U.S. patent application number 11/051013 was filed with the patent office on 2005-08-25 for dual mode laundry apparatus and method using the same.
This patent application is currently assigned to The Procter & Gamble Company. Invention is credited to Haught, John Christian, Price, Kenneth Nathan, Radomyselski, Arseni Valerevich, Scheper, William Michael, Thoen, Christiaan Arthur Jacques Kamiel.
Application Number | 20050183208 11/051013 |
Document ID | / |
Family ID | 34910802 |
Filed Date | 2005-08-25 |
United States Patent
Application |
20050183208 |
Kind Code |
A1 |
Scheper, William Michael ;
et al. |
August 25, 2005 |
Dual mode laundry apparatus and method using the same
Abstract
An apparatus and a method for treating, cleaning or refreshing
fabric articles. Specifically, the apparatus is dual mode apparatus
capable of both washing and drying operations wherein a lipophilic
fluid is used in at least one step of the fabric treatment process
in the apparatus. A kit containing replaceable/consumable
components is also provided.
Inventors: |
Scheper, William Michael;
(Guilford, IN) ; Haught, John Christian; (West
Chester, OH) ; Radomyselski, Arseni Valerevich;
(Loveland, OH) ; Price, Kenneth Nathan; (Wyoming,
OH) ; Thoen, Christiaan Arthur Jacques Kamiel; (West
Chester, OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY
INTELLECTUAL PROPERTY DIVISION
WINTON HILL TECHNICAL CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Assignee: |
The Procter & Gamble
Company
|
Family ID: |
34910802 |
Appl. No.: |
11/051013 |
Filed: |
February 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60546668 |
Feb 20, 2004 |
|
|
|
Current U.S.
Class: |
8/142 ; 68/12.18;
68/17R; 68/207; 68/5C; 8/159 |
Current CPC
Class: |
D06F 2105/28 20200201;
D06F 43/00 20130101; D06F 2103/32 20200201; D06F 25/00 20130101;
D06F 2103/34 20200201; D06F 43/02 20130101; D06F 2105/52 20200201;
D06F 39/02 20130101; D06F 33/52 20200201 |
Class at
Publication: |
008/142 ;
008/159; 068/005.00C; 068/012.18; 068/017.00R; 068/207 |
International
Class: |
D06F 037/00 |
Claims
What is claimed is:
1. A dual mode fabric treatment apparatus comprising: a chamber for
receiving a fabric article; a first reservoir for storing a
lipophilic fluid; a second reservoir for storing a fabric finishing
composition; a dispensing device configured to dispense the fabric
finishing composition in the form of droplets; optionally, a
heating device for heating the chamber; and optionally, a gas
sensor for monitoring the concentration of lipophilic fluid vapors
in the chamber; wherein the apparatus is configured to provide a
fabric treatment operation comprising a washing cycle and a drying
cycle; to dispense the lipophilic fluid into the chamber during the
washing cycle; and to dispense the fabric finishing composition via
the dispensing device into the chamber during a drying cycle,
thereby at least a portion of the dispensed fabric finishing
composition contacts the fabric article in the chamber.
2. The apparatus of claim 1 wherein the dispensing device and the
second reservoir are removably attached to the apparatus.
3. The apparatus of claim 2 wherein the dispensing device and the
second reservoir is an integral unit.
4. The apparatus of claim 1 wherein the fabric finishing
composition is dispensed in the form of droplets having an average
particle size in the range of from about 0.1 to about 1200
microns.
5. The apparatus of claim 1 wherein the dispensing device comprises
a component selected from the group consisting of a spraying
nozzle, a sonicator, a nebulizer, an electrostatic charger, and
combinations thereof.
6. The apparatus of claim 1 wherein the fabric finishing
composition is dispensed into the chamber when the chamber is at a
temperature of up to about 100.degree. C.
7. The apparatus of claim 1 wherein the fabric finishing
composition is dispensed into the chamber when the chamber is at a
temperature of from about 20.degree. C. to about 80.degree. C.
8. The apparatus of claim 1 wherein the fabric finishing
composition is dispensed into the chamber during the cool down
operation of the drying cycle.
9. The apparatus of claim 1 wherein the fabric finishing
composition comprises a fabric care agent selected from the group
consisting of finishing polymers, fabric softening agents,
anti-static agents, odor control agent, odor neutralizers, perfume,
insect and/or moth repelling agents, and mixtures thereof.
10. The apparatus of claim 1 further comprising a third reservoir
for storing a detergent composition.
11. The apparatus of claim 10 wherein the third reservoir is
removably attached to the apparatus.
12. The apparatus of claim 10 wherein the detergent composition
comprises a cleaning agent selected from the group consisting of
soil release polymers, surfactants, bleaches, enzymes, perfumes,
water, and mixtures thereof.
13. The apparatus of claim 10 wherein the detergent composition is
dispensed directly into the chamber during the washing cycle,
whereby the dispensed composition contacts the fabric article in
its undiluted form.
14. The apparatus of claim 13 wherein the detergent composition is
dispensed in the form of droplets having an average particle size
in the range of from about 0.1 to about 1200 microns.
15. A method of treating a fabric article in the dual mode fabric
treating apparatus of claim 1, the method comprising the steps of:
placing a fabric article in the chamber; dispensing the lipophilic
fluid into the chamber such that the fabric article is contacted by
the lipophilic fluid; removing at least a portion of the lipophilic
fluid from the chamber; and dispensing the fabric finishing
composition into the chamber in the form of droplets such that the
fabric article is contacted by the fabric finishing
composition.
16. The method of claim 15 wherein the fabric finishing composition
is dispensed into the chamber while the chamber is at a temperature
of from about 20.degree. C. to about 80.degree. C.
17. The method of claim 15 wherein the fabric finishing composition
is dispensed into the chamber while the fabric article is in
motion.
18. The method of claim 15 wherein the fabric finishing composition
is dispensed in the form of droplets having an average particle
size from about 0.1 to about 1200 microns.
19. The method of claim 15 further comprising the step of attaching
the dispensing device and/or the second reservoir to the
apparatus.
20. The method of claim 19 further comprises the step of replacing
the dispensing device and/or the second reservoir, after the
composition therein is partially or completely dispensed, with a
new dispensing device and/or a new second reservoir..
21. The method of claim 15 further comprising the step of attaching
a third reservoir containing a detergent composition to the
apparatus.
22. The method of claim 21 further comprising the step of
dispensing the detergent composition directly into the chamber
during the washing cycle, whereby the detergent composition
contacts the fabric article in its undiluted form.
23. The method of claim 22 further comprising the step of replacing
the third reservoir, after the composition therein is partially or
completely dispensed, with a new third reservoir.
24. A kit comprising: (a) a detergent composition, a fabric
finishing composition, or both; and at least one of the following
components: (b) a reservoir for storing the composition; (c) a
dispensing device for dispensing the composition; (d) attachment
means for removably attaching the reservoir and/or the dispensing
device to a fabric treatment apparatus; (e) optionally, packaging
for containing components (a-d); and (f) optionally, a set of
instructions in association with the reservoir or the packaging,
the instructions direct the user to attach and to detach the
reservoir and/or the dispensing device to the fabric treatment
apparatus, and optionally, to assemble the components of the kit
such that the dispensing device is in fluid communication with the
composition in the reservoir.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Application Ser. No. 60/546,668,
filed Feb. 20, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and a method
for treating, cleaning or refreshing fabric articles. Specifically,
the apparatus is dual mode apparatus capable of both washing and
drying operations wherein a lipophilic fluid is used in at least
one step of the fabric treatment process in the apparatus. A kit
containing replaceable/consumable components is also included.
BACKGROUND
[0003] For the cleaning of fabric articles consumers have the
choice of conventional aqueous immersive wash laundry cleaning or
dry cleaning.
