U.S. patent application number 11/005979 was filed with the patent office on 2005-07-14 for non-aqueous washing apparatus and method.
Invention is credited to Luckman, Joel A., Wright, Tremitchell L..
Application Number | 20050150059 11/005979 |
Document ID | / |
Family ID | 46205411 |
Filed Date | 2005-07-14 |
United States Patent
Application |
20050150059 |
Kind Code |
A1 |
Luckman, Joel A. ; et
al. |
July 14, 2005 |
Non-aqueous washing apparatus and method
Abstract
The invention relates to a non-aqueous washing machine, methods
of using the machine, methods of washing, and recycling.
Inventors: |
Luckman, Joel A.; (Benton
Harbor, MI) ; Wright, Tremitchell L.; (Elkhart,
IN) |
Correspondence
Address: |
WHIRLPOOL PATENTS COMPANY - MD 0750
500 RENAISSANCE DRIVE - SUITE 102
ST. JOSEPH
MI
49085
US
|
Family ID: |
46205411 |
Appl. No.: |
11/005979 |
Filed: |
December 7, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11005979 |
Dec 7, 2004 |
|
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|
10699159 |
Oct 31, 2003 |
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Current U.S.
Class: |
8/137 |
Current CPC
Class: |
D06F 43/085 20130101;
D06F 43/08 20130101; D06F 43/007 20130101; D06F 43/00 20130101 |
Class at
Publication: |
008/137 |
International
Class: |
D06F 001/00 |
Claims
1. A method of cleaning fabrics, including the steps of: disposing
a fabric load in a wash container; delivering a wash liquor to said
wash chamber, said wash liquor comprising a substantially
non-reactive, non-aqueous, non-oleophilic, apolar working fluid and
at least one washing adjuvant; removing said wash liquor from said
fabric load; delivering a liquid extraction solvent to said fabric
load; removing said liquid extraction solvent from said fabric
load; and recovering the liquid extraction solvent and working
fluid for reuse.
2. The method of claim 1 wherein the liquid extraction solvent has
at least one of the following properties: a KB Value less than 30,
a solubility in water of less than 10%, or a flash point greater
than 145 C.
3. The method of claim 2 wherein the liquid extraction solvent is
selected from the group consisting of: perfluorocarbons,
hydrofluoroethers, fluorinated hydrocarbons, fluoroinerts and
carbon dioxide.
4. The method of claim 3 wherein the liquid extraction solvent is
further selected from the group consisting of
methoxynonafluorobutane, ethoxynonafluorobutane and mixtures
thereof.
5. The method of claim 1 wherein said non-reactive, non-aqueous,
non-oleophilic, apolar working fluid under standard conditions is
further characterized by: a KB value less than 30; a surface
tension less than approximately 35 dynes/cm.sup.2; and a solubility
in water of less than 10%.
6. The method of claim 1 wherein the working fluid is selected from
the group consisting of hydrofluoroethers, highly fluorinated
hydrocarbons, volatile methyl siloxanes or mixtures thereof.
7. The method of claim 6 wherein the working fluid is further
selected from decamethylcyclopentasiloxane,
dodecamethylpentasiloxane, decamethyltetrasiloxane,
octylmethylcyclotetrasiloxane, hexamethyldisiloxane,
octamethyltrisiloxane, tetradecamethylhexasiloxane,
hexadecamethylheptasiloxane, methyltris(trimethylsiloxane) silane
or mixtures thereof.
8. The method of claim 1 wherein recovering the liquid extraction
solvent and working fluid further comprises recovering the liquid
extraction solvent before dissolved contaminants are removed from
the working fluid.
9. The method of claim 8, wherein the liquid extraction solvent is
subjected to a treatment selected from the group consisting of:
gravity separation, filtration, centrifugation, fractional
distillation, freeze distillation, temperature reduction,
adsorption, absorption, inducing electrical fields, vaporization,
pressure reduction or mixtures thereof.
10. The method of claim 1 wherein the temperature of the working
fluid never exceeds 30.degree. F. below its flash point.
11. The method of claim 8 wherein the working fluid is further
recovered from a wash liquor by sequentially performing the
following treatments: treating the wash liquor either with carbon
dioxide under pressure, performing temperature reduction,
contacting it with a flocculating agent, adjusting its pH or
contacting it with an ion exchange resin; and treating the effluent
from the above step by means of one of the following materials: a
dissolver, an emulsifier, an adsorption agent, an absorption agent,
a soap, a pH shifter, a flocculating agent, a filtration material,
a cake/drying material agent, by gravimetric means, by vortex
separation, by distillation, by freeze distillation; treating the
effluent from the above step with one of the following a
coalescence agent, an absorption agent, an adsorption agent, a pH
adjustment agent, an ion exchange resin; and treating the effluent
from the above step by means of one of the following carbon dioxide
under pressure, a flocculating agent, a pH adjuster, performing
temperature reduction, an adsorption agent, an absorption agent, an
ion exchange resin.
12. The method of claim 8 wherein the working fluid is further
recovered from a wash liquor by sequentially performing the
following treatments: treating the wash liquor either with carbon
dioxide under pressure, performing temperature reduction,
contacting it with a flocculating agent, adjusting its pH or
contacting it with an ion exchange resin; treating the effluent
from the above step with one of the following: a coalescence agent,
an absorption agent, an adsorption agent, a pH adjustment agent, an
ion exchange resin; then treating the effluent from the above step
by means of one of the following materials: a dissolver, an
emulsifier, an adsorption agent, an absorption agent, a soap, a pH
shifter, a flocculating agent, a filtration material, a cake/drying
material agent, by gravimetric means, by vortex separation, by
distillation, by freeze distillation; and then treating the
effluent by means of one of the following carbon dioxide under
pressure, a flocculating agent, a pH adjuster, temperature
reduction, an adsorption agent, an absorption agent, an ion
exchange resin.
13. The method of claim 1 wherein after recovering the liquid
extraction solvent and working fluid, they are stored separately
for reuse.
14. The method of claim 8 wherein after recovering the liquid
extraction solvent, the liquid extraction solvent contains less
than 25% working fluid.
15. The method of claim 1 wherein the liquid extraction solvent and
wash liquor undergo a treatment step to reduce the amount of
dissolved contaminants.
16. The method of claim 15 wherein the treatment step is further
characterized by a temperature reduction step.
17. The method of claim 16 wherein the temperature reduction step
reduces the temperature to the freezing point of at least one of
the solvents in the mixture.
18. The method of claim 16 wherein the treatment step is further
characterized by passing the liquid extraction solvent and wash
liquor through a filtration means.
Description
[0001] This application is a Continuation-in-Part of application
Ser. No. 10/699,159, filed Oct. 31, 2003, entitled "Non-Aqueous
Washing Machine and Methods".
TECHNICAL FIELD OF THE INVENTION
[0002] The invention relates to a non-aqueous laundering machine,
methods of using the machine, methods of washing, drying and
reclamation.
BACKGROUND OF THE INVENTION
[0003] The present invention generally relates to apparati,
methods, and chemistries employed in the home for laundering
clothing and fabrics. More particularly, it relates to a new and
improved method, apparatus, and chemistry for home laundering of a
fabric load using a wash liquor comprising a multi-phase mixture of
a substantially inert working fluid (IWF) and at least one washing
adjuvant.
[0004] As used herein, the terms "substantially non-reactive" or
"substantially inert" when used to describe a component of a wash
liquor or washing fluid, means a non-solvent, non-detersive fluid
that under ordinary or normal washing conditions, e.g. at pressures
of 0 Pa to 0.5.times.10.sup.6 Pa and temperatures of from about
1.degree. C. to about 100.degree. C., does not appreciably react
with the fibers of the fabric load being cleaned, the stains and
soils on the fabric load, or the washing adjuvants combined with
the component to form the wash liquor. An IWF ideally does very
little or nothing except act as a carrier or vehicle to carry an
adjuvant to the clothes so that the adjuvant can work on the
clothes.
[0005] Home laundering of fabrics is usually performed in an
automatic washing machine and occasionally by hand. These methods
employ water as the major component of the washing fluid. Cleaning
adjuvants such as detergents, enzymes, bleaches and fabric
softeners are added and mixed with the water at appropriate stages
of the wash cycle to provide cleaning, whitening, softening, and
the like.
[0006] Although improvements in automatic washing machines and in
cleaning agent formulations are steadily being made, as a general
rule, conventional home laundering methods consume considerable
amounts of water, energy, and time. Water-based methods are not
suitable for some natural fiber fabrics, such as silks, woolens and
linens, so that whole classes of garments and fabrics cannot be
home laundered, but instead, must be sent out for professional dry
cleaning. During water washing, the clothes become saturated with
water and some fibers swell and absorb water. After washing, the
water must be removed from the clothes. Typically, this is
performed in a two-step process including a hard spin cycle in the
washer and a full drying cycle in an automatic dryer. The hard spin
cycles tend to cause undesirable wrinkling. Even after spinning,
drying cycle times are undesirably long.
[0007] The solution to this problem was the advent of the
traditional dry cleaning business. Consumers had to travel to the
dry cleaners, drop off clothes, pay for dry cleaning, and pick the
clothes up. While the dry cleaning process is useful to the
consumer, it plays terrible havoc with the environment. Traditional
dry cleaning uses halogenated hydrocarbons, such as
perchloroethylene (nefariously known as "perc"). Because the use of
perc is calamitous, strict environmental regulations exist to
control its use and disposition. The stricter controls sent many in
the dry cleaning industry towards petroleum-based solvents. These
solvents are inflammable and are smog-producers. Accordingly, the
use of these solvents in the home is out of the question.
[0008] A further non-aqueous solvent based washing method employs
liquid or supercritical carbon dioxide solvent as a washing liquid.
As described in U.S. Pat. No. 5,467,492, highly pressurized vessels
are required to perform this washing method. In accordance with
these methods, pressures of about 3.45.times.10.sup.6 Pa to
6.89.times.10.sup.6 Pa are required. Pressures of up to about
0.206.times.10.sup.6 Pa are approved for use in the home. The high
pressure conditions employed in the carbon dioxide create safety
hazards that make them unsuitable for residential use.
[0009] Various perfluorocarbon materials have been employed alone
or in combination with cleaning additives for washing printed
circuit boards and other electrical substrates, as described for
example in U.S. Pat. No. 5,503,681. Spray cleaning of rigid
substrates is very different from laundering soft fabric loads.
Moreover, cleaning of electrical substrates is performed in high
technology manufacturing facilities employing a multi-stage
apparatus which is not readily adapted for home use.
SUMMARY OF THE INVENTION
[0010] The foregoing problems are solved and a technical advance is
achieved by the present invention. Disclosed is a laundering
machine, methods, and chemistries for home laundering of fabrics.
The machine may include a wash unit and a reclamation unit. Methods
of washing fabrics, washing, recirculating, drying, reclaiming, and
disposing are disclosed. In addition, wash fluid chemistries,
combinations, etc. are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 demonstrates an embodiment of the invention.
[0012] FIG. 2A demonstrates an embodiment of the invention.
[0013] FIG. 2B demonstrates an embodiment of the invention.
[0014] FIG. 3 demonstrates an embodiment of the invention.
[0015] FIG. 4 demonstrates an embodiment of the invention.
[0016] FIG. 5 demonstrates an embodiment of the invention.
[0017] FIG. 6A demonstrates an embodiment of the invention.
[0018] FIG. 6B demonstrates an embodiment of the invention.
[0019] FIG. 7 demonstrates an embodiment of the invention.
[0020] FIG. 8 demonstrates an embodiment of the invention.
[0021] FIG. 9 demonstrates an embodiment of the invention.
[0022] FIG. 10 demonstrates an embodiment of the invention.
[0023] FIG. 11 demonstrates an embodiment of the invention.
[0024] FIG. 12 demonstrates an embodiment of the invention.
[0025] FIG. 13 demonstrates an embodiment of the invention.
[0026] FIG. 14 demonstrates an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] At the outset it should be noted that various Figures
illustrate various components and subcomponents. Because of the
relative complexity involved, many Figures omit nonessential
features such as means for connecting components to a frame, or
showing various conduits, piping, or wiring. Accordingly, while it
may be appear that certain components are unconnected, it is
understood that the components are connected to something. In
addition, various structural features, such as frames may be
omitted to avoid confusion. In addition, although certain systems,
subsystems, and loops are described as having pumps, it should be
noted that in any part of the machine and along any part of a
system, more than one pump may be used to assist in fluid flow,
solid flow, recycling, recirculation, etc. Accordingly, it is
intended that between any two parts described, there may be a pump
to assist in flow. Furthermore, any part or conduit may have an
anti-static agent associated therewith. In addition, for any
numeric parameter, it is understood that embodiments of the
invention may include any range within a stated range (for example,
for a stated range of between X and Y shall be interpreted to mean
that any range between X and Y is contemplated), or may include a
base figure that has no upper or lower limit (for example, a
parameter>X shall be interpreted to mean that the parameter has
no upper limit and that the inventors may impose any upper limit as
desired; and a parameter<X shall be interpreted to mean that the
parameter is less than X and has no lower limit and that the
inventors may impose any lower limit as desired).
