consisting of metal salts of cumene sufonic acids, toluene
sulfonic acid, or xylene sulfonic acid, and mixtures thereof.
[0139] Nonlimiting examples of rinse activator is selected from the
group consisting of fatty mono- or oligo- amines, wherein one or
more of the nitrogen in the backbone has backbone has a substituent
(EO).sub.x wherein x is an integer from 7 to 30, and some or all of
the terminal OH groups have been substituted with sulfate groups
and/or some or all of the amine groups have been quaternized with
methyl, ethyl, or benzyl groups; analogs of the ethoxylated fatty
amines or quaternized fatty ethoxylated; and mixtures thereof.
[0140] Nonlimitng examples of dye transfer inhibition polymers are
selected from the group consisting of polyvinylpyrrolidone,
polyvinylpyridine-N-oxide,
poly(vinylpyrrolidone)-co-poly(vinylimidazole)- , manganese
phthalocyanine, peroxidases, and mixtures thereof.
[0141] PH modifiers include commonly known pH buffer materials.
[0142] Fabric Care Actives
[0143] Fabric care actives can be incorporated into the subsequent
rinse liquor or the finishing liquor, the latter is intended to be
left on the treated fabric articles, that is, the finishing step is
not followed by subsequent rinse step.
[0144] Fabric care actives suitable for use herein have low
fabric-water partition ratios, specifically, low "post-rinse
fabric-water partition ratios". The term "post-rinse fabric-water
partition ratio" is defined as {(X-Z)/X}, where X is defined as
above, and where Z is the mass of said active remaining in the
collected combined effluent wash and rinse liquor(s) after the
fabrics have been washed and rinsed on a "mixed fabric load"
according to the machine setting and water level as described
above. The "post-rinse fabric-water partition ratio" is applicable
to those actives which are desired to remain on the fabric into the
drying and/or wearing period (e.g. aesthetic benefit agents, soil
repellent finishes, perfumes, etc.)
[0145] Fabric care actives suitable for use herein have a
post-rinse fabric-water partition ratio (Q.sub.p) of greater than
about 0.2, or greater than about 0.3.
[0146] Suitable fabric care actives include, but are not limited
to, anti-abrasion agents, fabric enhancement agents, crystal growth
inhibitors, dye fixative agents, fabric softening agents, fabric
rejuvenating agents, fiber/water protection agents, soil repellent
agents, and mixtures thereof. Some of these fabric care actives are
disclosed in details below.
[0147] Non-limiting examples of anti-abrasion agents are selected
from the group consisting essentially of homo or copolymers
containing any one or more of the following monomers: acrylamide,
vinylamine, 3-trimethylammoniopropyl acrylate,
N-alkylvinylpyridine, N-oxide-vinylpyridine, vinylalcohol,
dialkyldiallylammonium chloride, N,N-dialkylamino
alkylmethacrylate, N,N-dialkylamino alkylacrylate, N,N-dialkylamino
alkylacrylamide, N,N-dialkylamino alkylmethacrylamide, and the
quaternized derivatives thereof.
[0148] Non-limiting examples of dye fixative agents may be selected
from the group consisting of the Sandofix.TM., Sandolec.TM.,
Lupasol-SK.TM., and Cartafix.TM. varieties; copolymers of
epichlorohydrin and amines such as imidazole,
dimethylaminopropylamine; polyvinylamine; water soluble salts of
magnesium(II) and zinc(II), and aluminum (III); the hydrochloride,
acetate, metosulphate and benzyl hydrochloride salts of diamine
esters, the N-oxides of tertiary amines; derivatives of polymeric
alkyldiamines, polyamine-cyanuric chloride condensates, and
aminated glycerol dichlorohydrins.