[0004] Conventional laundry cleaning is carried out with relatively
large amounts of water, typically in a washing machine at the
consumer's home, or in a dedicated place such as a coin laundry.
Although washing machines and laundry detergents have become quite
sophisticated, the conventional laundry process still exposes the
fabric articles to a risk of dye transfer and shrinkage. A
significant portion of fabric articles used by consumers are not
suitable for cleaning in such a conventional laundry process. Even
fabric articles that are considered "washing machine safe"
frequently come out of the laundry process badly wrinkled and
require ironing.
[0005] Most dry cleaning processes rely on non-aqueous solvents for
cleaning. By avoiding water, these processes minimize the risk of
shrinkage and wrinkling. The need for handling and recovering large
amounts of solvents makes these dry cleaning processes unsuitable
for use in the consumers' homes. The need for dedicated dry
cleaning operations makes this form of cleaning inconvenient and
expensive for the consumers.
[0006] More recently, dry cleaning processes have been developed
which make use of compressed gases, such as supercritical carbon
dioxide, as a dry cleaning medium. Unfortunately these processes
have many disadvantages, for example, they require very high
pressure equipment.
[0007] Other dry cleaning processes have recently been described
which make use of nonsolvents such as perfluorobutylamine. These
also have multiple disadvantages, for example, the nonsolvent fluid
cannot adequately dissolve body soils and is extremely
expensive.
[0008] Accordingly there are unmet needs for new apparatus,
methods, and compositions for cleaning or treating fabric articles
that are safe for a wide range of fabric articles, minimize
shrinkage and wrinkling, and can be adapted to a cost effective use
in the consumers' homes and/or in service businesses and commercial
establishments.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a dual mode fabric
treatment apparatus comprising:
[0010] a chamber for receiving a fabric article;
[0011] a first reservoir for storing a lipophilic fluid;
[0012] a second reservoir for storing a fabric finishing
composition;
[0013] a dispensing device configured to dispense the fabric
finishing composition in the form of droplets;
[0014] optionally, a heating device for heating the chamber;
and
[0015] optionally, a gas sensor for monitoring the concentration of
lipophilic fluid vapors in the chamber;
[0016] wherein the apparatus is configured for a fabric treatment
operation comprising a washing cycle and a drying cycle; for
dispensing the lipophilic fluid into the chamber during the washing
cycle; and for dispensing the fabric finishing composition via the
dispensing device into the chamber during a drying cycle, thereby
at least a portion of the dispensed composition contacts the fabric
article in the chamber
[0017] The present invention also relates to a method of treating a
fabric article in the dual mode fabric treating apparatus of the
present invention. The method comprising the steps of:
[0018] placing a fabric article in the chamber;
[0019] dispensing the lipophilic fluid into the chamber such that
the fabric article is contacted by the lipophilic fluid;
[0020] removing at least a portion of the lipophilic fluid from the
chamber; and
[0021] dispensing the fabric finishing composition into the chamber
in the form of
[0022] droplets such that the fabric article is contacted by the
fabric finishing composition;
[0023] wherein the fabric finishing composition is dispensed into
the chamber while the chamber is at a temperature of from about
20.degree. C. to about 80.degree. C.
[0024] A kit containing replaceable/consumable components is also
provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] While the specification concludes with claims particularly
pointing out and distinctly claiming the present invention, it is
believed the present invention will be better understood from the
following description in which:
[0026] FIG. 1 is a schematic view of an apparatus in accordance
with an embodiment of this invention;
[0027] FIG. 2 is a cut away side view of an apparatus in accordance
with an embodiment of this invention;
[0028] FIG. 3 is a front view of an apparatus in accordance with an
embodiment of this invention.
[0029] It should be understood that the drawings are not
necessarily to scale and that the embodiments are sometimes
illustrated by graphic symbols, phantom lines, diagrammatic
representations and fragmentary views. In certain instances,
details which are not necessary for an understanding of the present
invention or which render other details difficult to understand may
have been omitted. It should be understood, of course, that the
invention is not limited to the particular embodiments illustrated
herein.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Definitions
[0031] The term "fabric article" used herein is intended to mean
any article that is customarily cleaned in a conventional laundry
process or in a dry cleaning process. As such the term encompasses
articles of clothing, linen and drapery, clothing accessories, and
floor coverings. The term also encompasses other items made in
whole or in part of fabric, such as tote bags, furniture covers,
tarpaulins and the like.
[0032] The term "lipophilic fluid" used herein is intended to mean
any non-aqueous solvent capable of removing sebum, as described in
more detail hereinbelow. "Lipophilic fluid" as defined herein
generally does not include materials such as compressible gases,
such as carbon dioxide or the like. The present lipohilic fluids
are at least partially liquid at ambient temperature and
pressure.
[0033] The phrase "dry weight of a fabric article" as used herein
means the weight of a fabric article that has no intentionally
added fluid weight.
[0034] The phrase "absorption capacity of a fabric article" as used
herein means the maximum quantity of fluid that can be taken in and
retained by a fabric article in its pores and interstices.
Absorption capacity of a fabric article is measured in accordance
with the following Test Protocol for Measuring Absorption Capacity
of a Fabric Article.
[0035] These and other aspects, features and advantages will become
apparent to those of ordinary skill in the art from a reading of
the following detailed description and the appended claims. All
percentages, ratios and proportions herein are by weight, unless
otherwise specified. All temperatures are in degrees Celsius
(.degree. C.) unless otherwise specified. All measurements are in
SI units unless otherwise specified.
[0036] Test Protocol for Measuring the Absorption Capacity of a
Fabric Article
[0037] Step 1: Rinse and dry a reservoir or other container into
which a lipophilic fluid will be added. The reservoir is cleaned to
free it from all extraneous matter, particularly soaps, detergents
and wetting agents.
[0038] Step 2: Weigh a "dry" fabric article to be tested to obtain
the "dry" fabric article's weight.
[0039] Step 3: Pour 2 L of a lipophilic fluid at .about.20 C. into
the reservoir.
[0040] Step 4: Place fabric article from Step 2 into the lipophilic
fluid-containing reservoir.
[0041] Step 5: Agitate the fabric article within the reservoir to
ensure no air pockets are left inside the fabric article and it is
thoroughly wetted with the lipophilic fluid.
[0042] Step 6: Remove the fabric article from the lipophilic
fluid-containing reservoir.
[0043] Step 7: Unfold the fabric article, if necessary, so that
there is no contact between same or opposite fabric article
surfaces.
[0044] Step 8: Let the fabric article from Step 7 drip until the
drop frequency does not exceed 1 drop/sec.
[0045] Step 9: Weigh the "wet" fabric article from Step 8 to obtain
the "wet" fabric article's weight.
[0046] Step 10: Calculate the amount of lipophilic fluid absorbed
for the fabric article using the equation below.
FA=(W-D)/D*100
[0047] where:
[0048] FA=fluid absorbed, % (i.e., the absorption capacity of the
fabric article in terms of % by dry weight of the fabric
article)
[0049] W=wet specimen weight, g
[0050] D=initial specimen weight, g
[0051] By the term "non-immersive" it is meant that essentially all
of the fluid is in intimate contact with the fabric articles. There
is no more than a minimal amount of "free" wash medium. It is
unlike an "immersive" process where the washing fluid is a bath in
which the fabric articles are either submerged, as in a
conventional vertical axis washing machine, or plunged into, as in
a conventional horizontal washing machine. The term "non-immersive"
is defined in greater detail according to the following Test
Protocol for Non-Immersive Processes. A process in which a fabric
article is contacted by a fluid is a non-immersive process when the
following Test Protocol is satisfied.
[0052] Test Protocol for Non-Immersive Processes
[0053] Step 1: Determine absorption capacity of a fabric specimen
using Test Protocol for Measuring Absorption Capacity of a Fabric
Article, described above.