[0028] FIG. 1 shows an embodiment of the invention. Shown is the
non-aqueous washing machine 10, comprising a wash unit 12 and a
reclamation unit 14. The machine 10 also includes a wash unit outer
housing 13 and a reclamation unit outer housing 15. It is
understood that although FIG. 1 shows the wash unit 12 and
reclamation unit 14 in a side-by-side position, the units may be
stackable. In addition, although the units are shown as separate
units, it is understood that the units may be generally within the
same outer housing. Additionally, multiple wash drums may be used
with a single reclamation and storage unit. The wash unit 12
includes a wash unit door 16, preferably with a handle 18. The door
16 may be opened to add and remove the items, such as a fabric load
to be washed. The door 16 may include a door window 19 so that the
contents may be viewed. Although shown on the wash unit 12, a
control panel 20 may be used to control the operation of the
machine. In addition, the control panel 20 may be located on the
reclamation unit 14. The control panel 20 may include a variety of
buttons, dials, displays, gauges, lights, etc. The machine should
be proportioned such that it can be transversed through the
doorways conventionally found in homes and preferably with a depth
of no more than 60 cm. In the preferred embodiment, the machine
would have a footprint no larger than the footprint of full-size
conventional aqueous automatic washers. Additionally, the
reclamation and storage components of the system may be
incorporated within a base unit 12--24 inches in height. This base
unit is placed under the machine to provide the consumer with an
ergonomically-viable height.
[0029] Although FIG. 1 shows the wash unit 12 and the reclamation
unit 14 side-by-side, it is understood that the units may be at
some distance from each other. For example, the wash unit 12 may be
inside, such as in a laundry room, and the reclamation unit 14 may
be outside the dwelling. In this regard, servicing of the
reclamation unit 14 becomes easier as the consumer need not be home
in order to allow access to the reclamation unit. Another advantage
of having a reclamation unit 14 outside is that any leaks, in the
unlikely event they occur, will dissipate inside the dwelling.
Accordingly, where the reclamation unit 14 is intended to be
located outdoors, the unit 14 may include various weather
protection means, such as weather resistant paint, rust proofing,
locks to prohibit intermeddling, etc. The distance between the
units is a function of the length of conduits connecting the two.
For any distance, intermediate pumps may be added to assist in
fluid flow between the units. To further assist in assembly,
servicing, or movement, the connections between the units may
include quick release hydraulic connectors, such as a Packer USA
Series ST quick release connector. Of course traditional threaded
nut designs may be used. It is also desirable to locate the
connection between the units near the top so that as conduits are
removed, any residual fluids remain in the conduits and do not leak
out. The fluids would return to the lowest points in the respective
units.
[0030] The machine 10 may also include a receiver such that a
remote control unit 22, such as a handheld unit, may transmit one
or more control signals to the machine 10 receiver to control the
machine. For example, the receiver may be part of the control panel
20. The machine 10 and/or control panel 20 may also include a
transmitter that sends signals to the remote unit 22. The
transmitter may send any type of information to the remote unit 22,
such as status information, safety information, or emergency
information. In this regard, there may be two-way communication
between the machine 10 and the remote unit 22. One example of such
use would include the machine 10 transmitting status information,
such as time remaining, cycle step, unbalanced load information; or
emergency information such as blocked conduits, valve failure,
clogged filters, breach of the closed system, fluid leak, pressure
drops, temperature increase, chemical leakage, etc. After receiving
this information, the user may use the remote unit 22 to send
control signals, such as shut-off signals or a command delay start
of all or part of cycles, to the machine 10. The machine may also
store any information in a memory storage unit so that the
information can be retrieved later. This may be useful during
servicing to assist diagnosing information. Such technology could
be readily adapted from airline black box technology. Moreover, the
machine may be controlled or monitored via other wireless or
Internet technologies. For example, the machine may be Internet
connected so that a consumer can remotely control the machine.
Similarly, the machine may contact a customer service center
automatically to provide information. In addition, cell phone
technologies may also be used to "call" the machine and control the
machine. Accordingly, in one embodiment, there is disclosed a means
to remotely receive information, a means to remotely send signals
to the machine 10, a means to send signals from the machine 10, and
a means to receive signals at the machine 10.
[0031] FIG. 2A shows an embodiment of the wash unit 12, without the
outer housing 13. Shown is a tub assembly 24, which includes a wash
chamber 26 that is adapted to receive the contents to be washed,
such as a fabric load (not shown). The tub assembly is connected to
an outer structure via various suspension arms 25. The wash chamber
26 also includes a flexible boot 28 that circumferentially
surrounds the opening 30 of the wash chamber 26. The boot 28 is
adapted to provide a seal around the wash chamber 26 opening and
also provide a conduit to the door 16. The wash chamber 26 also
includes a rear section 32. Inside the wash chamber 26 is a basket
34 that includes one or more perforations. The perforations may be
uniformly dispersed about the basket 34, randomly dispersed, or
dispersed in some other fashion. The perforations provide fluid
communication between the interior of the wash basket 34 to the
wash chamber 26.
[0032] A. Wash Unit Recirculation System
[0033] FIG. 2A also demonstrates a wash unit recirculation system.
In various embodiments of the invention described herein, wash
liquor may be extracted from the wash chamber 26 and recirculated
back into the wash chamber 26. One embodiment is now described. The
wash chamber 26 includes a drain outlet (not shown) that is in
fluid communication with a wash chamber sump 36. The wash chamber
sump 36 may be designed to have a large volume capacity so that it
may store the entire volume of wash liquor introduced into the wash
chamber 26. For example, in the event of a system failure, the wash
liquor can drain into the chamber sump 36. The drain outlet (not
shown) may also include a gate or cover that can be sealed.
Accordingly, in the event of a system failure, the wash liquor
contents may be drained into the sump 36, the drain outlet closed,
and the fabric contents can be removed.
[0034] A heater (not shown) may be optionally associated with sump
36 so that the wash liquor in the sump may be heated. In various
embodiments, it may be desirable to recirculate heated wash liquor
back into the fabric so that the fabric maintains an elevated
temperature, or because various washing adjuvant(s) work--or work
better--in a heated environment. The heater may also heat the wash
liquor to deactivate adjuvant(s) in the wash liquor. Accordingly,
the heater may be programmed to activate or deactivate based on the
intended use.
[0035] Wash chamber sump 36 is in fluid communication with a filter
38, such as a coarse lint filter, that is adapted to filter out
large particles, such as buttons, paper clips, lint, food, etc. The
filter 38 may be consumer accessible to provide for removal,
cleaning, and/or replacement.
[0036] Accordingly, it may be desirable to locate the filter 38
near the front side of the wash unit 12 and preferably near the
bottom so that any passive drainage occurs into the sump 36 and the
filter 38. In another embodiment, the filter 38 may also be
backflushed to the reclamation unit 14 so that any contents may be
removed from the reclamation unit 14. In yet another embodiment,
the filter can be back-flushed within the wash unit to the sump and
then pumped to the reclamation unit. In this regard, consumer
interaction with the filter 38 can be intentionally limited.
[0037] Filtered wash liquor may then be passed to the reclamation
unit 14 for further processing or may be passed to a recirculation
pump 40. Although not shown, a multiway valve may also be
positioned between the filter 38 and the pump 40 to direct the wash
liquor to the reclamation unit 14 for the further processing. After
processing, the wash liquor may be returned to the recirculation
loop at an entry point anywhere along the loop. The recirculation
pump may be controlled to provide continuous operation, pulsed
operation, or controlled operation. Returning to the embodiment of
FIG. 2A, recirculation pump 40 then pumps the wash liquor to a
multi-way recirculation valve 42. Based on various programming, the
recirculation valve 42 may be defaulted to keep the wash liquor in
the recirculation loop or defaulted to route the wash liquor to
another area, such as the reclamation unit 14. For example,
recirculation valve 42 may include a recirculation outlet 44 and a
reclamation outlet 46. In the embodiment where recirculation is
desired, wash liquor is shunted via the recirculation outlet 44 to
a dispenser 48.
[0038] FIG. 2B shows the dispenser 48. The dispenser 48 may include
one or more dispenser inlets 49a, 49b, 49c and 49d on an inlet
manifold 49. The dispenser 48 may also include one or more mixing
means to mix the contents of the dispenser. For example, if
additional adjuvants are added to the wash liquor, they may be
added from independent chambers in the dispenser and then mixed in
the dispenser 48. Accordingly, dispenser 48 may include mixers that
actively mix the contents around or passive mixers such as baffles
or fins that mix the contents via obstructing the fluid path (e.g.,
create turbulence, eddys, etc.). Some potential methods of mixing
to create the wash liquor are vortex mixing, in-line mixing via
baffles in a tube, axial flow impellers, radial-flow impellers,
close-clearance stirrers, un-baffled tanks or tubes, tumbling in
the drum or potentially in the pump. The wash liquor can be a
micro-emulsion, macro-emulsion or a homogenous mixture dependant
upon the adjuvant and the mixing means.
[0039] As mentioned above concerning the sump 36, a heater may also
be associated with the dispenser to modulate the temperature of the
dispenser contents. After mixing or heating, if any is to be done,
the dispenser contents exit the dispenser via a dispenser outlet
50. Dispenser outlet 50 may be gated to control the outflow of the
contents. In this regard, each chamber in the dispenser may be
individually gated. The contents exit the dispenser via outlet 50
and enter a fill inlet 52, which is in fluid communication with the
wash chamber 26. As shown in FIG. 2A, the fill inlet 52 is
generally located in the boot 28. The dispenser may be consumer
accessible to refill the chambers if desired.
[0040] Fill inlet may also include one or more dispensing heads
(not shown), such as nozzles or sprayers. The head may be adapted
to repel wash liquor or a particular adjuvant so that clogging is
avoided or minimized.
[0041] Accordingly, wash liquor is reintroduced into the wash
chamber 26 and a recirculation loop is formed. As mentioned
earlier, at any point in the loop, a multiway valve may be used to
shunt the wash liquor to another area, such as the reclamation unit
14 so that the wash liquor may be further processed before
returning to the recirculation loop. In this regard, "cleaner" wash
liquor is returned to the loop during various wash cycles, such as
rinse cycles. In an alternative embodiment, during the rinse cycle,
clean working fluid may be routed from the reclamation unit into
the recirculation unit. Accordingly, rinse fluid can be derived
from (i) previously used working fluid from the current wash cycle
that has been cleaned and reintroduced; or (ii) clean working fluid
that is from the reclamation unit working fluid reservoir (that is,
"fresh" fluid that has not yet been used in the current cycle).
[0042] In addition, the conduits between the various components of
the recirculation loop may be adapted to reduce the existence of
static charge. Because wash liquor is being conducted through the
conduits, a static charge may be generated. To avoid this, the
conduits (or surrounding shields) may be made of a material that
eliminates static charge build-up in the first place or dissipates
the charge as it builds-up. Moreover, the conduit may be shielded
with an outer cover that is adapted to dissipate static charge,
such as a conductive braid. This cover or braid can be grounded,
for example, to the frame. Some potential solutions for minimizing
the static charge or dissipating the charge are: using conductive
polymers, coating the drum and tubing, bleeding air into the system
during the drying step, bleeding electrons into the environment
and/or using a relative humidity sensor to make the environment
more humid; therefore, less static build-up.
[0043] After the wash cycle is over, the wash unit 12 may begin a
drying cycle. Wash liquor remaining, as mentioned above, exits the
wash chamber 26, exits the wash chamber sump 36, and is eventually
shunted to the reclamation unit 14. Because some residual wash
liquor may remain in various sumps, filters, and conduits, a series
of one way valves (not shown) may be used anywhere along the system
to minimize the amount of wash liquor remaining in the wash unit 12
during the drying cycle.
[0044] In addition, to the above described embodiment, other
components may exist, such as sensors for temperature, humidity,
vapor, oxygen, CO and CO.sub.2, electrical conduction, enzyme
levels, siloxane vapor, siloxane liquid, HFE vapor, HFE liquid,
volume, IWF liquid or vapor, level, and pressure.
[0045] B. Wash Unit Drying System
[0046] FIGS. 3 to 6B illustrate a closed loop drying system. With
reference to FIG. 3, shown is a front view of the wash chamber 26
with the basket 34 removed. In the upper positions of the wash
chamber rear section 32 are one or more drying outlets 54. These
drying outlets provide fluid communication between the interior of
the wash chamber 26 and a tub assembly manifold 56. Also shown is
the tub assembly central portion 58 that communicates with the
drive system 60 (see FIG. 4) to drive the wash chamber. An interior
surface 62 of the manifold is seen in the top left outlet 54. The
position of the outlets 54 ought to be designed so that bulk fluid
does not enter the drying loop in appreciable amounts or fluid
entry is minimized. To this end, controlled gates (not shown) may
be added to block the outlet 54 until opened. The number of outlets
can be chosen to maximize the air flow in the basket 34 so that
maximal contact of air with the fabrics is achieved. Similarly, the
outlet size that is, the diameter of the outlet (if circular) may
also affect the air flow pattern and thus the size may be altered
to accommodate for optimal air flow patterns. To this end, the
controlled gates (not shown) may also be used to alter the air flow
pattern. In one embodiment the air flow rate is about 200
m.sup.3/hour.
[0047] FIG. 4 shows a rear view of the tub assembly 24. Shown is
the tub assembly manifold 56 and the tub central portion 58, and
part of the drive system 60. As part of the air flow during the
drying loop, air exits the drying outlet(s) 54, enters the tub
assembly manifold 56, and exits the manifold 56 through the
flexible conduit 64.
[0048] FIGS. 5 and 6A show another view of the drying loop. In one
embodiment, the flexible conduit 64 is in fluid communication with
a lint filter housing 66, which contains a lint filter 68. Large
particulates can be captured by the lint filter 68 to avoid the
build-up of particulates on the components in the drying loop, such
as the blower, the condenser, the heater, etc. The lint filter
housing 66 may also include a filter lock 70 that is adapted to
lock down the lint filter 68 when the machine 10 is activated to
avoid a breach of the closed system. In addition, when the machine
is deactivated, the consumer can clean the lint filter 68 as one
normally would do in traditional drying machines. The lint filter
68 may also include a gasket at the interface of the lint filer 68
and the wash unit outer housing 13. While shown as one filter,
there may be many lint filters in the air flow path to collect as
much particulates as possible and these lint filters may be located
anywhere along any path or loop or be incorporated into the
condenser design. The lint filter housing 66 is in fluid
communication with a blower 72. The use of multiple lint filters
before the blower 72 would minimize the amount of particulates
entering the remaining portion of the drying cycle.