[0149] Non-limiting examples of fabric enhancement agents are
amines selected from the group consisting of triethanolamine;
monoethanolamine; N,N'-bis(3-aminopropyl)-1,3-propylenediamine
(TPTA), dipropylenetriamine (5-N'-methyl dipropylenetriamine),
1,4-piperazines, their N-alkylated and N-hydroxyalylated
derivatives, and mixtures thereof. Preferred fabric rejuvenating
agents are selected from the group consisting essentially of
aminopropylated polydimethylsiloxane, aminopropyl-aminoethylated
polydimethylsiloxane, aminosilicones, cationic aminosilicones,
polydimethylsiloxanes; polydimethylsiloxanes or trisiloxanes with
pendant polyethylene or polyethylene/polypropylene sidechains,
alkylated or hydroxyalkylated celluloses
[0150] Non-limiting examples of crystal growth inhibitors may be
selected from the group consisting of glycolic acid, phytic acid,
polycarboxylic acids, polymers and co-polymers of carboxylic acids
and polycarboxylic acids, ether hydroxypolycarboxylates,
polyacrylate polymers, copolymers of maleic anhydride and the
ethylene ether or vinyl methyl ethers of acrylic acid, citric acid
and soluble salts thereof, 3,3-dicarboxy-4-oxa-1,6-hexanedioates,
alkyl and alkenyl succinic acid and salts thereof,
organo-diphosphonic acids or salts such as ethylene diphosphonic
acid, alpha-hydroxy-2 phenyl ethyl diphosphonic acid, methylene
diphosphonic acid, vinylidene-1,1-diphosphonic acid,
1,2-dihydroxyethane-1,1-diphosphonic acid, hydroxy-ethane 1,1
diphosphonic acid, the salts thereof, and mixtures thereof.
[0151] Non-limiting examples of fiber-water protecting agents may
be selected from the group consisting of low molecular weight
aliphatic or aromatic alcohols, low molecular weight alkylene
glycols, low molecular weight alkylene glycol ethers, low molecular
weight esters, or low molecular weight alkylene amines or
alkanolamines. Herein, "low molecular weight" means the molecule's
backbone length is less than 12 carbons, or is about
C.sub.6-C.sub.10 in length.
[0152] Nonlimitng examples of fabric softening agents may be
cationic dialkyl or sister quaternary ammonium salts.
[0153] In a typical embodiment, each rinse active comprises at
least about 0.01%, or at least 0.05% or at least 0.1%, by weight of
the detergent composition; and less than 99%, or less than 10% or
less than 5%, by weight of the rinse active composition.
[0154] Nonlimiting Examples of the Thin Film Laundering Process
EXAMPLE 1
[0155] place a load of fabric articles (such as garments) into a
horizontal axis automatic washing machine;
[0156] begin tumbling the fabric articles at a speed capable of
generating a force of about 1 G;
[0157] spray/mist a wash liquor comprising 75 g of a detergent
composition diluted in enough water such that the resulting liquor
to fabric ratio is between 0.25:1 to 2:1 onto the tumbling clothes
according to droplet size and other spray/mist requirements
described above;
[0158] continue tumbling for a total tumbling time of about 15
minutes;
[0159] rapidly add (e.g., by pumping at a rate of 1.87 liters per
minute) fresh water to the tumbling load such that the resulting
liquor to fabric ratio is about 15:1;
[0160] high-speed spin to remove all excess liquor;
[0161] resume tumbling and spray/mist a finishing composition
comprising 50 g of finishing actives diluted in enough water such
that the resulting liquor to fabric ratio is between about 2:1 to
5:1 onto the tumbling clothes according to the spray/mist
requirements of the invention;
[0162] high-speed spin (e.g., at a rate of at least about 450 rpm)
to remove of at least all free liquor;
[0163] optionally, tumble drying in the same apparatus.
EXAMPLE 2
[0164] place a load of garments into the horizontal axis
machine;
[0165] begin tumbling the fabric articles at a speed capable of
generating a force of about 0.5 G to about 3 G;
[0166] add fresh water and spray/mist 75 g of detergent composition
onto the tumbling clothes such that the resulting liquor to fabric
ratio is about 7:1;
[0167] continue tumbling for a total tumbling time of 15 minutes
while heat is applied to partially remove water from the applied
liquor such that the remaining liquor to fabric ratio is about
0.75:1 or less;
[0168] rapidly add fresh water to the tumbling load such that the
resulting liquor to fabric ratio is about 15:1;
[0169] high-speed spin to remove of at least all free liquor;
[0170] rapidly add fresh water to the tumbling load such that the
resulting liquor to fabric ratio is about 7:1;
[0171] high-speed spin to remove of at least all free liquor;
[0172] resume tumbling and spray a rinse liquor comprising about
30-50 g of a rinse active and enough water such that the resulting
liquor to fabric ratio is between about 2:1 to 5:1 onto the
tumbling clothes according to the mist/spray requirements of the
invention;
[0173] high-speed spin to remove of at least all free liquor;
[0174] optionally, tumble drying in the same apparatus.