[0054] Step 2: Subject a fabric article to a fluid contacting
process such that a quantity of the fluid contacts the fabric
article.
[0055] Step 3: Place a dry fabric specimen from Step 1 in proximity
to the fabric article of Step 2 and move/agitate/tumble the fabric
article and fabric specimen such that fluid transfer from the
fabric article to the fabric specimen takes place (the fabric
article and fabric specimen must achieve the same saturation
level).
[0056] Step 4: Weigh the fabric specimen from Step 3.
[0057] Step 5: Calculate the fluid absorbed by the fabric specimen
using the following equation:
FA=(W-D)/D*100
[0058] where:
[0059] FA=fluid absorbed, %
[0060] W=wet specimen weight, g
[0061] D=initial specimen weight, g
[0062] Step 6: Compare the fluid absorbed by the fabric specimen
with the absorption capacity of the fabric specimen. The process is
non-immersive if the fluid absorbed by the fabric specimen is less
than about 0.8 of the absorption capacity of the fabric
specimen.
[0063] The lipophilic fluid may be used alone or with the optional
liquid (such as water and/or polar solvents) and/or any
compositions described hereinafter, to form the fabric treating
medium and/or wash liquor used in the fabric treating process. It
is understood that that the fabric treating encompasses cleaning,
conditioning, sizing and refreshing. The lipophilic fluid typically
comprises at least about 50% by weight of the fabric treating
medium. In one embodiment, the fabric treating medium contains less
than about 30%, or less than about 10% by weight of water.
[0064] In the present appliance and process, it is not recommended
to clean or treat fabric articles which are soaking wet. However,
most fabric articles contain varying amounts of water absorbed from
the air or from contact with the wearer. Such articles as well as
the occasional water wet article, e.g., swimwear, can be treated in
the present appliance and process.
[0065] Apparatus
[0066] FIG. 1 is a schematic illustration of an embodiment of
apparatus for carrying out the fabric treating process in
accordance with the present invention. This and other embodiments
of apparatus for carrying out the fabric treating process in
accordance with the present invention are described in details in
WO 01/94675 (P&G Case 8119M).
[0067] The apparatus 70 comprises a chamber 1 capable of receiving
a fabric article to be treated and a cleaning fluid comprising a
lipophilic fluid, wherein when a fabric article to be treated is
present in the chamber and a cleaning fluid comprising a lipophilic
fluid is introduced into the fabric-treating chamber 1, the chamber
1 retains an amount of the lipophilic fluid up to the absorptive
capacity of the fabric contained therein. Additionally, the chamber
1 can be a lipophilic fluid pervious chamber.
[0068] The apparatus 70 further comprises an outer chamber 2
capable of receiving the lipophilic fluid from the fabric-treating
chamber 1 that is not retained in said fabric-treating chamber. The
outer chamber 2 is configured to house the chamber 1. The outer
chamber 2 typically comprises an exit port or drain 7 through which
the lipophilic fluid received by the outer chamber 2 exits the
outer chamber 2. It is desirable that the exit of the lipophilic
fluid from the outer chamber 2 is at a rate such that the amount of
lipophilic fluid in the fabric-treating chamber 1 does not exceed
the absorptive capacity of the fabrics contained within the
fabric-treating chamber 1.
[0069] In one embodiment, chamber 1 and outer chamber 2 are of
cylindrical construction and have a horizontal access opening 58,
as shown in FIG. 2. The horizontal center line of the outer
chamber, which is typically stationary with respect to the chamber
1 coincides with the axis of rotation 100 of the movable chamber 1
movably mounted within the outer chamber 2. The chamber 1 can in
general have any suitable pattern of perforations or openings and
is designed consistently with design principles for maximizing
fluid flow through its perforated surface without weakening it to
an unacceptable extent. The chamber 1 is designed to remain fully
rigid when rotated at a high speed in the presence of a load of
lipophilic fluid-containing fabric articles. Chamber 1 may contain
strengthening elements, such as struts, not shown, and has a back
face not visible in FIG. 1, which is typically flat, and may be
perforated or non-perforated. The appliance is configured to
preferentially direct lipophilic fluid toward the lipophilic
fluid-pervious surfaces of chamber 1, rather than toward the back
face of the chamber 1.
[0070] As is more clearly illustrated in the cross-sectional views
of FIG. 2, outer chamber 2 comprises a peripheral wall 62, a back
wall 63 secured to one edge of the peripheral wall, a front wall 64
secured to the opposite edge of the peripheral wall; said front
wall has a tubular-shaped extension 55 having an access opening 58
used to load and unload laundry from the apparatus 70. This
flexible tubular-shaped extension 55 connecting the stationary drum
2 minimizes transmission of vibrations which occur during operation
of the machine. Access opening 58, forms a gas seal with front door
59 which is secured about its outermost periphery to the front wall
56 of the washing machine cabinet. Front door 59 optionally
includes additional means for assuring a good seal, such as rubber,
synthetic rubber, or elastomeric sealing material formed into any
suitable shape for assuring the seal. When the fabric treating
apparatus 70 is in operation, the access door 59 is in the closed
position shown in FIG. 2 and forms a "gas-tight" seal against the
outermost portion of flexible tubular-shaped extension 55. The
quality of the seal is sufficient to permit overpressures or
reduced pressures in the appliance, but need not be of the quality
required for extreme pressure, e.g., supercritical carbon dioxide
operation. These latter elements are illustrated only in the
cross-section of FIG. 2 to ensure maximum clarity in the remaining
drawing figures.
[0071] As can be seen in FIG. 2, outer chamber 2 is supported by
means of four suspension springs 47 (only two of which are shown)
which are connected at one end to the uppermost portion of the
outer chamber 2 and at their other end are secured to the fabric
treating apparatus cabinet. The top spring 47a is connected to a
load sensor 48 interfaced with controller. In variations of the
appliance not shown, any desirable high-speed suspension, load
balancing or stabilizer system, for example of types known or
disclosed for modern European front-loader washing machines, can be
adapted for use in the present apparatus.
[0072] In one embodiment, chamber 1 comprises a lipophilic
fluid-pervious (e.g., perforated) peripheral wall 65, a
substantially imperforate back wall 66 secured to said peripheral
wall and a substantially imperforate front wall 67, secured to the
opposite edge of said peripheral wall. Said front wall 67 has a
tubular-shaped extension 55 with an access opening 58, which is
used to load and unload laundry from the fabric treating apparatus
70, and is concentrically aligned with the access opening 58 in
outer chamber 2. Equally spaced on the inner circumference of
peripheral wall 65 are three lifting vanes 60, having cross-section
that are substantially triangular or other shapes. In a specific
embodiment, each of the vanes is symmetrically-shaped about a
radially extending line originating at the axis of rotation 100 of
chamber 1 and passing through its altitude. This permits rotation
of chamber 1 in opposite directions with equal lifting effect on
the articles being laundered. It should be understood and
appreciated that most conventional laundering machines do not have
lifting vanes, while tumble-dryers have lifting vanes designed for
low-speed and/or unidirectional "tumbling" operation. Further, the
chamber 1 may comprise baffles or other structures a long its
interior surface to aid in repositioning the fabrics contained
therein.
[0073] Chamber 1 is rotatably secured to outer chamber 2 by means
of drive shaft 49. Power to rotate chamber 1 is transmitted by
means of a concentrically mounted driven pulley 50. The drive
system comprises a variable speed drive motor 54 secured to
peripheral wall 62 of outer chamber 2. Any movement of outer
chamber 2 does not affect the speed of rotation of chamber 1. The
output shaft 53 of drive motor 54 has a secured drive pulley 52.
Pulley 52 is connected to pulley 50 by means of conventional drive
belt 51. A possible alternative drive system, not shown in the
figures, has instead of a single drive pulley 52, two drive
pulleys, one eccentrically mounted and one concentrically mounted.