[0049] The blower 72 is preferably a sealed blower to control the
output slow rate and the output slow temperature so that the air in
the drying loop is controlled. The blower may be a fixed rate
blower or a variable rate blower. The blower 72 may also be sealed
to prevent leakage or contamination of the air to be dried. In
addition, the blower may be encased to contain any leakage. The
blower 72 is in fluid communication with a condenser system 74 via
a condenser conduit 76. Not shown is an optional conduit damper
that may be adapted to control the flow rate into the condenser
system 74. In this regard, the air flow into the condenser system
74 can be modulated by using the damper or by altering the blow
rate of the blower 72 or both.
[0050] FIGS. 5, 6A, and 6B show an illustrative condenser system
74. In FIG. 5, shown is a condenser fan 78 that blows air onto one
or more condenser units 80. FIGS. 6A and 6B show an illustrative
view of the condenser units 80, in particular showing a first
condenser unit 82 and a second condenser unit 84 inside the
condenser body 85. FIGS. 5 and 6A also show a condenser pan 86
generally located at the bottom of the body 85. In this regard, air
is blown from the blower 72 into the condenser system 74 and is
passed over the condenser units 80. In one embodiment, the air
inflow may be passed over a diffuser to diffuse the air over the
condenser units 80. In another embodiment, the body 85 is divided
into two or more chambers by at least one septum. Accordingly, air
is blown from the blower 72 into the system 74, passes into the
body 85, and thereby passes over the first condenser unit 82.
Condensation occurs and the condensate drips down into the pan 86.
Meanwhile, the air is routed, optionally via a molded piece or a
baffle, from the first chamber into a second one and over the
second condenser unit 84. Condensation from the second condenser
unit 82 drips down into the condenser pan 86. The condensate in the
drip pan 86 is routed to a condenser sump 88. The condenser sump
can be separate from or integral to the wash chamber sump (not
shown). The air that passes the second condenser unit 84 is routed
via a heater conduit 90 that ultimately connects to a heater 92.
The condenser units 80 may be consumer accessible and may be
adapted to be accessed once the machine 10 is deactivated. FIG. 6A
shows a condenser unit 82 partially removed from the condenser body
85.
[0051] Although shown in FIG. 6A as a vertical condenser unit 82,
84, the condenser units may be angled relative to the air flow. In
this regard, the individual plates 94 of the unit are in maximum
contact with the air flow. In addition, as condensation forms on
the plates, the condensation may form droplets that further
increase the surface area in contact with the air flow. This
stimulates further condensation. In addition, as the droplet size
increases beyond the point where the droplet can remain static on
the plate 94, it will drip down into the pan. The stream of liquid
caused by the droplet movement also increases the surface area
exposed to the air flow and thereby stimulates further
condensation.
[0052] In addition, the condenser system 74 may also be provided
with a direct-spray condensation method that utilizes a direct
contact condensation phase change mode. "Cold" working fluid (that
is, working fluid that is at a temperature less than the
temperature of the air flow) may be sprayed into the air flow
stream. As the sprayed fluid impacts the vapor in the air flow
stream, the sprayed fluid absorbs some of the vapor's latent heat
causing some of the vapor to condense into a liquid. This
condensate will also fall into the condenser pan 86. This cold
working fluid may be obtained from the chiller process described in
the reclamation loop, as shown in FIG. 11.
[0053] Although mentioned in the context of the condenser system
74, this direct contact condensation method may also be used as air
enters the manifold 56. A sprayer may spray cold working fluid into
the air flow stream causing the vapor to condense in the manifold
56. Cold working fluid may be routed from the reclamation unit
after the working fluid has been chilled (see FIG. 11). The
condensate will drip down into the lower portion of the manifold
56. A conduit (not shown) may be in fluid communication with the
condenser pan 86 thereby routing manifold derived condensate to the
pan 86 or to the condenser sump 88. Alternatively, the condensate
may be routed to the sump 36. In another embodiment, direct contact
condensers may be used at either the manifold 56, at the condenser
system 74 as described above, or both. One advantage of using a
manifold direct contact condensation method is that particulates
can be trapped by the condensate, shunted to any pan or any sump,
and later filtered. In this regard, the amount of particulates that
enter the lint filter 68 and the subsequent drying loop is
reduced.
[0054] An alternate condensation system includes a condenser system
similar to a radiator condensation system. For example, in the
reclamation unit (see FIG. 11), chilled coolant is produced. This
chilled coolant can be shunted into a condenser coil in the
condenser body 85. As such, air that enters the system 74 passes
over the condenser coils carrying the coolant and thus causes
condensation on the coils. The condensation accumulates in the
condenser pan 78. The coolant is recirculated back to the coolant
compressor system in the reclamation unit. In yet another
embodiment, the condenser units 82, 84 may be used in conjunction
with the coolant compressor system of the reclamation unit. In yet
another embodiment, during the reclamation process, working fluid
that has been cooled via the chiller (see FIG. 11) can be routed
into the radiator condensation system just described. In any
condensation system, water may be used as a coolant in tubing or
for direct contact condensation.
[0055] In any embodiment where condensation is occurring, the
condenser can be used as a lint collector as condensation forming
on the units will attract lint and condensation droplets dropping
will impact lint. Accordingly, an embodiment of the invention
resides in using a condensation system to minimize the amount of
lint in an air flow.
[0056] In yet another embodiment, in the condenser system, the
working fluid, water, and some residual adjuvants, may condense in
the first pass. As these components have different phases, the
working fluid may have a different phase than water. As such, the
water (and residual adjuvants for that matter) can be captured and
returned to the reclamation unit. The water can be captured via
gravimetric separation or membrane separation or can be collected
in an absorption bed and re-used as needed in another cycle or
later in the same cycle.
[0057] To ensure that air flow is maximized in the condenser
system, in an alternate embodiment, the blower 72 may blow air into
the condenser system 74 from the bottom of the condenser body 85. A
diffuser may be used at the bottom of the condenser body 85 to
break up the air flow and diffuse the air over the condenser units
82, 84 (or the radiator tubing as described above). The condenser
fan 78 may also be large enough to blow air over the entire surface
area of the condenser units 82, 84. That is, a diffuser may be used
to diffuse the incoming air over the condenser units 82, 84, or
over the condensing radiator coils.
[0058] Another alternate condensation system includes a spinning
disk system. The description and drawings can be found in
DE19615823C2, hereby or incorporated by reference. In addition to
water as a cooling media, IWF from the storage tank can be placed
over the spinning disc and this can be accomplished at room
temperature but also at a below room temperature via the
chiller/compressor. Any other cooling technology may be
utilized.
[0059] FIG. 6B shows another alternate condensation system of a
fin-tube arrangement. In this arrangement, condenser tubes 99 pass
through a plurality of fins 97. On each fin, there are a plurality
of condenser tubes. The fins may be spaced very close to each
other. As coolant travels through the condenser tubes, it cools
part of the fin. Because many tubes are attached to a fin, the net
effect is that the fin cools. In addition, the fin may be shaped to
create an airflow change across the width or length of the fin.
This change exposes more air to the fin for a longer period of
time. Accordingly, as the air flow passes, it contacts the
condenser tubes and starts a condensation process along the tubes.
In addition, the air flow contacts the vertical fins and starts a
condensation process along the fin. As such, condensation forms
along the tubes and the fins. This greatly enhances the
condensation efficiency, and hence the drying efficiency. Thus, a
great deal of condensation is removed in the first pass. In those
embodiments where a mini-recondensation loop is formed (that is, a
second loop which takes the first pass air flow and recirculates it
through the condensing system before being routed to the heater),
the condensation system efficiency is greatly enhanced before that
vapor is routed to the heater to be warmed up.
[0060] Another alternate condensation system includes a bubble
condensation system. A bubble condensation system works on the
principle that the airflow or vapor stream passes through one or
more perforated conduits, such as an air diffuser. The vapor stream
escapes from these perforations, in a bubble fashion, into a
chilled condensation bath. The chilled condensation bath may
comprise a bath of the working fluid. In this regard, the vapor
stream is bubbled into the condensation bath of the chilled working
fluid. The chilled working fluid cools the vapor stream, thereby
condensing it into a liquid. The contents of the condensation bath
may then be directed to the reclamation unit for reclamation. An
advantage of using a bubble condensation system is that the
condenser fan 78 is eliminated. Only the blower 72 need be used. In
another embodiment, the condensation can take place in the storage
tank. The chilled working fluid may be obtained from the chiller
system of the reclamation unit. Another advantage is that the
condensation bath acts as a particulate and lint filter such that
upon condensation, the particulates are trapped in the condensation
bath. Because of the various boiling points of the chemicals in the
airflow, the condensation bath may be adapted to capture various
chemicals as they condense out. For example, water may be captured
separately from the working fluid. Various beds, such as a zeolite
bed or silica bed, may be used to capture the water. Accordingly,
an embodiment of the invention resides in blowing an airflow
through a bubble forming mechanism to bubble the airflow into a
chilled condensation bath.
[0061] Alternative condensing technologies include, but are not
limited to thermoelectric coolers, peltier elements,
thermo-acoustic and membrane technologies. Membranes, more
specifically, cross-flow membranes, will generate a pressure drop
across the membrane material that will act as a driving force to
condense the IWF from the air.
[0062] Similarly, in any condensation modality described herein,
controlling the condensation may control chemical separation. As
mentioned, various chemical absorbing beds may be used to select
out chemicals. In addition, temperature may be altered in the
condensation system to control condensation rates. Because various
chemicals have differing densities or miscibility quotients, liquid
layer separation techniques, such as skimming, siphoning, or
gravimetric methods may be used.
[0063] When using a condenser sump 88, the contents of the
condenser sump 88 or the condensation bath may take several routes.
Contents may be routed directly into the reclamation unit by a
conduit. On the other hand, the contents may be routed to the wash
unit recirculation system previously described. For example,
contents may be routed to the wash chamber sump 36, to a position
before or after the filter 38, to a position before or after the
recirculation pump 40, to a position before or after the
recirculation valve 42, or to an area between the wash chamber 26
and the basket 34. In this regard, routing the contents to the wash
unit recirculation system permits the use of the existing plumbing.
It is advantageous to avoid introducing the contents directly into
the basket 34 so as to avoid wetting the fabrics that are intended
to be dried. Notwithstanding, the contents may be selectively
introduced back into the basket 34 (either directly or through the
dispenser system) so that the fabrics are not over-dried and that
the desired amount of fabric humidity is maintained.
[0064] In addition, the condensation may be selectively routed to
the reclamation unit or the wash unit recirculation system. For
example, the initial drying airflow may contain residues from the
wash cycle. Accordingly, upon condensation, this residue containing
liquid may be routed to the reclamation unit for processing. As the
drying cycle progresses, the amount of residue decreases and thus
the condensation contents may be routed to the wash unit
recirculation system until it is selectively reclaimed.
[0065] As with any sump, tank, container, dispenser described
herein, a fill sensor, such as a float sensor may be used to
monitor the volume of the item so that a pump can be activated to
pump out the volume and avoid overflowing or spillage. Similarly,
fill sensors may be used to activate or deactivate the
recirculation process, drying, or the reclamation loops.
[0066] Returning now to FIGS. 5 and 6A, a heater conduit 90 is
shown in communication with a heater 92. In this embodiment, the
heater 92 heats the air so that hotter air is returned to the
fabric load to be dried. To optimize the heat transfer from the
heating units within the heater 92 to the air flow, the heater
conduit 90 may be in a position away from the wash chamber conduit
96 (which may be insulated), which connects to the wash chamber
inlet 98. The chamber inlet 98 may be located in the boot 28. In
this embodiment, the heater conduit 90 is in an opposite corner
than the wash chamber conduit 96 such that the air flow entering
the heater 92 is heated optimally before exiting the heater 92 into
the wash chamber conduit 96. To further optimize heat transfer, the
heater 92 may contain various baffles, mazes, walls, deflectors,
etc. that are configured to steer the air flow into a long path
whilst inside the heater 92. Optimization may occur by increasing
the number of heater elements within the heater 92, increasing the
time spent in the heater, and/or increasing the air flow distance
it travels in the heater. For example, if resistance wire
thermocouple type heating is being used, then the number of
thermocouples may be increased accordingly. In addition, to
optimize heating, various circuits may be used with various
controllers to control the heat application in various sectors of
the heater. The heater 92 itself may be designed to create
optimized air flow, such as being conical, football, or triangular
shaped so as to steer the air to the wash chamber conduit 96 during
heating.
[0067] In one embodiment, the condenser conduit 76 enters the
condenser system 74 from the bottom and provides a substantially
straight path through the condenser system 76 to the heater conduit
90 and a substantially straight path to the heater 92. In this
regard, flow losses are significantly reduced and flow rates can be
better controlled.
[0068] In addition, although shown in FIGS. 5 and 6 as one wash
chamber conduit 96, there may be several outlets from the heater
into the same conduit 96. Furthermore, there may be one conduit 96
splitting into multiple wash chamber inlets 98. In effect, it may
be desirable to have multiple inlets into the wash chamber so that
hot airflow may be maximized and that excellent drying
achieved.
[0069] In one embodiment, a heater capable of maintaining about
70.degree. C. may be used. A heater that is capable of doing so is
a 3300 W, 240 V, 15 Amp heater. The heater ought to be designed as
to keep the air hot but not so hot as to approach the flash point
of the residual vapor in the air flow. Accordingly, an embodiment
of the invention resides in a heater that is adapted to maintain a
temperature that is less than the flash point of a working fluid.