[0175] optionally, mist application of a finishing liquor
[0176] Nonlimiting Formulation Examples
1 (A) Detergent Formulas (weight %) ingredient 1 2 3 4 5 6 Linear
alkyl benzene sulfonate -- 5 -- -- -- -- surfactant (e.g. LAS)
Alkyl ethoxylate sulfate 10 10 10 -- -- -- surfactant
(C25AE.sub.1.1S) Alkyl ethoxylate sulfate -- -- 2 10 10 12
surfactant.sup.1 amine oxide surfactant -- -- 0.5 0.5 -- -- Citric
acid 2 2 -- 2 2 -- Enzymes (savinase, duramyl, 1 1 -- 1 1 -- and
mixtures thereof) Ethoxylated Amine Polymers.sup.2 -- 1 2 -- 1 2
Water and minors.sup.3 balance balance balance balance balance
balance .sup.1Neodol .RTM. 23-9, Neodol .RTM. 45-7 and mixtures
thereof. .sup.2Ethoxylated tetraethylenepentamine (PEI 189
E.sub.15-E.sub.18) according to U.S. Pat. No. 4,597,898 Vander Meer
issued Jul. 1, 1986; PEI 1800 E.sub.7 (according to U.S. Pat. No.
5,565,145 Watson et al., issued Oct. 15, 1996); PEI-600-E.sub.20;
quaternized, sulfonated ethoxylated hexamethylenediamine according
to U.S. Pat. No. 6,579,839 Price et al. issued Jun. 17, 2003.
.sup.3Minors may include additional actives such as optical
brightener, perfume, suds suppresser, soil dispersant, chelating
agents, dye transfer inhibiting agents, additional water, enzyme
stabilizers, buffers, solvents, solvatropes, aethetics, and
fillers.
[0177]
2 (B) Care Formulas (weight %) Ingredient 1 2 3 4 5 6 fabric care
amine.sup.1 8 5 5 -- -- -- Monoethanolamine -- -- -- 8 5 5
HEDP.sup.2 0.8 0.4 0.4 -- -- -- DTPA.sup.3 -- -- -- 0.5 0.5 0.5
cationic polacrylamide 5 2.5 2.5 -- -- -- Polyacrylamide -- -- -- 5
2.5 2.5 BFA.sup.4 (fabric softener quat) 20 5 -- 10 -- --
DTMAC.sup.5 (fabric softener quat) -- -- -- -- 5 -- Cartafix .RTM.
(dye fixative) 2.5 1 1 2.5 1 1 MgCl2 2.5 1 1 2.5 1 1 Nonionic
surfactant (Neodol .RTM. 1 1 1 1 1 1 23-9) Water & minors.sup.8
balance balance balance balance balance balance
.sup.1N'-(3-(dimethylamino)propyl)-N,N-dimethylpropane-1,3-diamine,
1,4-bis(3-aminopropyl)piperizine. .sup.21-hydroxyethylidene-1,1-d-
iphosphonic acid .sup.3diethylene triamine penta acetate
.sup.4acrylamide/dimethylamino ethylacrylate methochloride (molar
ratio 24:1, K-value 85), or cationically modified polyacrylamides:
acrylamide/dimethylamino ethylacrylate methochloride (molar ratio
9:1, K-value 70). .sup.5dimethyl bis(steroyl oxyethyl) ammonium
chloride .sup.6di(hydrogenated tallow)dimethylammonium chloride
.sup.7available from Clariant, Inc. .sup.8Minors may include
optical brightener, perfume, suds suppresser, soil dispersant,
chelating agents, dye transfer inhibiting agents, additional water,
enzyme stabilizers, buffers, solvents, solvatropes, aethetics, and
fillers.
[0178] While particular embodiments of the present invention have
been illustrated and described, it would be apparent to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
[0179] All percentages stated herein are by weight unless otherwise
specified. It should be understood that every maximum numerical
limitation given throughout this specification will include every
lower numerical limitation, as if such lower numerical limitations
were expressly written herein. Every minimum numerical limitation
given throughout this specification will include every higher
numerical limitation, as if such higher numerical limitations were
expressly written herein. Every numerical range given throughout
this specification will include every narrower numerical range that
falls within such broader numerical range, as if such narrower
numerical ranges were all expressly written herein.
[0180] All documents cited are, in relevant part, incorporated
herein by reference; the citation of any document is not to be
construed as an admission that it is prior art with respect to the
present invention.
* * * * *