In this alternative drive system power to rotate chamber 1 is
transmitted to the external portion of drive shaft 49 either by
means of an eccentrically mounted driven pulley or by means of a
concentrically mounted driven pulley which are both secured in
fixed relation to drive shaft. The eccentrically mounted driven
pulley would be used to vary the speed of rotation of the chamber 1
throughout each revolution of the chamber, while the concentrically
mounted driven pulley would be used to drive the chamber 1 at a
constant speed of rotation throughout each revolution.
[0074] In an embodiment of the present invention, drive motor 54 is
not only variable speed, but is also reversible so that chamber 1
may be rotated first in one direction and then in the opposite
direction during specific portions of the laundering cycle.
Reversing the direction of chamber rotation several times during
stages of fluid application/removal provide more uniform agitation
and more uniform heat transfer to the fabric articles being
treated, and hence more effective removal of soil and/or lipophilic
fluid.
[0075] At least one of large storage tanks 19 and 20 will contain
the lipophilic fluid; the other large storage tank may contain a
mixture of lipophilic fluid and a detergent composition or a fabric
finishing composition, which can be applied to fabric articles in
the apparatus 70 during the fabric treatment process. In another
embodiment, the composition may be combined with the lipophilic
fluid prior to being applied to fabric articles in the apparatus 70
during the fabric treatment process. These compositions may be in
any readily dispensable or flowable form, such as, thixotropic gel,
shear thinning liquid, liquid, gel, powder, granule, paste, flake,
micropaticles, nanoparticles, suspensions, etc. In yet another
embodiment, both of large storage tanks 19 and 20 will contain the
lipophilic fluid, wherein one tank contains the fresh lipophilic
fluid and the other tank contains the used or recycled lipophilic
fluid. In still another embodiment, the composition is present in
one or both of large storage tanks 19 and 20 along with the
lipophilic fluid. This can eliminate the need for any mixing prior
to delivery of the contents of the tank to the chamber 1 via the
applicator 26. Alternatively, the lipophilic fluid from the large
storage tanks 19 and 20, may be mixed with detergent or fabric
finishing compositions that are stored in small storage tanks 27
and 28, e.g., prior to application on to the discrete fabric load
present in the apparatus 70 during the fabric treating process.
Alternatively, additional storage tanks or sources are included in
apparatus 70 to provide the fluids (including lipophilic fluids,
water, or other polar solvents, such as lower alcohols or diols)
for the washing or rinsing cycle. Bi-modal fabric treating process
using lipophilic fluids, water, polar solvents, or mixtures thereof
is disclosed in WO 01/94678 (P&G Case 8121).
[0076] In one embodiment, the large tanks 19 and 20, and the small
tanks 27 and 28 may optionally be detachable from the apparatus 70.
The tank along with its content may then be recycled or refilled
and reattached to the apparatus. Various known "quick-connect"
devices, not shown in the Figures, are known in the art and may be
employed to assure quick or convenient release or connection of the
tanks. In a specific embodiment, each tank comprises a physical
configuration such that it is attachable and detachable from the
apparatus 70 in a "lock and key" manner. In other words, each tank
fits selectively into an intended "receiving port" or receptacle of
the apparatus 70. This "lock and key" system is useful when a tank
comprises a consumable, such as a detergent composition or a fabric
finishing composition. In an alternative embodiment, one or more of
the tanks may be replaceable or disposable cartridges. In another
embodiment, a large tank can be permanently attached to the
appliance, or removable only by a trained serviceman, while a small
tank can be a consumer-replaceable cartridge, which is sold
individually or as part of a kit; the kit may optionally include
usage instructions, e.g., instructions for the removal of the spent
tanks, and the installation of the new tanks filled with the
desired liquid and/or composition. In the permanently attached
mode, the content of the large tank can be periodically replenished
or flushed out and replaced with fresh liquid or composition of the
same or different types. In the detachable or replaceable mode,
once the content of the tank is partially or completely consumed,
the tank, with its used/dirty content or with its empty content, is
removed and replaced with a new tank similarly configured for the
"lock and key" connection and containing the desired content which
may be the same or different from the previous content. The
replaced tank can be either disposed of by the consumer or returned
for refilling by a third party, such as a retailer, a wholesaler,
or a manufacturer. The number of tanks, both large and small, can
be varied depending on the benefits desired. Any large or small
tank permanently affixed to the apparatus will have means (for
example, a pierceable seal or a re-sealable lid) for their
refilling with the desired fluid and/or compositions.
[0077] In one embodiment, the desired fluid and/or compositions are
delivered into the applicator 26 by pumping with pump 24. The fluid
and/or compositions stored in the large storage tanks 19 and 20 are
pumped from conduits 22 and 21 respectively, first passing through
valve 23, then through pump 24, then finally conduit 25 to
applicator 26. The fluid and/or compositions stored in the small
storage tanks 27 and 28 are pumped from conduits 29 and 30
respectively, first passing through valve 23, then through pump 24,
then finally conduit 25 to applicator 26. Various types of pumps
may be used herein, including gear pumps, centrifugal pumps,
diaphragm pumps, piston pumps, or peristaltic pumps. A gear pump is
used because it generally generates higher pressure than any other
type of pump and it produces pulseless flow, which is desired for a
good spraying pattern. Other means of conveying fluids may be used,
such as an air compressor, which pushes the fluid out the storage
tanks by applying an overhead pressure in the tanks. In one
embodiment, a gear pump 24, capable of providing a maximum flow
rate of about 0.5 GPM (about 1.87 liters per minute) and a maximum
pressure of about 110 psi (758 kPa), is used to deliver fluids
and/or compositions to the applicator 26 via a 1/4" (6 mm) diameter
flexible delivery conduit 25.
[0078] The fluid and/or compositions stored in both the large tanks
19 and 20 and small tanks 27 and 28 are mixed by opening valves in
4-to-1 valve manifold 23 corresponding to conduits connected to
corresponding tanks containing fluid and/or compositions. For
example, it is possible to mix lipophilic fluid stored in large
tank 19 with a composition stored in large tank 20 by valve
manifold 23. Alternatively, it is possible to mix lipophilic fluid
stored in large tank 19 with compositions stored in small tanks 27
and 28 by valve manifold 23. In another embodiment, fluid and/or
compositions are delivered separately, i.e. without pre-mixing.
[0079] Pump 24 is connected to applicator 26 via conduit 25 in
order to introduce fluids into interior of chamber 1. The
applicator 26 may be of any suitable configuration. In one
embodiment, applicator 26 is configured to deliver a flat fan spray
and/or a conical fan spray. A flat fan spray produces a liquid
sheet parallel to the major axis of the orifice. The spray is in
the shape of a sector of a circle of about 75.degree. angle,
elliptical in cross section. The particular flat fan spray is
useful because it produces droplets which are large enough not to
be carried away by circulating air stream resulting from the
spinning or tumbling movement of the chamber 1 in the washing
and/or drying cycle or from airflow resulting from the venting
operation in the drying cycle.
[0080] A spray nozzle typically provides an average droplet size
that is less than about 1200 microns, typically from about 100 to
about 1000 microns, or from about 120 to about 500 microns, or from
about 150 to about 300 microns. This average droplet size is
measured by either a Malvern particle analyzer or high speed
photography. When a spray nozzle is covered with a fine grid or a
membrane to produce a finer mist of droplets with an average
particle size of less than 100 microns, the spray pattern is
typically disturbed by air movement in chamber 1. Higher rotation
speed of the chamber 1, typically above 735 m/s.sup.2, requires
larger droplets in spray pattern.