Any heater may be insulated to assist in heat retention. In
addition, the heater can be located near the wash chamber inlet 98
as to minimize the heat loss in the wash chamber conduit 96. The
heater 92 may also be located above the condenser system 74 to
avoid any liquid condensate from entering the heater. Accordingly,
an embodiment of the invention resides in a heater that is at a
location higher than a condenser system 74. Furthermore, the heater
control may be designed as to increase the heating capacity if the
initial fabric load was a wet load. (Commonly, the fabric load is
generally dry prior to washing. A wet load, such as rain soaked
clothing or wet towels, starts off wet.) Accordingly, the machine
10 may sense that the initial fabric load is a wet load or the
consumer may initiate the wash cycle and select a wet load start
cycle. This auto-detection or consumer selection may control the
heating cycle at a later time. The heater 92 may also include a
sensor to measure the humidity of the air flow.
[0070] The heater 92 may also include a working fluid sensor to
sense the presence of any working fluid. If the sensor detects very
little to no residual working fluid, the heating control may step
up the heating to achieve a reduced drying time cycle. For example,
the heating may increase to above 70.degree. C. An additional
feature that may be incorporated in the heater is a sensor to
measure the concentration of IWF present inside the heater. If a
critical concentration is exceeded, the shut-off procedure will be
activated.
[0071] Although not shown, the drying cycle may include a means to
add drying adjuvants. Some potential adjuvants that may be added to
improve the drying process include, but are not limited to heating
the IWF prior to extraction spin-out 173, via a sump heater,
heating the air during the extraction step, alcohol or other
solvents that have any affinity for water and the IWF, additives
that decrease the viscosity of the IWF, anionic or cationic
surfactants added during the rinse or during the extraction to
further facilitate the decrease in interfacial tension and the
subsequent improvement in the extraction rate, a lower pressure in
the system to facilitate increased temperatures and increased vapor
removal, an increase in an inert gas such as nitrogen in the
environment which can be accomplished via a gas purge or a membrane
that selectively removes oxygen from the environment thus
increasing the temperature allowed in the drum as well as the
removal rate of vapor and/or a perfume to deodorize or mask any
odors.
[0072] In a preferred embodiment of the invention, a drying
additive that has a high affinity for the IWF would help decrease
the cycle time of the system. This additive can be a liquid
extraction solvent and the preferred liquid extraction solvent
would have at least one of the following properties: a KB value
less than 30; a solubility in water less than 10%; or a flash point
greater than 145 C. Some preferred liquid extraction solvents would
be perfluorocarbons, hydrofluoroethers, fluorinated hydrocarbons,
fluoroinerts and carbon dioxide. Even more specifically, the liquid
extraction solvent is selected from the group consisting of
methoxynonafluorobutane, ethoxynonafluorobutane and mixtures
thereof.
[0073] The liquid extraction solvent should be preferably separated
from the working fluid before dissolved contaminants are removed
from the fluid. Methods of separating the liquid extraction solvent
and working fluid are similar to techniques identified in this
specification. For example, the liquid extraction solvent could be
fractionally distilled from the working fluid, leaving the working
fluid and the remaining contaminants to pass through unit
operations aimed at purifying the working fluid. Upon separation
and purification, the liquid extraction solvent should contain less
than 25% of the working fluid.
[0074] The drying cycle also may take into consideration the tub
assembly characteristics. For example, to effectively and
efficiently dry fabrics, the air flow ought to travel through the
fabrics to the rear section 32. It is undesirable to have a
constant patterned air flow through the basket if that air flow
pattern does not pass through a substantial portion of the fabrics.
To this end, it is desirable to change the air flow in the basket
so that hot air will pass through the fabrics. Accordingly, the tub
assembly may include a drive motor that is adapted to change the
speed of the basket rotation, change the direction of the basket
rotation, and a means to create a partial low pressure area at the
rear section 32. In this last regard, the air flow travels from the
high pressure area by the wash chamber inlet 98 across the gradient
to the low pressure area at the rear section 32. Various flappers
or baffles may be used to change the air flow pattern. These
flappers or baffles may be molded into the basket or may be
retractable. In addition because some baskets are tilted towards
the back, a baffle may be added to the rear section of the basket
that pushes fabrics away from the back to avoid clumping at the
rear section. Other modes to change the air flow pattern include
varying the perforation openings, closing some perforations during
the drying cycle, or the like.
[0075] C. Reclamation of Fluids and Waste Disposal
[0076] FIG. 7 demonstrates an embodiment of the reclamation unit 14
with the reclamation unit outer housing removed. Fluid returned
from the wash unit 12 is preferably routed to an optional waste
tank 100. The optional waste tank 100 includes a waste tank top
surface 102, a waste tank bottom area 104, and a waste tank outlet
(not shown). The waste tank 100 comprises a material compatible
with the working fluid used. The tank is preferably clear or
semi-opaque so that the fluid level of the tank can be readily
determined. In addition, the tank may also include internal or
external fluid level indicators, such as graduated markings. The
tank volume may be greater than the sum total volume of working
fluid plus any adjuvants used such that the entire fluid volume of
the machine can be adequately stored in the waste tank. The waste
tank bottom area 104 may be shaped as to direct the waste tank
contents towards the waste tank outlet (not shown). In one
embodiment, the waste tank outlet is generally located at the
bottom of the waste tank so that gravity assists the fluid
transport through the waste tank outlet. The waste tank may also
include a pressure relief valve 106 to relieve accumulated
pressures in the tank.
[0077] With regard to tank construction, if the tank is not
uniformly molded, then any seals ought to be tight and resistant to
wear, dissolution, leaching, etc. The inside walls of the tank can
be microtextured to be very smooth, without substantial surface
defects, so that waste fluid entering the tank is easily flowed to
the tank bottom. In addition, the inside wall should be easily
cleanable. To this end, the tank may include a series of scrapers
that periodically scrape the side walls and bottom to ensure that
little or no waste sticks to the walls and the bottom and that such
waste is channeled to the tank outlet. The scrapers may be
controlled via programming. Although not shown, the tank outlet may
also include a removable particulate filter. Additionally, the tank
may include a layer of insulation material that helps sustain the
desired temperatures for each systems' heating/cooling mechanisms
either within or surrounding the tanks.
[0078] The tank outlet is in fluid communication with a high
pressure pump 108, which pumps the waste tank contents into a
chiller 110, which further cools the waste tank contents. The
chiller preferably resides in an insulated box to maintain a cooler
environment.
[0079] FIG. 8 demonstrates a partial back end view of the
reclamation unit. The cooled waste tank contents are then pumped
from the chiller to a chiller multiway valve 112. Between the
chiller and the multiway valve 112 is a temperature sensor (not
shown). The default position of the valve shunts the cooled waste
tank contents back into the waste tank 100. Thus, cooled waste tank
contents are returned to the waste tank 100. The waste tank 100 may
also include a temperature sensor to measure the temperature of the
waste tank contents. When the desired temperature is achieved, for
example, less than 0.degree. C., the multiway valve 112 may shunt
the cooled waste tank contents into a cross flow membrane 114. A
less than zero temperature is desirable as water will freeze and
thus not permeate in the cross flow membrane.
[0080] FIG. 8 also shows the chiller 110 with the back panel
removed to show the chiller contents. The chiller 110 may comprise
a chilling coil 116 that has an coil inlet (not shown) and a coil
outlet 118. The chilling coil 116 may include an outer cover 120
such that the chilling coil 116 and the outer cover 120 form a
coaxial arrangement. Disposed between the coil 116 and the outer
cover 120 is a coolant. Accordingly, the coolant being carried by
the outer cover 120 chills waste tank contents flowing through the
coil 116. The coolant is circulated into the chiller 110 via a
compressor system, which includes a coolant coil 122 and a coolant
compressor 124. Thus, the compressor 124 cools the coolant in the
coolant coil 122. This cooled coolant is then pumped into the
coaxial space between the outer cover 120 and the chilling coil
116, such that the waste tank contents are ultimately cooled. This
default loop continues for as long as necessary.
[0081] It is also understood that other cooling technologies may be
used to cool the waste tank contents as desired. For example,
instead of having water cool the compressor system, an air-cooled
heat exchanger similar to a radiator can be used. Alternatively,
the IWF may be cooled by moving water through cooling coils, or by
thermoelectric devices heaters, expansion valves, cooling towers,
or thermo-acoustic devices to, cool the waste tank contents
[0082] In addition, as mentioned earlier, and in reference to FIG.
11, because this cooled coolant is being generated, it may be used
for the condensation system in the wash unit 12. As such, various
multiway valves may be used to shunt coolant to the wash unit 12,
for example, for use as a coolant in radiator-type tubing.
Moreover, as mentioned above, cooled working fluid 156 may be used
to assist in condensation in the direct condensation methods
described above. Accordingly, the multiway valve may shunt cooled
working fluid to the wash unit to assist in condensation.
[0083] FIGS. 8 and 9 demonstrate the waste tank content flow. As
mentioned above, once the desired temperature is achieved, the
multiway valve 112 shunts the flow to the cross flow membrane 114.
In an alternate embodiment, a recirculation loop may be set up such
that the waste tank contents are recirculated through the chiller
110, as opposed to being routed back into the waste tank 100. In
this regard, the chiller multiway valve 112 may have an additional
shunt that shunts the contents back into the path between the high
pressure pump 108 and the chiller 110. Once the desired temperature
is achieved, the multiway valve 112 shunts the flow to the cross
flow membrane 114. The cross flow membrane 114 has a proximal end
126 and a distal end 128. As waste tank contents are pumped into
the proximal end 126, filtration begins and a permeate and a
concentrate waste are formed 169.
[0084] The permeate flows down to the bottom of the cross flow
membrane and exits the membrane 114 and enters a permeate pump 130.
This permeate pump 130 pumps the permeate into a permeate filter
132, such as a carbon bed filter. The permeate enters the permeate
filter 132 via the permeate filter proximal end 134, travels across
the filter media, and exits via the permeate filter distal end 136.
The permeate filter is selected for its ability to filter out
organic residues, such as odors, fatty acids, dyes, petroleum based
products, or the like that are miscible enough with the bulk
solvent to pass through the cross flow membrane. Such filters may
include activated carbon, alumina, silica gel, diatomaceous earth,
aluminosilicates, polyamide resin, hydrogels, zeolites,
polystyrene, polyethylene, divinyl benzene and/or molecular sieves.
In any embodiment, the permeate may pass over or through several
permeate filters, either sequentially or non-sequentially. In
addition, the permeate filter may be one or more stacked layers of
filter media. Accordingly, the flow may pass through one or more
sequential filters and/or one or more stacked and/or unstacked
filters. The preferred geometry for liquid and vapor removal for
activated carbon is spherical and cylindrical. These systems may
have a density between 0.25 to 0.75 g/cm.sup.3 with preferred
ranges of 0.40 to 0.70 g/cm.sup.3. Surface areas may range from 50
to 2500 m.sup.2/g with a preferred range of 250 to 1250 m.sup.2/g.
The particle size may range from 0.05 to 500 .mu.m with a preferred
range of 0.1 to 100 .mu.m. A preferred pressure drop across the
packed bed would range from 0.05 to 1.0.times.10.sup.6 Pa with a
preferred range of 0.1 to 1000 Pa. A porosity may range from 0.1 to
0.95 with a preferred range from 0.2 to 0.6.
[0085] For silica beds, the following characteristics may be
present. The preferred geometry for liquid and vapor removal is
spherical and cylindrical. These systems may have a density from
0.25 to 0.95 g/cm.sup.3 with a preferred range from 0.60 to 0.85
g/cm.sup.3; a particle size range of 0.0005 to 0.010 m with a
preferred range of 0.001 to 0.005 m; a preferred pressure drop
across the packed bed between 0.05 to 1.0.times.10.sup.6 Pa with a
preferred range of 0.1 to 1000 Pa; and a porosity ranging from 0.1
to 0.95 with a preferred range from 0.2 to 0.6.
[0086] After the permeate is filtered, the permeate is routed into
the clean tank 138, where the permeate, which is now substantially
purified working fluid, is stored. The purified working fluid
should be greater than 90% free from contaminants with a preferred
range of 95% to 99%. As desired, the working fluid is pumped from
the clean tank 138 via a fill pump 140 to the wash unit 12.
[0087] The cross flow membrane 114 is also selected for its ability
to filter out the working fluid as a permeate. Cross flow membranes
may be polymer based or ceramic based. The membrane 114 is also
selected for its ability to filter out particulates or other large
molecular entities. The utility of a cross flow membrane, if
polymer based, is a function of, inter alia, the number of hollow
fibers in the unit, the channel height (e.g., the diameter of the
fiber if cylindrical), length of the fiber, and the pore size of
the fiber. Accordingly, it is desirable that the number of fibers
is sufficient to generate enough flow through the membrane without
significant back up or clogging at the proximal end. The channel
height is selected for its ability to permit particulates to pass
without significant back up or clogging at the proximal end. The
pore size is selected to ensure that the working fluid passes out
as permeate without significant other materials passing through as
permeate. Accordingly, a preferred membrane would be one that would
remove all particulate matter, separate micelles, separate water
and other hydrophilic materials, separate hydrophobic materials
that are outside the solubility region of the working fluid, and
remove bacteria or other microbes. Nano-filtration is a preferred
method to remove bacteria and viruses.