[0081] The pressure in the delivery conduit 25 should be high
enough to produce a substantially flat fan-shaped spray of the
fluid through the applicator 26 to cover the entire depth of the
chamber 1. Suitable pressures in delivery conduit 25 will vary
depending upon what is being passed along the delivery conduit 25
to the applicator 26. For example, a paste typically requires
different pressure to a thixotropic gel, or a liquid. Similarly,
lipophilic fluid which is mixed with a composition may require a
different pressure to a lipophilic fluid without any compositions.
By adjusting the spray pressure and optionally by changing the
temperature with a heater, the present apparatus is capable of
applying all types of fluids, gels and other materials, including
Newtonian and non-Newtonian fluids, shear-thinning and non-shear
thinning fluids, multiphase mixtures, emulsions, micro-emulsions,
and dynamically changing emulsion systems.
[0082] In one embodiment, the lipophilic fluid is delivered via
multiple spray nozzles; each spray nozzle is positioned such that
the lipophilic fluid is sprayed from the multiple spray nozzles in
a fashion to evenly distribute the fluid on the fabric articles
being treated. In another embodiment, the apparatus has one nozzle
for delivering the lipophilic fluid and other nozzles for
delivering the rinse fluid, the detergent composition and/or the
fabric finishing compositions. Such other spray nozzles can operate
at any suitable cycle (such as washing, rinsing, extracting or
drying) in a fabric treating process and can be sequential with or
concurrent with lipophilic fluid application and/or removal.
[0083] In an alternative embodiment, instead of spraying, the
lipophilic fluid is pumped into the chamber 1 at a rate of from
about 1 to about 20 liters/minute, or from about 1 to about 10
liters/minute, or about 2-5 liters/minute.
[0084] In a typical embodiment of the present invention, pump 24
and valve 23 can be located below tanks 19, 20, 28, and 27 to
provide gravity priming.
[0085] FIG. 2 shows the internal configuration of applicator 26, as
a spray nozzle in the following embodiments. The applicator 26 is
shown in FIG. 2 as parallel to the axis of rotation 100 of the
chamber 1. In another embodiment the applicator 26 is located on
the axis of rotation 100 of the chamber 1. The applicator 26 is
supported by a spraying arm 57 secured to the front door 59. The
fluids are delivered to the nozzle 26 via conduct 61 connecting
fluid delivery conduit 25 to the nozzle 26. Applicator 26 is
located parallel to the axis of rotation 100, so that it directs a
flat, fan-shaped spray to strike peripheral wall 65, front wall 67,
and back wall 66 of the chamber 1. Spray arm 57 allows spraying
onto the front wall of the chamber 1 without any of the garments in
the discrete fabric articles been wrapped around the spray arm 57
during tumbling cycle and consequently inhibit or possibly even
prevent efficient cleaning of the discrete fabric articles.
[0086] In an alternative embodiment, not illustrated in the FIG. 2,
the applicator 26 can be directly secured to flexible
tubular-shaped extension 55, eliminating the need for spray arm 57
and conduct 61. Thus, applicator 26 can be directly linked to fluid
delivery conduit 25. Applicator 26 can be located in a position on
the flexible tubular-shaped extension 55 which can allow it to
direct a flat, fan-shaped spray to strike peripheral wall 65, front
wall 67, and back wall 66 of the chamber 1. Different location
and/or configuration of the applicator 26 and/or the spray arm 57
are also suitable so long as the applicator nozzle or plurality of
nozzles is not located where the fabric articles in the chamber can
get tangled with or wrapped around the spray arm 57, applicator 26,
or any other structure associated with the applicator 26, during an
operating cycle (e.g., a tumbling cycle). In one embodiment of the
invention, the location and/or configuration of the applicator 26
(in the form of a spray nozzle or a plurality of such nozzles) is
selected such that the applicator 26 directs a flat, fan-shaped
spray to strike preferentially at the fluid-pervious peripheral
wall 65, and optionally, to the front wall 67 and/or the back wall
66 as well.
[0087] The spray nozzle suitable for use in the present invention
is rated to deliver 0.5 gallons per minute (about 1.87 liters per
minute) at 40 psi (about 275 kPa) fluid pressure, maximum pressure
100 psi (about 690 kPa), and forms a spray angle of 80.degree..
[0088] In the non-immersive embodiment of the invention, the extent
of accumulation of fluids on the bottom of the outer chamber 2
inside surface is insufficient to form an immersion bath for the
fabric articles because they are removed by pump 3 through valve 5
and conduit 7. Pump 3 is able to handle lint and particulate matter
without clogging and may be able to run dry without damage over
time. Centrifugal pumps and gear pumps are suitable pumps for use
in the present invention. Centrifugal pump is useful because such
pump has a large moving part (propeller or impeller) which is not
easily clogged by undissolved solids and contains no rubbing parts
that can be damaged by abrasion. Pump 3 is located below outer
chamber 2 for gravity priming. To assure good pumping, air in
conduit 7 needs to be substantially eliminated. Therefore, length
of conduit 7 may be minimized to decrease the amount of fluids
required to replace air in conduit 7. In a particular non-immersive
embodiment, the fluid level on the bottom of the outer chamber 2 is
below the bottom level of chamber 1 so that the fluid level in
chamber 1 does not rise to the level of submerging the fabric
articles inside the chamber 1. In a particular immersive
embodiment, pump 3 may be idled to allow the fluid to accumulate
such that the excess fluid in chamber 1 may rise to the level of
submerging the fabric articles therein.
[0089] Due to gravity, fluids removed from chamber 1 can pass
through the perforations 46 of chamber 1, and gravity pulls the
liquids down the outer surface of the chamber 1 until they reach
the bottom (i.e., the lowest point) of the outer surface of the
chamber 1, pass through the perforations in chamber walls, then to
the bottom of the inner surface of the outer chamber 2. Conduit 7
is located at this bottom (i.e., lowest point). The inner surface
of the outer chamber is designed to direct all fluids/droplets into
conduit 7. Fluids in conduit 7, as well as those from conduit 37,
described in more detail hereinafter, are then fed into the filter
6 and tank 8 by means of a pump 3 having a maximum rated capacity
of 3 gallons per minute and maximum pressure 50 psi (345 kPa). The
delivery conduit 7 typically has a diameter of 1/2" (127 mm).
[0090] Prior to delivering fluids into recovery tank 8, fluids are
filtered in filter 6 after passing 3-way valve 5. In its first
position, valve 5 connects conduits 4 with 7, allowing fluids to be
pumped by pump 3 into tank 8 through filter 6. In its second
position, valve 5 allows fluids to be pumped from conduit 37 to
conduit 4. And in its third position, valve 5 is closed. Filter 6
removes lint, fabric fibers and large particulate soil, so they
don't settle on the tank 8 bottom and clog downstream conduits.
Also, filter 6 assures reliable operation of pump 10, since pump 10
is a typically higher pressure pump which generally is of a type
more easily damaged by solids and particulate matters. Also, filter
6 will extend lifetime of recovery system 15. Filter 6 may be any
conventionally used filter and includes, but is not limited to
Fulfo.RTM. basket strainers or pleated cartridges such as those
manufactured by Parker Filtration, e.g. US mesh 20 to 100 (840
micron to 149 micron filters) cartridge filter. In one embodiment,
the filter 6 may be periodically removed from the apparatus for
cleaning, such as removal of lint, fabric fibers and large
particulate soil and the cleaned filter is reinstall in the
apparatus. In another embodiment, the filter 6 can be replaced with
a new identical, but unused, filter and the used filter can be
discarded or recycled by a third party for resale and reuse. In
another embodiment the filter 6 can be self-cleaning. The removed
lint and large particulate soil can then be disposed via domestic
garbage, or can be brought to a collection facility for
disposal.
[0091] Recovery tank 8 is used for fluids separation. The fluid
comes out of the chamber 1 is collected in tank 8. Typically, a
sufficient amount of fluids is collected in tank 8 before further
processing is performed on the collected fluids therein. Tank 8 is
equipped with a fluid level sensor, 44, such as conductive,
capacitive or optical sensor, located along the inside wall of the
tank 8, at an appropriate location, to determine when to start
emptying tank 8. The sensor is connected to the controller
described later.
[0092] Recovery tank 8 performs gravity separation or any other
type of separation to separate different fluids as well as any
suspended solids present. These solids will be typically, soil
removed from the textiles by the cleaning process. In this case,
when using fluids with different densities, they will separate in
tank 8 by gravity, and can be removed sequentially. In such case,
the bottom fluid would be pumped first by pump 10 conduit 11
through 3-way valve 12 and conduit 14 into recovery system 15 and
conduit 16. Then, depending on where this particular fluid was
originally stored, e.g in tank 19, 2-valve manifold directs the
bottom fluid into conduit 18. After all the bottom fluid has been
removed from tank 8, and the phase separation conduit reached valve
17 that is equipped with a sensor to distinguish fluids, such as
conductivity, optical or capacitive sensor, valve 17 opens and
closes conduit 18 to deliver the top fluid into tank 20. If needed
or desired, the invention can further employ adjuncts specifically
designed to assist in emulsion breaking, thereby providing
additional assistance to separation operations.
[0093] Valve 12 has two positions. In its first position, valve 12
connects conduits 11 and 13 allowing to drain contents of tank 8.
Conduit 13 may be a direct conduit to domestic sewerage or to a
stand alone separate fluid container, not shown. In its second
position, valve 12 connects conduit 11 and 14 to direct fluids into
recovery system 15.
[0094] Pump 10 creates higher pressures, typically 10-100 psi
(69-689 kPa) to push dirty fluids through recovery system 15.
Recovery system 15 removes fine soil particulate and has means of
separating out dissolved non-cleaning fluid components such as
soils, surfactants, water etc. by means of fine
filtering/separation such as molecular sieve filtration etc. One
possible way to remove contaminants from the solvent is by an
electrostatic fluid filtration system such as described in U. S.
Pat. No. 5,958,205 to Ingalls et. al., issued on Sep. 28, 1999.
Other possible ways to remove contaminants are by, for example,
membrane evaporation technologies, or the PACE ultrafiltration
system as manufactured by Smith and Loveless Inc. In one embodiment
the recovery system 15 may be periodically removed to facilitate
removal of the collected dissolved non-cleaning fluid components.
In another embodiment, the recovery system 15 can be replaced with
a new, but unused, identical recovery system 15 and the removed
recovery system 15 discarded or recycled by a third party for
resale and reuse. In another embodiment, the recovery system 15 can
be self-cleaning. The collected dissolved non-cleaning fluid
components can either then be disposed of by removal to domestic
sewerage or by collection in a separate location where the
collected dissolved non-cleaning fluid components may conveniently
be disposed of by the consumer.
[0095] In one embodiment, fluids are fed into the recovery system
15 by means of a pump 10 having a maximum rated capacity of 2.8
liters per minute at maximum pressure 250 psi (1724 kPa) via a 1/4
(6 mm) diameter stainless steel delivery conduits 11 and 14.
[0096] It is also possible in the recovery system 15 to use means
other than fine filtering/separation to separate out dissolved
non-cleaning fluid components from the fluid. One exemplary
alternative system is one in which the recovery system 15 comprises
a distillation system. Suitable distillation systems include the
distillation solvent recycling system as described in U.S. Pat. No.
5,876,567 to Yamamoto et. al., issued on Mar. 2, 1999. When the
recovery system 15 is a distillation system, pump 10 need not be a
higher pressure pump, as higher pressures are typically not
required. However, the higher cost of distillation or vacuum
devices render such recovery system
[0097] It should of course be understood that depending on the
intended use of the apparatus,. For example, a service or
commercial operation will be able to afford an appliance having a
more expensive distillation or vacuum system, whereas other
simpler, more convenient, or lower cost recovery system will be
most desirable and affordable for in- home appliances.
[0098] Fluid valves 12, 5, 7, and 23 are actuated using solenoids
or ball valve motors similar to drive apparatus well known in the
art.
[0099] The apparatus 70 illustrated in FIGS. 1-3 typically includes
an air circulation system. The air circulation system comprises
suction blower 31 and air duct 32 connecting the blower to a heater
33. The heater 33 can be an electric heater, includes a heating
element over which the air must pass prior to entering connecting
duct 34, which conveys heated air from the heater 33 to an inlet
opening located in the door 59 of the apparatus. Alternatively, the
air may enter the inner drum by an opening in the rear wall of the
outer drum 63 and the rear wall of the inner drum 66. This latter
arrangement is typical of those found in conventional tumble-dryers
and location of the connecting duct would be readily apparent.
Typically, blower 31 is of centrifugal type powered by variable
speed drive motor. A suitable heating element is a resistive coil,
the temperature of which is adjusted by regulating coil voltage.
Alternative heating means may also be used, for example, an
infrared radiation source, or a microwave radiation source. In an
alternative embodiment, the air can be supplemented with steam,
whereby the use of heated air becomes optional, with the steam
providing part or all of the heated gas.
[0100] In one alternative embodiment, not shown in the figures, the
air may be ionized before it contacts the fabric articles, for
example by corona discharge.
[0101] In one alternative embodiment, not shown in the figures,
ozone may be added to the air before it contacts the fabric
articles. Alternatively, the ozone may be added to the chamber 1
through a system of conduits which is independent of the air
circulation system.
[0102] In the embodiment disclosed in FIG. 2, heated air is
introduced in the interior of the chamber 1 to remove residual
fluid from the cleaned articles. The chamber 1 is rotated at
varying speed and direction during a drying cycle. Since the
articles being dried are normally located at or adjacent the
innermost surface of peripheral surface of the chamber 1 during the
drying cycle, the heated air introduced in the interior of movable
drum is caused to penetrate the textiles being dried on its way to
return to opening to a duct 35 located in the stationary drum
peripheral surface.
[0103] In the apparatus illustrated in FIGS. 1-3, the air
circulating blower 31 utilized to recirculate air during drying and
vapor treatment cycles has rated capacity 160 cfm (272 m.sup.3/hr)
and 5500 lfm (27.9 m/s) velocity at the outlet. Typically in a
domestic apparatus, i.e., one designed for home or the like use,
would have an air flow rate of from about 15 L/s (35 cfm) to about
272 l/s (160 cfm). Commercial or industrial scale apparatus go up
to about 1200 l/s (2542 cfm). The connecting ducts used to
construct circulation loop are sized to permit circulation of air
at the rated flow. The heater 33 contains a heating element 33
comprising 115 V AC, 2300 watt, spiral wound, nichrome coil. The
temperature sensing element 45 comprises a thermistor inserted into
duct 34. A voltage regulating rheostat, 0-120 V AC, is utilized to
regulate variable speed motor of the blower 31 and temperature of
the heating element 33.
[0104] In an alternative embodiment, gas, such as air, nitrogen,
ozone, argon, helium, neon, xenon, and mixtures thereof, is
introduced in the interior of the inner chamber 1 to remove
particulate soil from textiles prior to treating with the
lipophilic fluid. Optionally, these gases may be heated. The inner
chamber 1 is rotated at varying speed and direction during this
optional pretreatment cycle. More detailed disclosure of apparatus,
components, elements and exemplification of this optional
pretreatment step can be found in U.S. Pat. No. 6,564,591.