[0088] Ceramic membranes offer high permeate fluxes, resistance to
most solvents, and are relatively rigid structures, which permits
easier cleaning. Polymer based membranes offer cost effectiveness,
disposability, and relatively easier cleaning. Polymer based
membranes may comprise polysulfone, polyethersulfone, and/or methyl
esters, or any mixture thereof. Pore sizes for membranes may range
from 0.005 to 1.0 micron, with a preferred range of 0.01 to 0.2
microns. Flux ranges for membranes may range from 0.5 to 250
kg/hour of working fluid with a preferred minimum flux of 30
kg/hour (or about 10-5000 kg/m.sup.2). Fiber lumen size or channel
height may range from 0.05 to 0.5 mm so that particulates may pass
through. The dimension of the machine determines the membrane
length. For example, the membrane may be long enough that it fits
across a diagonal. A length may, preferably, be between 5 to 75 cm,
and more preferably 10 to 30 cm. The membrane surface area may be
between 10 to 2000 cm.sup.2, with 250 to 1500 cm.sup.2 and 300 to
750 cm.sup.2 being preferred.
[0089] The preferred membrane fiber size is dependent upon the
molecular weight cutoff for the items that need to be separated. As
mentioned earlier, the preferred fiber would be one that would
remove all particulate matter, separate micelles, separate water
and other hydrophilic materials, separate hydrophobic materials
that are outside the solubility region of the working fluid, and
remove bacteria or other microbes. The hydrophobic materials are
primarily body soils that are mixtures of fatty acids. Some of the
smaller chain fatty acids (C.sub.12 and C.sub.13) have lower
molecular weights (200 or below) while some fatty acids exceed 500
for a molecular weight. A preferred surfactant for these systems
are silicone surfactants having an average molecular size from
500-20000.
[0090] For example, in siloxane based working fluid machines, the
fiber should be able to pass molecular weights less than 1000, more
preferably less than 500 and most preferably less than 400. In
addition, the preferred fibers should be hydrophobic in nature, or
have a hydrophobic coating to repel water trying to pass. For the
contaminants that pass through the fibers, the absorber and/or
absorber filters will remove the remaining contaminants. Some
preferred hydrophobic coatings are aluminum oxides, silicone
nitrate, silicone carbide and zirconium. Accordingly, an embodiment
of the invention resides in a cross flow membrane that is adapted
to permit a recovery of the working fluid as a permeate.
[0091] Returning to FIGS. 8 and 9, the permeate took the path that
led to a permeate pump. The concentrate, however, takes another
path. The concentrate exits the cross flow membrane distal end 128
and is routed to a concentrate multiway valve 142. In the default
position, the concentrate multiway valve 142 shunts the concentrate
to the waste tank 100. The concentrate that enters the waste tank
100 is then routed back through the reclamation process described
above. Once the concentrate multiway valve is activated, the
concentrate is routed to a dead end filter 144.
[0092] Because a goal of the concentrate multiway valve 142 is to
shunt (by default) to the waste tank 100, the result is that more
waste tank contents are filtered and more working fluid is
recovered as permeate. Eventually though, it becomes necessary for
the multiway valve 142 to shunt the concentrate to the dead end
filter. This activation may be triggered by various events. First,
the activation may be timed, either in terms of real-time
monitoring or by the number of times the reclamation process has
occurred. For example, the real time monitoring may control the
shunting to occur every hour, day, week, month, etc. For cycle
timing, the shunting may occur every n.sup.th wash cycle or every
n.sup.th reclamation cycle (where n>0). In addition, various
sensors may be used to control the valve activation. For example, a
turbidity sensor may be used to measure how turbid the concentrate
is. In addition, a conductivity sensor may be used. One potential
application of a conductivity sensor is to measure the water
concentration. A viscosity sensor may be used to measure the
viscosity. A light transmittance sensor may be used to measure the
relative opacity or translucence of the concentrate. Drawing off a
fixed volume of concentrate into a loop, measuring the mass, and
calculating the density may use a density sensor. A volumetric
sensor may be used to measure the amount of working fluid recovered
by comparing the volume of working fluid at the beginning of the
wash cycle to the volume of working fluid recovered after some of
the reclamation process. The comparison would result in an estimate
of the amount of working fluid in the concentrate. Finally, the
activation may be simply a manual activation as desired. In any
sensor use, once reaching a desired threshold, the sensor activates
the valve to shunt to the dead end filter 144.
[0093] The dead end filter 144 may be a container that includes an
internal filter 146. As concentrate enters the dead end filter 144,
the concentrate collects on the internal filter 146. Based on the
type of filter used, permeate will pass through the filter 146 and
be routed to the waste tank 100 or eventually into the clean tank.
The concentrate will remain in the dead end filter. To assist in
drawing out remaining liquids from the concentrate so that it
passes to the waste tank, a vacuum may be created inside to draw
out more liquid. In addition, the dead end filter 144 may include a
press that presses down on the concentrate to compact the
concentrate and to squeeze liquids through the internal filter 146.
The dead end filter 144 may also include one or more choppers or
scrapers to scrape down the sides of the filter and to chop up the
compacted debris. In this regard, in the next operation of the
press, the press recompacts the chopped up debris to further draw
out the liquids. The dead end filter may be consumer accessible so
that the dead end filter may be cleaned, replaced, or the like; and
the remaining debris removed. In addition, the dead end filter may
be completed without the assistance of a vacuum, in a low
temperature evaporation step or an incineration step. Capturing the
concentrate/retentate and then passing a low heat stream of air
with similar conditions to the drying air over the filter will
complete the low temperature evaporation step. The IWF will be
removed and then routed to the condenser where it will condense and
then returned to the clean tank.
[0094] Another concern that needs to be addressed in the re-use of
the filters beds. Some potential means to prevent fouling or to
reduce fouling are via chemical addition or cleaning, reducing the
temperature and phase changing the water to ice and then catching
the ice crystals via a filter mechanism, or coating the membranes
with special surfaces to minimize the risk of fouling. A way to
regenerate the filters includes but is not limited to the addition
of heat, pH, ionic strength, vacuum, mechanical force, electric
field and combinations thereof.
[0095] Sensors
[0096] Various sensors may be located along any path, such as the
drying, recirculation, wash, or reclamation paths. For example,
temperature sensors may be associated with the waste tank 100 to
measure the temperature of the waste tank contents; with the
chiller 110 to monitor the temperature of the contents and to
activate the chiller multiway valve 112; with the clean tank 138 to
monitor the temperature of the working fluid; with the coolant
compressor-coil system to ensure that the chiller 110 operates
efficiently; or anywhere else as desired.
[0097] Other sensors may include a single pressure sensor to
monitor the pressure at a given point. For example, a single
pressure sensor may be associated with the waste tank 100 to ensure
that pressure is adequately relieved via the pressure relief valve
106; with the clean tank 138; with the coolant compressor-coil
system; with the high pressure pump 108 to ensure that the high
pressure pump is operating at a high enough pressure; or as desired
anywhere else. In addition, double paired pressure sensors in which
one-half of the pair is located on either side of a component, may
be used. This arrangement permits a pressure gradient measurement
across the component. For example, the double pressure sensor
system may be associated with the cross flow membrane 114 to
measure if there is a questionable pressure drop across the
membrane that may indicate that the membrane is becoming clogged;
with the permeate filter 132 to measure a pressure drop that may
indicate that the filter is becoming clogged; or anywhere else as
desired. Additionally, the present sensors can be used to measure
the levels in the tank and/or the drum.
[0098] Other sensors may include leak sensors in the pans to sense
if leaking occurs, leak sensors to sense for fluid leaks, flow rate
sensors or meters to measure the quantity of fluid or quantity of
air that has moved past the flow meter point; a weight sensor to
estimate the size of a load or the saturation of a load; sensors to
indicate when the machine is deactivated so that the consumer may
interact with it (e.g., ready to clean lint filter, clean condenser
units, clean condenser radiator coils, ready to swap out
cartridges, ready to load/unload fabrics, etc.)
[0099] Level detection is an important feature that may be used to
determine if service needs to be scheduled, when the reclamation
cycle is complete, potential leaking of the system, etc. Some
potential methods to detect levels in the drum, storage tanks and
condensing reservoirs are continuous and point level sensing. One
method for continuous level sensing is through pressure, but these
sensors need to be robust to the IWF and isolated from the system.
Another continuous level sensor is ultrasonic and the material
choices are PVDF, ceramic crystals, quartz cyrstals, electrostatic
and MEMS. Shaped electromagnetic field (SEF), float sensing, laser
deflection and petrotape/chemtape are other continuous level
sensing techniques. Potential point level sensing techniques are
capacitive, float sensing, conductivity and electric field
imaging.
[0100] Turbidity is another important sensing feature useful in
determining contamination level that could facilitate more
detergent dispensing or another cycle through the reclamation
system. Turbidity sensors can be placed in the storage tanks or the
sump area of the wash system and can be accomplished via
conductivity measurements, infrared technology and the combination
of level sensor such as SEF and flow measurements.
[0101] Flow sensing can be used to determine the amount of fluid in
the storage tanks, the drum, and the condenser as a possible means
to terminate the drying cycle, the fullness of the filter beds,
etc. This can be completed using turbines or positive displacement
sensors.
[0102] Another useful sensor measurement is humidity for both water
vapor and IWF detection. This can be utilized to help determine the
presence of a leak, the termination of the drying cycle, if a
dehydration step to remove water needs to be completed before an
IWF wash. Some technologies that may be useful are non-dispersive
infrared, solid state, acoustic wave and metal oxide
semiconductors.
[0103] Alternate Heat Use
[0104] FIG. 10 describes an alternate embodiment for utilizing the
heat from the chiller system. As shown above, the compressor system
includes a series of coolant coils that assist in cooling the waste
tank contents. As such, that coolant begins to heat up. The coolant
as the compressor is cooling it can be shunted to the wash unit for
use in the condensation loop, the heated coolant may be used also.
Accordingly, heated chiller coolant 149 may be shunted to the
drying cycle to assist 150 in drying. The heat in the coolant may
be used in the heater 92 to assist in heating the air. That is, it
can be used to assist the heater wires. In addition, the heated
coolant 151 may be directed to the wash chamber 26 to assist in
heating the wash chamber 26 or the basket 34. In this regard,
energy savings is achieved because heat generated elsewhere is
being used in the drying cycle.
[0105] The heated coolant may, however, be used in the reclamation
unit 14. In some embodiments, various adsorbent beds may be used to
trap various chemicals. The heated coolant may be used to remove
the adsorbed 152 chemical from the bed, thereby refreshing the bed.
In addition, the heated coolant may be passed through a phase
change material 153 for storage. For example, the phase of certain
chemicals may be changed by the introduction of the heat. Later
when necessary, the phase can be returned to the original phase
thereby liberating the heat in an exothermic reaction. In this
regard, the heat may be stored until desired.
[0106] In some instances, thermal management may be very effective
in such a process. The motors turning the drum and operating the
pump traditionally give off heat. This heat may be effectively used
in heating the non-aqueous fluid for drying, spinning and/or
heating the rinse fluid to promote increased cleaning.
Additionally, some type of cooling mechanism is a preferred
embodiment to the reclamation system and this cooling system can be
interspersed throughout the product to provide more energy
efficient heating and cooling.
[0107] Alternate Condensation Loop
[0108] FIG. 11 demonstrates an alternate condensation loop 161. In
this case, fluid from the manifold 56 may be collected 162 for
direct spray condensation, as described above. Similarly, fluid
collected in the condenser 74 may be used for direct spray
condensation 154. As described above, the chiller system 110 may be
used for direct spray condensation either in the manifold 56 or in
the condenser 74. Coolant 155 from the chiller system may be used
in the condenser system 74. Fluid in the condenser 74 may also be
directed to the waste tank 100, such as when the last wash cycle is
over. Condenser 74 fluid may be routed to the wash chamber sump for
recondensation, especially if phase separation is desired.
Similarly, fluid collected in the condenser sump 88 can be rerouted
back through the condenser system 74. All heaters in the fluid path
are optional, but in FIG. 11, it shows a heater between the
condenser sump 88 and the wash chamber 26. Also shown is that the
condenser sump 88 may be used for phase separation. The various
phases, whether water, working fluid, adjuvants, etc., may be used
elsewhere or recovered. Optionally, the water may be sent to the
drain 159 and/or used for condenser cleaning 160.
[0109] Alternate Recirculation Loop
[0110] FIG. 12 shows an alternate recirculation loop. Various
pathways exist if the intent is to heat the fluid, although any
heater shown is optional. Valves may exist to direct the fluid to
the reclamation unit 14 from the wash chamber 26, the wash chamber
sump 36, after the coarse lint filter 36, or after the
recirculation pump 40. Similarly, a path may exist from the
recirculation pump 40 to the tub inlet 52 directly, thereby
bypassing the dispenser 48. In another path, fluid may travel from
the dispenser 48 to the wash chamber 26 via a heater (e.g., to heat
the dispenser additions).
[0111] Although the dispenser may be routed to the wash chamber
sump 36, so that any addition added to the fluid from the dispenser
is not added to the fabrics in the wash chamber 26, but that is
routed to the sump, for example, to be used in the reclamation unit
14. In other words, an adjuvant intended for use in the reclamation
unit may be added to the recirculation loop but by-passing the wash
chamber. Similarly, the dispenser may have a separate conduit to
the reclamation unit 14. In addition, the reclamation unit 14 may
have conduits to the dispenser via an additive reservoir 148 (which
may be in the reclamation unit 14 or in the wash unit 12) so that
adjuvants may be added. Reclamation unit fluids may be routed into
the dispenser 48, for example, cleaned working fluid for cleaner
rinsing. Accordingly, the dispenser may dispense additions that are
washing specific, reclamation unit specific or both.