[0105] The duct 35 is connected to a condenser 36. Condenser 36
removes all the vapors and undissolved solids picked up by the
heated air from the dried textiles, so that duct 38 contains no
other vapors but air. Condenser 36 subjects the moving air to
filtering and cooling in order to condense the vapors into a
conduit 37. The vapors condensed in conduit 37 then pass to the
three way valve 5 where mixing occurs with the fluid removed from
the outer chamber 2 via conduit 7. A water-cooled condenser or a
refrigerated condenser as described in U.S. Pat. No. 3,807,948 to
Moore issued on Apr. 30 1974; U.S. Pat. No. 4,086,705 to Wehr
issued on May 2, 1978 and U.S. Pat. No. 4,769,921 to Kabakov et.
al., issued on Sep. 13, 1988 can suitably be used. The condenser
may also be connected with a columnar body of an adsorbent such as
a molecular sieve or activated carbon, in one or more layers to
collect non-condensed organic solvents. Examples of such absorption
devices are described in U.S. Pat. No. 3,955,946 to Fuhring et.
al., issued on May 11, 1976; U.S. Pat. No. 3,883,325 to Fuhring et.
al., issued on May 13, 1975; U.S. Pat. No. 4,440,549 to Girard et.
al., issued on Apr. 3, 1984; U.S. Pat. No. 4,583,985 to Preisegger
issued on Apr. 22, 1986; U.S. Pat. No. 4,788,776 to Fuhring et.
al., issued on Dec. 6, 1988; U.S. Pat. No. 4,622,039 to Merenda
issued on Nov. 11, 1986, and U.S. Pat. No. 5,277,716 to Boppart et.
al., issued on Jan. 11, 1994. The absorbent can be desorbed by
passing a "blanket" of steam through the bed. Other solvent
recovery systems are described in U.S. Pat. No. 5,467,539 to Hahn
issued on Nov. 21, 1995 and U.S. Pat. No. 5,195,252 to Yamada et.
al., issued on Mar. 23, 1993.
[0106] In another embodiment, vapors of lipophilic fluid, are
prevented from being vented from the appliance by contacting them
with an additional filter element or cartridge comprising a
catalyst; the filter element may be complemented or supported by a
porous material, or alternatively, a filter element or cartridge
comprising at least one highly effective chemisorption or physical
adsorption agent. Such a system essentially reduces the vapor
pressure of the vapor to zero, and can even, for example,
polymerize and/or solidify one or more components of the lipophilic
fluid. More particularly, for example, a suitable catalytic
converter cartridge can include a porous material or support, and a
catalyst supported thereon. Such a catalyst can include any known
ring-opening polymerization catalyst for cyclic silicones;
including but not limited to phosphazene or phosphazene base
catalysts; hindered amine base catalysts; electron-deficient silane
catalysts; sulfonium or iodonium derivatives; alkali metal
silanoates; Pt, Rh and Co hydrosilation catalysts; SiH-containing
co-catalysts; Li and K silanolates. The catalysts can be modified
in any manner, for example by clathration, absorption on the
support, etc., such that they have no or very low intrinsic
volatility and good stability for the usage lifetime. Exemplary
supports include those having a high void volume while having low
resistance to flow. The supports can be homogeneous or
heterogeneous, for example including a primary support material,
such as a mesoporous silica, affixed to a mechanical supporting
structure, such as a synthetic plastic.
[0107] It should be understood and appreciated that this aspect of
the invention is independently useful and can be used to safely
control venting in any application, including immersive and
non-immersive processes for cleaning any material, whether a fabric
article or a hard surface, especially wherever a linear or cyclic
siloxane is part of the solvent system.
[0108] The combination of the ring-opening polymerization catalyst
and the storage capacity of a high void volume porous material,
such as a mesoporous silica, makes it possible to eliminate
lipophilic fluid and prevent any venting to the outside atmosphere.
The cartridge can be removed periodically, for disposal and
replacement with a fresh cartridge, or alternatively for removal of
the polymerized lipophilic fluid, and, optionally, regeneration of
the catalyst for reuse.
[0109] The apparatus 70 may also remove residual fluid in much the
same fashion as a conventional clothes drying apparatus. This is
done by actuating the diverter valve 40 into its first position
connecting duct 43 to duct 41 and duct 38 to duct 42. In its second
position, diverter valve 40 permits fresh air to be drawn into
connecting duct 43 through connecting duct 41 and into the inlet of
the blower 31, heated to a predetermined temperature by heater 33,
circulating through the dried textiles contained in the movable
chamber 1, cleaned of vapors picked during contact with the
textiles, and vented to the atmosphere via duct 42. When the vapors
are vented to the atmosphere via duct 42 it is preferable to treat
the vapors in some fashion so that only air, water vapor and
similar materials, are passed into the atmosphere via duct 42. This
can include passing the vapors through a scrubber, or a cartridge
which includes a supported catalyst as disclosed herein above. The
catalyst could include a polymerization catalyst which would
polymerize the lipophilic fluid to produce a solid polymer which
would the deposit on the support. The cartridge would allow air,
water vapor and similar materials to pass through easily while
retaining vapors such as the lipophilic fluid. The cartridge could
be removed periodically, for disposal and replacement with a fresh
cartridge, or alternatively for removal of the polymerized
lipophilic fluid, and regeneration of the catalyst for reuse.
[0110] In its second position, connecting ducts 43 and 42 are
blocked off and all of the vapor-air mixture withdrawn from the
stationary chamber 1 is returned to the suction side of the blower
31 via connecting duct 41. In this position the apparatus 70 may
also be used for vapor treatment of the textiles by recirculating
heated air through the inner chamber 1 containing textiles which
have been contacted with the lipophilic fluid.
[0111] The temperature of the air is sensed by in connecting duct
34 by means of sensing element 45, which can be a thermistor type
sensor, sends a signal to the heater. This ensures continuous
monitoring of the temperature of heated air, air/ozone, air/vapor
or air/ozone/vapor mixture during any cycle and can be maintained
at predetermined level or varied, depending on what stage of the
cleaning cycle the apparatus 70 is presently in. For example, one
temperature may be used for pretreatment, and another temperature
is used for assisting in removing the lipophilic fluid.
[0112] Diverter valve 40 may be automatically actuated. This may be
accomplished utilizing solenoids or similar to drive apparatus well
known in the art.
[0113] Connecting duct 35 is equipped with a gas sensor to monitor
vapor concentration in air stream exiting the stationary chamber 2.
Gas sensor transmits signal proportional to vapors concentration to
the machine controller. Depending on magnitude of the signal, the
controller either continues, stops, or selects a new cycle. Gas
sensor may be a metal oxide type, but other alternative sensors
based on infrared, capacitive, or conductive sensing, can be used.
In a particular embodiment, when at some point in a drying cycle,
gas sensor signal reaches some minimal value that indicates low
amounts of vapors present at the exhaust, the controller stops the
drying cycle by deactivating heater 33, and continuing with a
cooling cycle.
[0114] Another gas sensor may be included in the apparatus to
monitor the solvent vapor concentration in chamber 1, especially
during the drying cycle. The gas sensor may be operatively linked
to a controller. When the gas sensor detects that the solvent vapor
concentration exceeds a threshold value, the controller may
interrupt the drying cycle temporarily by shutting down the heat,
increasing the air flow, or both. When the gas sensor detects that
the solvent vapor concentration drops below a minimal level, the
controller signals the user that it is safe to open the apparatus
to remove the fabric articles.
[0115] In another embodiment, weight of the fabric articles and the
lipophilic fluid thereon, as well as any compositions, is measured
from load characteristics of electrical motor 54, such as voltage
across motor terminals. In another embodiment, a device system for
determining the load of fabric articles and the lipophilic fluid
thereon, as well as any compositions, in the chamber 1, includes
one capable of determining the moment of inertia of the mass of
load of fabric articles and the lipophilic fluid thereon, as well
as any compositions, in the chamber 1, from data relating the drive
torque of the chamber 1, the friction torque of the chamber 1, the
moment of inertia of this chamber and the acceleration of the
chamber.