[0112] FIGS. 13 and 14 show other embodiments of the invention
generally related to reclamation. Although not shown, any loop or
path may be re-looped so that it is repeated. In addition, it
should be recognized that any step may be combined with another
step or omitted entirely. That is, each step is optional, may be
combined, or its order changed. FIG. 13 shows that one of the
initial steps in the reclamation process is to remove large
particulates 167. As mentioned herein, any mode of large
particulate removal is contemplated, including using the coarse
lint filter, filtration, and other separation techniques. Large
particulates can be buttons, lint, paper clips, etc., such as those
having a size of greater than 50 microns. Small particulates may be
less than 50 microns. A method of particulate removal may include a
dehydration step in the wash chamber by heating the fabrics so that
any residual water is removed. By doing so, the electrostatic bond
between the dirt and fabric is broken, thereby liberating the dirt.
This dirt can then be recovered. Other methods of particulate
removal includes vortex separation and chemical digestion.
[0113] Dissolved soils include those items that are dissolved in
the working fluid, such as oils, surfactants, detergents, etc.
Mechanical and chemical methods, or both may remove dissolved soils
166. Mechanical removal includes the use of filters or membranes,
such as nano-filtration, ultra-filtration and microfiltration,
and/or cross flow membranes. Pervaporation may also be used.
Pervaporation is a process in which a liquid stream containing two
or more components is placed in contact with one side of a
non-porous polymeric membrane while a vacuum or gas purge is
applied to the other side. The components in the liquid stream sorb
into the membrane, permeate through the membrane, and evaporate
into the vapor phase (hence the word pervaporate). The vapor,
referred to as "the permeate", is then condensed. Due to different
species in the feed mixture having different affinities for the
membrane and different diffusion rates through the membrane, a
component at low concentration in the feed can be highly enriched
in the permeate. Further, the permeate composition may widely
differ from that of the vapor evolved after a free vapor-liquid
equilibrium process. Concentration factors range from the single
digits to over 1,000, depending on the compounds, the membrane, and
process conditions.
[0114] Chemical separation may include change of state methods,
such as temperature reduction (e.g., freeze distillation),
temperature increase, pressure increase, flocculation, pH changes,
and ion exchange resins.
[0115] Other removal methods include: electric coalescence,
absorption, adsorption, endothermic reactions and thermo-acoustic
cooling techniques.
[0116] Insoluble soils may include water, enzymes, hydrophilic
soils, salts, etc. Items may be initially insoluble but may become
soluble (or vice versa) during the wash and reclamation processes.
For example, adding dissolvers, emulsifiers, soaps, pH shifters,
flocculants, etc., may change the characteristic of the item. Other
methods of insoluble soil removal include filtration,
caking/drying, gravimetric, vortex separation, distillation, freeze
distillation and the like.
[0117] Reducing impurities 165 may include any of the above steps
done that are done to reduce, and thereby purify, the working fluid
recovery. Reducing impurities may involve the use of multiple
separation techniques or separation additives to assist in
reclamation. It may also involve the use of a specific separation
technique that cannot be done until other components are
removed.
[0118] In some instances, the surfactants may need to be recovered.
A potential means for recovering surfactants is through any of the
above-mentioned separation techniques and the use of CO.sub.2 and
pressure.
[0119] Sanitization
[0120] As used herein, sanitization 168 means the generic principle
of attempting to keep the unit relatively clean, sanitary,
disinfected, and/or sterile from infectious, pathogenic, pyrogenic,
etc. substances. Potentially harmful substances may reside in the
unit because of a prior ambient introduction, from the fabrics
cleaned, or from any other new substance added. Because of the
desire to retrieve clean clothes from the unit after the cycles are
over, the amount of contamination remaining in the clothes ought to
be minimized. Accordingly, sanitization may occur due to features
inherent in the unit, process steps, or sanitizing agents added.
General sanitization techniques include glutaraldehyde tanning,
formaldehyde tanning at acidic pH, propylene oxide or ethylene
oxide treatment, gas plasma sterilization, gamma radiation,
electron beam, ultraviolet radiation, peracetic acid sterilization,
thermal (heat or cold), chemical (antibiotics, microcides, cations,
etc.), and mechanical (acoustic energy, structural disruption,
filtration, etc.).
[0121] As for inherent features, one method of sanitizing is to
manufacture conduits, tanks, pumps, or the like with materials that
confer sanitization. For example, these components may be
manufactured and coated with various chemicals, such as
antibiotics, microcides, biocides, enzymes, detergents, oxidizing
agents, etc. Coating technology is readily available from catheter
medical device coating technology. As such, as fluids are moving
through the component, the fluids are in contact with the inner
surfaces of the component and the coatings and thereby achieves
contact based sanitization. For tanks, the inner surfaces of tanks
may be provided with the same types of coatings thereby providing
longer exposure of the coating to the fluid because of the extended
storage times. Any coating may also permit elution of a sanitizer
into the fluid stream. Drug eluting stent technology may be adapted
to permit elution of a sanitizer, e.g., elution via a parylene
coating.
[0122] Another inherent feature is to manufacture any surface by
micro-texturing the surface. For example, it is known that certain
organisms seek to adhere to surfaces and rough surfaces provide
areas for adhesion. Accordingly, micro-texturing the surface to
become very smooth eliminates any rough area where organisms can
adhere.
[0123] Components may also exist that specifically provide
sanitization. For example, a UV light may be provided anywhere
along the washing, drying, or reclamation cycles. One convenient
location for the UV light can be at the entrance of the reclamation
unit from the wash unit. As such, as fluid enters the reclamation
unit from the wash unit, it is exposed to UV light prior to any
initial reclamation steps. In addition, other locations may include
prior to any filtration, upon exit of a tank, or anywhere where the
conduit length is lengthy. Conduits may be made of a clear material
wherever necessary to permit UV exposure.
[0124] Another component available for sanitization is a filter.
The filter may be sized to permit continued progress of a desired
permeate but trap undesirable concentrates. For example, filtration
can include large size filtration, micro-filtration,
ultra-filtration, or the like. As with any embodiment herein using
filters, the filters may be sequential with varying filtering
capabilities. For example, sequential filters may be used that have
decreasing pore sizes. These pore size changing filters may also be
stacked. In addition, to facilitate any filtration (e.g., in the
wash unit or the reclamation unit), any particle may be subject to
additional processing such as chopping, grinding, crushing,
pulverizing, sonic pulverization, etc., to reduce the particle
size.
[0125] In addition, various sanitization additives may be added to
assist in periodic cleaning. For example, bleach, oxidizers,
enzymes, acids, alkalis, degreasers, ozone, plus the other organism
cleaners mentioned above, may be added to the wash chamber and the
unit cycled. For example, ozone in a level greater than 1 ppm at
less than 20.degree. C. may be used.
[0126] FIG. 14 shows yet another reclamation embodiment. In this
embodiment, shown is an initial pretreatment step 170, which may
include stabilizers, precipitators, flocculants, etc. Then a
separation step occurs in which concentrated 169 and
non-concentrated 171 waste is created. Each component can then be
treated separately depending on the desired treatment 172. There is
an optional sanitization step.
[0127] Service Plan Method
[0128] Yet another embodiment of the invention resides in
interacting with the apparatus. For example, because the unit can
be a closed system, it may be necessary to replace components.
Accordingly, an embodiment of the invention resides in inspecting
components for usage, determining if the component requires
replacement, and replacing the component. For example, filters may
become irreversibly clogged in the machine and thus require
periodic maintenance or replacement. Because some of the components
may require special handling, the service technician may possess
special implements to successfully clean and/or replace components.
The technician may, for instance, possess special hazardous waste
disposal bags to dispose of replaced components. The technician may
also possess specialized cleaning implements or diagnostic
implements to clean non-replaceable components or to calibrate
certain components. In another embodiment, a method involves
receiving information about use from the apparatus, analyzing the
information to generate diagnostic information, and performing a
service in response to the diagnostic information generated. As
mentioned earlier, the unit may include a memory storage that
stores information about the unit's performance, safety
information, status information, or the like. The technician may
read the information, perform a diagnostic or treatment, and reset
the unit for operation. Similarly, the unit may be provided with a
lock down mechanism that locks down the unit by sealing off door
and entry points, so that no leakage occurs. In this regard, the
technician may be provided with a special code or tool to unlock
the machine and reset it for re-use.
[0129] Working Fluid Description
[0130] In an embodiment, the working fluid is a liquid under
washing conditions and has a density of greater than 1.0. The
working fluid has a surface tension of less than or equal to 35
dynes/cm.sup.2. The oil solvency of the working fluid should be
greater than water without being oleophilic. Preferably, the
working fluid has an oil solvency as measured by KB value of less
than or equal to 30. The working fluid also has a solubility in
water of less than about 10%. The viscosity of the working fluid is
less than the viscosity of water under ordinary washing conditions.
The working fluid has a pH of from about 6.0 to about 8.0.
Moreover, the working fluid has a vapor pressure higher than the
vapor pressure of water and has a flash point of greater than or
equal to 145.degree. C. The working fluid is substantially
non-reactive under washing conditions with fabrics in the fabric
load, with the adjuvants present in the at least one washing
adjuvant and with oily soils and water soluble soils in the fabric
load.
[0131] In another embodiment, the working fluid may include a
surface tension less than 25 dynes/cm.sup.2, a vapor pressure less
than 150 [Pa], and a KB value less than 20.
[0132] The working fluid is substantially non-swelling to natural
fabrics present in the fabric load. In an embodiment, the working
fluid is a fluorine-containing compound selected from the group
consisting of: perfluorocarbons, hydrofluoroethers, fluorinated
hydrocarbons, and fluoroinerts.
[0133] As noted above, one family of chemicals particularly suited
for use as IWFs in the methods and apparatuses of the present
invention are "fluoroinert" liquids. Fluoroinert liquids have
unusual properties that make them particularly useful as IWFs.
Specifically, the liquids are clear, colorless, odorless and
non-flammable. Fluoroinerts differ from one another primarily in
boiling points and pour points. Boiling points range from about
56.degree. C. to about 253.degree. C. The pour points typically
range from about 30.degree. C. to about -115.degree. C.
[0134] All of the known fluoroinert liquids possess high densities,
low viscosities, low pour points and low surface tensions.
Specifically, the surface tensions typically range from 12 to 18
dynes/cm.sup.2 as compared to 72 dynes/cm.sup.2 for water.
Fluoroinert liquids typically have a solubility in water ranging
from 7 ppm to 13 ppm. The viscosity of fluoroinerts typically
ranges from 0.4 centistokes to 50 centistokes. Fluoroinerts also
have low KB values. The KB value is used as a measure of solvent
power of hydrocarbon solvents. Fluoroinerts have little or no
solvency.
[0135] In addition to fluoroinerts, hydrofluoroethers,
perfluorocarbons and similarly fluorinated hydrocarbons can be used
as an IWF in the methods and apparatuses of the present invention.
These additional working fluids are suitable due to their low
surface tension, low vapor pressure and high fluid density.
[0136] Other types of working fluids may also be used. For example,
a Class 3-A solvent (a solvent having a flash point between 140 F
and 200 F) may be used. In addition, cyclic siloxanes including,
but not limited to, octamethylcyclotetrasiloxane,
decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, or
tetradecamethylcycloheptasiloxane, may be used.
[0137] Other compounds include linear or branched, volatile
siloxane solvents, such as those containing a polysiloxane
structure that includes from 2 to 20 silicon atoms. Preferably, the
linear or branched, volatile siloxanes are relatively volatile
materials, having, for example, a boiling of below about
300.degree. C. point at a pressure of 760 millimeters of mercury
("mm Hg").
[0138] In a preferred embodiment, the linear or branched, volatile
siloxane comprises one or more compounds of the structural formula
(I):
M.sub.2+y+2zD.sub.xT.sub.yQ.sub.z (I)
[0139] wherein:
[0140] M is R.sup.1.sub.3SiO.sub.1/2;
[0141] D is R.sup.2.sub.2SiO.sub.2/2;
[0142] T is R.sup.3SiO.sub.3/2;
[0143] Q is SiO.sub.4/2
[0144] and wherein R.sup.1, R.sup.2, and R.sup.3 are each
independently a monovalent hydrocarbon radical; and x and y are
each integers, wherein 0.ltoreq.x, y, z.ltoreq.10.
[0145] Suitable monovalent hydrocarbon groups include acyclic
hydrocarbon radicals, monovalent alicyclic hydrocarbon radicals,
monovalent and aromatic hydrocarbon radicals. Preferred monovalent
hydrocarbon radicals are monovalent alkyl radicals, monovalent aryl
radicals and monovalent aralkyl radicals.
[0146] In an embodiment, the linear or branched, volatile siloxane
comprises one or more of, hexamethyldisiloxane,
octamethyltrisiloxane, decamethyltetrasiloxane,
dodecamethylpentasiloxane, tetradecamethylhexasiloxane or
hexadecamethylheptasiloxane or methyltris(trimethylsiloxy)silane.
In another embodiment, the linear or branched, volatile siloxane
comprises octamethyltrisiloxane, decamethyltetrasiloxane, or
dodecamethylpentasiloxane or methyltris(trimethylsiloxy)silane. In
another embodiment, the siloxane component of the composition
consists essentially of decamethyltetrasiloxane. Mixtures of any
working fluid are also contemplated, e.g., any mixture of one or
more siloxanes, fluorinated compounds, or a combination of
fluorinated compounds plus siloxanes.
[0147] Adjuvants
[0148] One or more washing adjuvants may used in combination with
the working fluid to form a wash liquor combination. Such adjuvants
include, but are not limited to, builders, surfactants, enzymes,
bleach activators, bleach catalysts, bleach boosters, bleaches,
alkalinity sources, antibacterial agents, colorants, perfumes,
pro-perfumes, finishing aids, lime soap dispersants, composition
malodor control agents, odor neutralizers, polymeric dye transfer
inhibiting agents, crystal growth inhibitors, photobleaches, heavy
metal ion sequestrants, anti-tarnishing agents, anti-microbial
agents, anti-oxidants, linkers, anti-redeposition agents,
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, fabric softeners, antistatic agents, dye
fixatives, dye abrasion inhibitors, anti-crocking agents, wrinkle
reduction agents, wrinkle resistance agents, soil release polymers,
soil repellency agents, sunscreen agents, anti-fade agents, and
mixtures thereof.
[0149] (a) Other Additives--These may include: phase transfer
catalysts, alkylboronic acids, silicone-based boronic acids, bleach
boronic acids, crown ether, PEOs, potassium hydroxide, magnesium
hydroxide, amine salts, APMS; soil stabilizers (e.g., carboxymethyl
cellulose, acrylates, methacrylates, colloidal suspensions).
[0150] (b) Surfactants. Surfactants suitable for inclusion in the
composition, include anionic, cationic, nonionic, Zwitterionic and
amphoteric surfactants, alkylbenzene sulfonates, ethoxylated alkyl
phenols, ethoxylated fatty alcohols, alkylester alkoxylates, alkyl
sulfonates, quaternary ammonium complexes, block propyleneoxide,
ethyleneoxide copolymers, sorbitan fatty esters, sorbitan
ethoxylates, Tergitols, tridecylalcohol ethoxylates, alkanolamides,
sodium lauryl sulfonate, sodium stearate, sodium laureth sulfate,
ammonium lauryl ether sulfonate, and silicone surfactants, such as
for example, quaternary alkyl ammonium siloxanes, carboxyalkyl
siloxanes, and polyether siloxane surfactants. In one embodiment,
the surfactant exhibits an hydrophilic-lipophilic balance ("HLB")
of from 3 to 14, more preferably 5 to 11, as for example polyether
siloxanes. Surfactants are generically known in the art and are
available from a number of commercial sources.
[0151] Examples of cationic surfactants include:
didodecyldimethylammonium bromide (DDAB), dihexadecyldimethyl
ammonium chloride, dihexadecyldimethyl ammonium bromide,
dioctadecyldimethyl ammonium chloride, dieicosyldimethyl ammonium
chloride, didocosyldimethyl ammonium chloride, dicoconutdimethyl
ammonium chloride, ditallowdimethyl ammonium bromide (DTAB).
Commercially available examples include, but are not limited to:
ADOGEN, ARQUAD, TOMAH, VARIQUAT.
[0152] Nonionic surfactants which may be employed are
octylphenoxypoly(ethyleneoxy) (11)ethanol,
nonylphenoxypoly(ethyleneoxy) (13)ethanol,
dodecylphenoxypoly(ethyleneoxy) (10)ethanol, polyoxyethylene (12)
lauryl alcohol, polyoxyethylene (14) tridecyl alcohol,
lauryloxypoly(ethyleneoxy) (10)ethyl methyl ether,
undecylthiopoly(ethyleneoxy) (12)ethanol,
methoxypoly(oxyethylene(10)/(ox- ypropylene(20))-2-propanol block
co-polymer, nonyloxypoly(propyleneoxy) (4)/(ethyleneoxy)
(16)ethanol, dodecyl polyglycoside, polyoxyethylene (9)
monolaurate, polyoxyethylene (8) monoundecanoate, polyoxyethylene
(20) sorbitan monostearate, polyoxyethylene (18) sorbitol
monotallate, sucrose monolaurate, lauryldimethylamine oxide,
myristyldimethylamine oxide, lauramidopropyl-N,N-dimethylamine
oxide, 1:1 lauric diethanolamide, 1:1 coconut diethanolamide, 1:1
mixed fatty acid diethanolamide, polyoxyethylene(6)lauramide, 1:1
soya diethanolamidopoly(ethyleneoxy) (8) ethanol, and coconut
diethanolamide. Other known nonionic surfactants may likewise be
used.
[0153] A surfactant for HFE systems is Zonyl-UR, in a range of
0.1-2.5% for cleaning and 0.05-15% for emulsification. A surfactant
for siloxane systems is: Fabritec 5550, Tegopren 7008, 7009, 6920,
Crodofos 810A, Dow Coming 8692, 1248, 5097, 5329, 5200, 5211,
FF400, Sylgard 309, SF 1528, 1328. A range of 0.05 to 15% is
desirable, with a range of less than 5% for emulsion purposes. For
cleaning purposes the range is less than 5%, preferably less than
2%, and more preferably is less than 1.5% up to 5% but preferably
less than 2% and even further preferred less than 1.5%.
[0154] (c) Perfumes or Deodorizers--Perfumes include: aromatic and
aliphatic esters, aliphatic and aromatic alcohols, aliphatic
ketones, aromatic ketones, aliphatic lactones, aliphatic aldehydes,
aromatic aldehydes, condensation products of aldehydes and amines,
saturated alcohols, saturated esters, saturated aromatic ketones,
saturated lactones, saturated nitrites, saturated ethers, saturated
acetals, saturated phenols, saturated hydrocarbons, aromatic
nitromusks and mixtures thereof.
[0155] Enduring perfumes include: allyl cyclohexane propionate,
ambrettolide, amyl benzoate, amyl cinnamate, amyl cinnamic
aldehyde, amyl cinnamic aldehyde dimethyl acetal, iso-amyl
salicylate, aurantiol (trade name for hydroxycitronellal-methyl
anthranilate), benzophenone, benzyl salicylate, iso-butyl
quinoline, beta-caryophyllene, cadinene, cedrol, cedryl acetate,
cedryl formate, cinnamyl cinnamate, cyclohexyl salicylate, cyclamen
aldehyde, dihydro isojasmonate, diphenyl methane, diphenyl oxide,
dodecalactone, iso E super (trade name for
1-(1,2,3,4,5,6,7,8-octahydro-2,3,8,8-tetramethyl-2-naphthalenyl)-ethanone-
-), ethylene brassylate, ethyl methyl phenyl glycidate, ethyl
undecylenate, iso-eugenol, exaltolide (trade name for
15-hydroxypentadecanoic acid, lactone), galaxolide (trade name for
1,3,4,6,7,8-hexahydro-4,6,6,7,8,8-hexamethylcyclopenta-gamma-2-benzopyran-
), geranyl anthranilate, hexadecanolide, hexenyl salicylate, hexyl
cinnamic aldehyde, hexyl salicylate, lilial (trade name for
para-tertiary-butyl-alpha-methyl hydrocinnamic aldehyde), linalyl
benzoate, 2-methoxy naphthalene, methyl cinnamate, methyl
dihydrojasmonate, beta-methyl naphthyl ketone, musk indanone, musk
ketone, musk tibetine, myristicin, delta-nonalactone,
oxahexadecanolide-10, oxahexadecanolide-11, patchouli alcohol,
phantolide (trade name for 5-acetyl-1,1,2,3,3,6-hexamethylindan),
phenyl ethyl benzoate, phenylethylphenylacetate, phenyl heptanol,
phenyl hexanol, alpha-santalol, thibetolide (trade name for
15-hydroxypentadecanoic acid, lactone), tonalid,
delta-undecalactone, gamma-undecalactone, vetiveryl acetate,
yara-yara, allyl phenoxy acetate, cinnamic alcohol, cinnamic
aldehyde, cinnamyl formate, coumarin, dimethyl benzyl carbinyl
acetate, ethyl cinnamate, ethyl vanillin (3-methoxy-4-ethoxy
benzaldehyde), eugenol, eugenyl acetate, heliotropine, indol,
isoeugenol, koavone, methyl-beta-naphthyl ketone, methyl cinnamate,
methyl dihdrojasmonate, beta methyl naphthyl ketone,
methyl-n-methyl anthranilate, delta-nonalactone, gamma-nonalactone,
para methoxy acetophenone (acetanisole), phenoxy ethyl iso
butyrate, phenoxy ethyl propionate, piperonal, triethyl citrate,
vanillin, and mixtures thereof.
[0156] Deodorizers may include: molecular encapsulation agents
(e.g., cyclodextrin), quaternary amines (e.g., Pinesol, etc.), pH
adjusters to neutralize odors, or agents that are capable of
saturating a double bond or cleaving a double bond.
[0157] Other odor absorbents may also include, but are not limited
to, silica gel, fullers earth, alumina, diatomaceous earth,
magnesium silicate, granular activated carbon, molecular sieves,
powdered decolorizing charcoal, magnesium sulfate, corn cob powder,
zeolites, clays, hydrogel-forming polymers, surfactants, binders
and high surface area materials desirably hydrophobic glass
micro-fibers, glass wool, cellulose and acetate fibers. Preferably,
the adsorbent is granular activated carbon, 4A molecular sieves, or
13X molecular sieves.
[0158] (d) Enzymes--Enzymes are incorporated in the formulations
herein to enhance and provide superior fabric cleaning, including
removal of protein-based, carbohydrate-based, or lipid
(triglyceride-based) stains. The enzymes to be incorporated include
lipases, proteases and amylases, as well as mixtures thereof. The
enzymes may be of any suitable origin, such as vegetable, animal,
bacterial, fungal, and yeast origin.
[0159] Suitable lipase enzymes for use herein include those
produced by microorganisms of the Pseudomonas group, such as
Pseudomonas stutzeri ATCC 19.154, as disclosed in British Patent
1,372,034. See also lipases in Japanese Patent Application
53,20487, laid open to public inspection on Feb. 24, 1978. This
lipase is available from Amano Pharmaceutical Co. Ltd., Nagoya,
Japan, under the trade name Lipase P "Amano," hereinafter referred
to as "Amano-P." Other commercial lipases include Amano-CES,
lipases ex Chromobacter viscosum, e.g. Chromobacter viscosum var.
lipolyticum NRRLB 3673, commercially available from Toyo Jozo Co.,
Tagata, Japan; and further Chromobacter viscosum lipases from U.S.
Biochemical Corp., U.S.A. and Disoynth Co., The Netherlands, and
lipases ex Pseudomonas gladioli. The LIPOLASE enzyme (Lipolase 100L
(9001-62-1), Lipolase 100T (9001-62-1)) derived from Humicola
lanuginosa and commercially available from Novo is a lipase for use
herein.
[0160] Suitable protease enzymes are the subtilisins that are
obtained from particular strains of B. subtilis and B.
licheniforms. Another suitable protease is obtained from a strain
of Bacillus, having maximum activity throughout the pH range of
8-12, developed and sold by Novo Industries A/S under the
registered trade name ESPERASE. The preparation of this enzyme and
analogous enzymes is described in British Patent Specification No.
1,243,784 of Novo. Proteolytic enzymes suitable for removing
protein-based stains that are commercially available include those
sold under the tradenames ALCALASE and SAVINASE by Novo Industries
A/S (Denmark) and MAXATASE by International Bio-Synthetics, Inc.
(The Netherlands). Other proteases include Protease A (see European
Patent Application 130,756, published Jan. 9, 1985) and Protease B
(see European Patent Application Serial No. 87303761.8, filed Apr.
28, 1987, and European Patent Application 130,756, Bott et al,
published Jan. 9, 1985). Protease enzymes are usually present in
such commercial preparations at levels sufficient to provide from
0.005 to 0.1 Anson units (AU) of activity per gram of
composition.
[0161] Amylases include, for example, alpha-amylases described in
British Patent Specification No. 1,296,839 (Novo), RAPIDASE,
International Bio-Synthetics, Inc. and TERMAMYL, Novo
Industries.
[0162] A wide range of suitable enzymes are also disclosed in U.S.
Pat. No. 3,553,139 (McCarty et al.); U.S. Pat. No. 4,101,457 (Place
et al); U.S. Pat. No. 4,507,219 (Hughes); and U.S. Pat. No.
4,261,868 (Hora et al). Enzymes for use in detergents can be
stabilized by various techniques. Enzyme stabilization techniques
are disclosed and exemplified in U.S. Pat. No. 3,600,319 (Gedge, et
al) and European Patent Application Publication No. 0 199 405,
Application No. 86200586.5, published Oct. 29, 1986 (Venegas).
Enzyme stabilization systems are also described, for example, in
U.S. Pat. No. 3,519,570.
[0163] (e) Bleach--Bleaching agents include perborates, e.g.,
sodium perborate (any hydrate but preferably the mono- or
tetra-hydrate), sodium carbonate peroxyhydrate or equivalent
percarbonate salts, sodium pyrophosphate peroxyhydrate, urea
peroxyhydrate, or sodium peroxide can be used herein. Also useful
are sources of available oxygen such as persulfate bleach (e.g.,
OXONE, manufactured by DuPont). Sodium perborate monohydrate and
sodium percarbonate are particularly preferred. Other examples
include TAED (hydrophilic), percarbonate (hydrophilic), steel
(hydrophilic), dragon (hydrophilic), alkyl-hydroperoxides
(hydrophobic), SNOBS, P15, hydroperoxides, titanium dioxide,
lucine, peroxysilicones, perborate, and combinations of
percarbonate, perborate, BzCl, BOBS, NOBS, LOBS, DOBA, sodium
percarbonate, organic peroxides, metal containing bleach catalysts,
bleach boosting compounds, performed peracids, photobleaches,
enzyme bleaches, cationic imines, zwitterionic imines, anionic
imines, polyionic imines & TAED.
[0164] (f) Co Solvents: Co-solvents may include:
N-methylpyrrolidone (used with HFE), THFA (tetrahydrofurfuryl
alcohol), .alpha.-terpinene, ethyl lactate ELS, ethyl
L-(-)-lactate, 2-ethyl lactate, Vertrel (trans-dichloroethylene,
2-propanol), Vertrel XF (decafluoropentane), Vertrel KCD 9583,
Vertrel KCD 9585, Borothene, heptanol, methanol, ethanol,
isopropanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol,
1-heptanol, 1-octanol, ethylene glycol, propylene glycol, ethylene
glycol dimethyl ether, propylene glycol n-propyl ether, propylene
glycol n-butyl ether, dipropylene glycol methyl ether, dipropylene
glycol propyl ether, dipropylene glycol n-butyl ether, dipropylene
glycol t-butyl ether, tripropylene glycol methyl ether,
tripropylene glycol n-butyl ether, t-butyl methyl ether, t-amyl
mether ether, tetrahydrofuran, tetrahydropyran, diethyl ether,
diisopropyl ether, ethyl acetate, propyl acetate, isobutyl acetate,
cyclohexyl acetate, methyl propionate, ethyl propionate,
2-methylpentane, 3-methylpentane, 2,2-dimethylbutane,
2,3-dimethylbutane, hexane, heptane, iso-octane, methyl
cyclohexane, 2-butanol, i-butanol, t-butanol, trifluoroethanol,
pentafluoropropanol, hexafluoro-2-propanol, 1-chlorobutane,
2-chlorobutane, i-butyl chloride, t-butyl chloride,
1,2-dichloropropane, 2,2-dichloropropane, methylene chloride,
t-1,2-dichloroethylene, cis-1,2-dichloroethylene,
2,3-dichloro-1-propene, 1,1,2-trichloroethylene
(trichloroethylene), 1-bromopropane, 2-bromopropane, acetonitrile,
1-octene, butyl lactate, n-decane, isopar-M, petroleum SA-70,
perfluorohexane, fluorinated isopropyl alcohol, undecane, dodecane,
c14-c17 cyclosol-150, D-limonene (citrus terpene), 1,2-propanediol,
2-ethoxyethanol, DS-108 solvent (Dynamo solvent), 2-ethyl hexyl
lactate, acetone, propylene carbonate, benzyl alcohol, glycerine,
2-ethyl-1-hexanol, diethyl glycol butyl ether, dipropylene glycol
butyl ether, propylene glycol butyl ether, ethylene glycol butyl
ether, petroleum ether, cyclohexanol, diacetone alcohol,
cyclohexane, n-pentane, n-octane, n-nonane, n-tridecane, methyl
ethyl ketone, methyl isobutyl ketone, 2-pentanone,
3-methyl-2-butanone, cyclohexanone, trans-dichloroethylene,
1,3-dichloropropane, methylene chloride, perchloroethylene,
HCFC-141b, HCFC-225 ca/cb, toluene, m-xylene, trifluorotoluene,
parachlorobenzitrifluoride, hexafluoro-m-xylene,
hexamethyldisiloxane, octamethyltrisiloxane, water, acetonitrile,
petroferm SA-18, Petroferm SA-19, Petroferm SA-24, solventless
silicones, DTE 797 oil, Mobilmet Omicron, Silicon fluid F815, Arma
245, Ecocut 322, 10W40 ATF, Soygold, NMP, Triacetin, Dowanol,
cyclopentane, nitromethane, ethyl ether, THF, chloroform,
1,1,2-trichloroethane, 1,1,1-trichloroethane, DF-2000, Petroferm
Solvating Agent 21, tetradecanoic acid, 1-methylethyl ester,
Fluorinert (FC-72), Invert 1000, Invert 2000, Invert 5000, Castrol
Kleen 3414, Arcosolv PT-8, and Shell-Sol 142H; or any mixture
thereof
EXAMPLES
[0165]
1 Substance Purpose Range Water hydrophilic soil Preferred = 0-5%
removal Acceptable = 0-99.9% Perfluorocarbons increase flash points
Preferred = 0-20% (fluorocarbons) Acceptable = 0-75% Hydrocarbons
hydrophobic soil Preferred = 0-25% removal Acceptable = 0-80%
Alcohols drying or rinse aids Preferred = 0-25% Acceptable = 0-80%
Hydrocarbons fluid reclamation Preferred = 0-25% (provide a
Acceptable = 0-80% separation device- liquid--liquid extraction)
Silicone &/or improved fabric care Preferred = 0-99.995%
Fluorinated Acceptable = 75-99.995% materials Fragrances improved
odor Preferred = 0-5% performance Acceptable = 0-25%
[0166] (h) Fabric Softeners
[0167] Fabric softeners or conditioners useful herein can have
linear or branched, saturated or unsaturated hydrophobes and can
include certain amines, quaternary amines, or protonated amines, or
mixtures thereof. Such materials particularly include diesters of
diethanolammonium chlorides, sometimes termed "diester quats";
dialkyl imidazoline esters, diesters of triethanolammonium
methylsulfates, ester amide-tertiary amines sometimes termed
amidoamineesters, esteramide-quaternary amine chloride salts, and
diesters of dihydroxypropyl ammonium chlorides.
[0168] Some Working Fluid Combinations
[0169] Embodiments of invention reside in a combination of one or
more types of the working fluid with one or more types of the
washing adjuvant. In any embodiment, adjuvants may be added to
working fluid to stabilize the working fluid. For example, a
mixture of working fluids may be combined to form an azeotrope of
the working fluids. Any one or more adjuvants may be added to the
azeotropic mixture. The ultimate mixture or combination may be
contacted with fabrics to be cleaned. Dry laundering with any
composition may occur by exposing the composition (or its
individual constituents) to the fabrics and moving the composition
through the fabrics to be cleaned. As with any embodiment the
composition, including its constituents whether initially present
or subsequently added, may be recovered and/or reclaimed. The
recovered constituents may be processed, such as cleaned for
re-use.
[0170] Other examples of a composition are now more fully
described. In one embodiment, there is a wash liquor composition
for use in laundering a fabric load comprising: (a) a non-reactive,
non-aqueous, non-oleophilic, apolar working fluid, and (b) at least
one non-aqueous, fluid washing adjuvant selected from the group
consisting of a surfactant, bleach, ozone, hydrophobic solvent,
hydrophilic solvent, and mixtures thereof. In another embodiment, a
wash liquor composition to assist in washing fabrics in a fabric
washing machine, comprises: (a) a non-oleophilic working fluid
adapted to be substantially non-reactive with the fabrics, the
working fluid having a KB value of less than or equal to 30; and
(b) at least one washing adjuvant selected from the group
consisting of a surfactant, bleach, ozone, hydrophobic solvent,
hydrophilic solvent, and mixtures thereof. And yet another
embodiment is a wash liquor composition to assist in washing
fabrics in a fabric washing machine, comprising: (a) at least one
washing adjuvant selected from the group consisting of a
surfactant, bleach, ozone, hydrophobic solvent, hydrophilic
solvent, and mixtures thereof; (b) a working fluid adapted to be
substantially non-reactive with the fabrics, the working fluid
having a KB value of less than 30, a surface tension less than or
equal to 20 dynes per square centimeter, and a vapor pressure less
than 150 mm Hg. And yet another embodiment is a wash liquor
composition to assist in washing fabrics in a fabric washing
machine, comprising: (a) a working fluid adapted to be
substantially non-reactive with the fabrics; (b) at least one
washing adjuvant selected from the group consisting of a
surfactant, bleach, ozone, hydrophobic solvent, hydrophilic
solvent, and mixtures thereof; (c) wherein the working fluid has a
surface tension of less than or equal to 35 dynes/cm.sup.2; (d)
wherein the working fluid has an oil solvency greater than water
without being oleophilic, and the KB is less than or equal to 30;
(e) wherein the working fluid has a solubility in water of less
than about 10%; (f) wherein the working fluid has a viscosity less
than water under normal washing conditions; (g) wherein the working
fluid has a pH from about 6.0 to about 8.0; (h) wherein the working
fluid has a vapor pressure higher that the vapor pressure of water;
and (i) wherein the working fluid has a flash point of greater than
or equal to 145.degree. C.
[0171] The composition may also be associated with the machine,
such as a wash liquor composition and laundering machine
combination for use in laundering a fabric load, comprising: (a) a
non-reactive, non-aqueous, non-oleophilic, apolar working fluid;
(b) at least one washing adjuvant; and (c) a laundering machine.
The composition may also be associated with the fabrics, such as a
wash liquor composition and fabric combination for use in
laundering a fabric load comprising: (a) a non-reactive,
non-aqueous working fluid; (b) at least one washing adjuvant; and
(c) at least one article of article of fabric interspersed with the
working fluid and the at least one washing adjuvant.
[0172] In yet another embodiment, the composition may be used in
laundering, such as a method of using a wash liquor composition in
a laundering machine, comprising the step of adding the wash liquor
combination to a fabric to clean the fabric, the wash liquor
combination comprising: (a) a non-aqueous, non-oleophilic working
fluid; and (b) at least one washing selected from the group
consisting of a surfactant, bleach, ozone, hydrophobic solvent,
hydrophilic solvent, and mixtures thereof.
[0173] As mentioned above, the composition and its constituents may
be substantially or entirely recovered by a method such as, a
recovered non reactive, non-oleophilic, non-aqueous working fluid
made by the process of: (a) washing at least one fabric with an
initial working fluid; (b) capturing at least part of the initial
working fluid after washing the at least one fabric; (c) filtering
the captured working fluid to generate a permeate and a retentate;
(d) recovering the permeate or retentate as the recovered working
fluid.
[0174] Although mentioned in greater detail above, the composition
may also include a co-solvent selected from the group consisting of
water, alcohol, ether, glycol, ester, ketone, and aldehyde, and
wherein the mixture is sufficiently stable for a fabric washing
application. Similarly, although any adjuvant described above may
be used singularly or in combination with any other adjuvant, the
combination may include an adjuvant that is at least one of a
surfactant, bleach, enzyme, deodorizer, fragrance, hydrophobic
solvent, hydrophilic solvent, and mixtures thereof and the
co-solvent is selected from the group consisting of water, alcohol,
ether, glycol, ester, ketone, and aldehyde, and wherein the mixture
is sufficiently stable for a fabric washing application.
[0175] Another embodiment of a wash liquor combination includes a
working fluid, a soda ash to increase the pH, a chelation agent
(e.g., disodium EDTA), a water softener (e.g., sodium citrate), a
bleach (e.g., percarbonate), an initiator for radical formation
(e.g., tetraacetoethylene diamine), an enzyme (e.g., protease,
lipase, amylase, cellulase), an anti-deposition agent (e.g., sodium
carboxymethylcellulose or polyacrylic acid), a surfactant, an odor
control, and a brightener (e.g., CBSX).
[0176] Safety Features
[0177] As mentioned above, various sensors may be used to monitor
temperature, pressure, volume, conductivity, turbidity, etc. In
addition to sensors, the materials may be designed to withstand
chemicals or make the material chemical compatible. For example,
any tank or conduit can be made siloxane resistant or HFE
resistant. This may include forming any conduit, gasket, seal,
valve, etc. to be resistant.
[0178] Due to the fact that most home care systems are concerned
with aqueous systems, there are some special considerations that
need to be given for materials compatibility. Some examples of
acceptable housing materials for silicone-based fluids are ABS.
Acetal, Acrylic, Chlorinated Polyvinyl Choride, Epoxy, Ionomer,
Nylon, Polytertrafluoroethylene (Teflon), Polyvinylidene Fluoride,
Polycarbonate, Polyethermide, Polyethylene, Polyethylene
Terephthalate, Polypropylene, Polystyrene, Polysulfone and
Polyvinyl Choride (PVC), Fluorosilicone, Polydimethylsiloxane,
Ethylene-Propylene Terpolymer (EPDM), Isobutylene-Isoprene (Butyl)
and Acrylonitrile-Butadiene (Buna N), Aluminum, Anodized Aluminum,
Beryllium, Brass, 60 Sn/40 Pb Solder and Stainless Steel and
Copper. Additionally, many polymers based materials contain
plasticizers in order to manipulate physical properties and provide
a cost effective process. However, the IWF may remove the
plasticizers destroying the physical properties, therefore,
relatively pure polymer-based systems should be used.
[0179] It should be understood that the foregoing relates only to a
limited number of embodiments that have been provided for
illustration purposes only. It is intended that the scope of
invention is defined by the appended claims and that modifications
to the embodiments above may be made that do not depart from the
scope of the claims.
[0180] There is some potential suggesting the use of recovered
non-aqueous fluid in the same process. For example, siloxane used
in the first wash can be sent through the reclamation process and
then used later during the same load as a rinse option. This would
suggest the importance of a reclamation system that does not
necessarily need to remove all of the contaminants from a specific
process but more importantly have contaminants that are stabilized
so that they can not redeposit onto the fabric articles.
Additionally, if some fluid is to be re-used in the same process,
the cycle time for the reclamation system should be faster than
that for the selected machine cycle. Another embodiment is that the
fluid from the rinse portion of the system may not need go through
all of the proposed reclamation operations, especially the
temperature reduction step.
[0181] In an embodiment, the wash chamber oscillates for a
plurality of periods of clockwise and counter-clockwise
oscillations, wherein the time duration of the speed and time
duration of the strokes are selected for each period. The strokes
can be symmetrical or asymmetrical, and can have a speed or time
duration that is selected randomly or from some predetermined
varying pattern. Further, in another embodiment, the time duration
of the oscillations vary for consecutive periods. The average or
mean speed or time of the time-varying oscillations can be adjusted
by the controller responsive to an amount of the items or to a size
of the items.
[0182] The items in the wash chamber can move, for example, in a
tumbling pattern.
[0183] In accordance with apparatuses consistent with the present
invention, an automatic washer is provided. The automatic washer
comprises a cabinet, a wash chamber with a central axis supported
within the cabinet, a motor suspended outside the wash chamber and
drivingly connected to the wash chamber, the wash chamber
oscillating about the central axis by speed- and time-varying
oscillations. The wash chamber may have a horizontal axis, a 45
degree tilted axis or a vertical axis.
[0184] The above-mentioned and other features, utilities, and
advantages of the invention will become apparent from the following
detailed description of the preferred embodiments of the invention
together with the accompanying drawings.
* * * * *