[0116] An out-of-balance control for the described apparatus is
incorporated via monitoring a current signal which is proportionate
to the current drawn by the motor 54. When the chamber 1 is
accelerated, the current signal variations reflect torque required
to rotate the chamber 1. The magnitude of the variations is
proportional to load unbalance which causes excessive vibrations of
the machine. When the unbalance signal magnitude exceeds the
maximum permissible value, the machine controller executes
re-balancing cycle by slowing the rotation, reorganizing the fabric
load by tumbling, and accelerating to a set speed again.
Alternative means of sensing unbalanced state can be use of a
tachometer or a static switch.
[0117] In alternate embodiments, the apparatus of the present
invention may optionally be operated at reduced or elevated
pressure, typically achieved via a vacuum pump or by supplying a
gas, such as nitrogen, to the apparatus thereby increasing the
pressure in the washing chamber. Such embodiments can even include
modifications of appliances designed for supercritical or dense gas
cleaning.
[0118] FIG. 3 shows a front view of the apparatus 70. The apparatus
70, has front panel 71, two side panels 72 (only one of which is
shown), and top panel 73. Door 59 contains spray nozzle cover 76,
which covers conduit 25, which delivers the fluids to spray head
26; gas cover 77, which covers the 33 which delivers gas to the
chamber 1 via connecting duct 34; and handle 75. Door 59 may be
made of any suitable material and at least a portion of door 59 can
be opaque to enable the operator to watch the apparatus in
operation.
[0119] Also on front panel 71 is the apparatus controller 81. The
apparatus controller 81 is the controller responsible for the
timing and sequencing of the various process steps involved in
using the apparatus. For example, apparatus controller 81 controls
the amount of lipophilic fluid delivered to the fabric articles,
and at what speed the drum is spun at, how long are the fabric
articles tumbles for etc. The apparatus controller 81 also has
provision for the consumer/operator to enter directly relevant
information about the fabric articles being cleaned and/or the type
of cleaning desired.
[0120] Access door 80 is also located on front panel 71. Access
door 81 enables the operator/consumer to access the inner workings
of the apparatus to remove and replace any consumables, such as
filters, fluids, adjuncts etc., Access door 81 more specifically
allows access to small tanks 27 and 28 and large tanks 19 and 20,
for removal and replacement if they are replaceable or for
re-filling. Access door 81 also allows easy access for any needed
maintenance or repairs.
[0121] Panels 78 and 79 are access ports for the easy removal and
cleaning or replacement by the operator/consumer of filters. Panel
79 provides access to the recovery system 15 and panel 79 provides
access to filter 6.
[0122] Located on the side panel 72 shown in FIG. 3 are fluid
outlet 85 and gas outlet 84. Fluid outlet 85 is connected to
conduit 13 and is then connected to the domestic sewerage, another
fluid storage container or both. Gas outlet 84 is linked to duct
42. The optional scrubber, baffle or cartridge, referred to
previously, may be located between gas outlet 84 and duct 42 or it
may be linked to gas out let 84. That is any gas or vapor first
passes through duct 42, then gas outlet 84 then to the optional
scrubber, baffle or cartridge.
[0123] Located on to panel 73 are air inlet 83, which provide an
additional source of air to the apparatus via duct 43, and access
port 82 which allows for the easy removal and cleaning or
replacement by the operator/consumer of any filter associated with
the air system 35, 36, 38, and 40-43.
[0124] The apparatus also includes components for recovery and
reuse of the lipophilic fluid. Specifically, the lipophilic fluids
removed from the treated fabric articles typically comes as a
mixtures of lipophilic fluids and contaminants acquired during the
fabric treatment process. Contaminants include, but are not limited
to, water, laundry soils, surfactants, bleaches, enzymes, and other
fabric cleaning adjuncts that are used in the detergent
compositions. The contaminants can be separated from the mixture
using various recovery methods, and the recovered lipophilic fluid
can be stored in the apparatus and reused in s fabric treatment
processes. Suitable recovery methods are described in U.S. Pat.
Publications US 2002/0004952A1 (P&G Case 8483M), US
2003/0069159A1 (P&G Case 8689M); U.S. Provisional Pat.
Application No. 60/483,290 (P&G Case 9289P), filed on Jun. 27,
2003, and co-filed provisional patent applications titled "Process
for Purifying A Lipophilic Fluid Employing A Functionalized Fabric
Treating Agent" and "Process for Recovering A Lipophilic Fluid From
A Mixture By Modifying The Mixture"; both of which are filed on
Feb. 24, 2004 (P&G Cases 9542P and 9543P).
[0125] In one embodiment of the present invention, the apparatus is
a modified domestic appliance. Conventional aqueous-based laundry
appliances, such as top-loading washers, horizontal axis washers,
low wash volume washers, dryers, and washer/dryer combination
machines can be modified for the processes or the apparatus of the
present invention. In one example, a modified washer retains the
ability to wash and/or dry clothes as they did before modification.
This would include all the associated connections and/or plumbing,
such as, connection to a water supply, and sewage for waste wash
water, etc. For example, the non-aqueous method of the present
invention can be included as a set of additional cycles on a
conventional laundry appliance. Either the consumer or a controller
built into the appliance would select the appropriate wash cycle,
depending on the fabric articles to be washed and the soils
present. In another example, a modified dryer or washer/dryer
combination would retain all associated connections and/or
plumbing, such as air inlet and outlet, heater, etc. in addition to
connections to a water supply, a solvent supply, and a drain.
[0126] In another embodiment of the present invention the apparatus
is not a modification of the existing apparatus, rather, it is
built specifically to conduct the process of the present
invention.
[0127] The apparatus of the present invention may optionally have
dimensions similar to those of a domestic washer or dryer. That is,
the external dimensions and/or the internal dimensions are similar
to those of a domestic washer or dryer. Alternatively, apparatus of
the present invention may have dimensions similar to those of a
commercial dry-cleaning machine or industrial scale laundering
apparatus, such as those used in commercial laundry services or
laundromats.
[0128] The apparatus of the present invention may further comprise
at least one trap comprising a filter element; the filter element
can be contained in a cartridge that is detachably mounted in said
laundering apparatus. The trap may be located in any part of the
apparatus. There may be more than one trap, each designed for
filtering fluids or air/gases.
[0129] The filter element, may be a lint filter for removing any
loose particles, lint, fabric fibers and the like, which are
dislodged form the fabric articles during the treatment
process.
[0130] A water hardness remover or filter may also be present to
remove any water hardness causing ions (e.g., calcium, magnesium)
from any water used in the apparatus or process of the present
invention. This water hardness filter would only be present where
water is used in some fashion, such as an adjunct in the lipophilic
fluid, or as part of an independent water wash or pretreat cycle.
Such apparatus would be connected to a main water source, or
another convenient water supply. Water for washing or pretreating
would pass through the water hardness filter prior to its use in
the apparatus or methods of the present invention. The water
hardness filter, may be in the form of a cartridge, which may be
detachable for easy cleaning or disposal and replaceable with a
fresh unused water hardness filter.
[0131] Soil filter may be present in the apparatus of the present
invention to remove any soil removed from the fabric articles. A
solvent filter may also be present to remove spent ingredients of
the treatment compositions, such as water, surfactants, enzymes,
etc., during the treatment process. This would enable the
lipophilic fluid and/or the treatment composition to be regenerated
and reused.
[0132] The apparatus used in the process and the apparatus of the
present invention will typically contain a program selector control
system, accessible by a user via dials, buttons, touch panels or
the like. The control system can be a "smart control system", that
is, the appliance acts autonomously in response to a signal from a
sensor; or the control system can be a manual system or traditional
electro-mechanical system. The control systems can enable the user
to select the size of the fabric load to be cleaned, the type of
soiling, the extent of the soiling, the time for the cleaning
cycle, and the type of cycle (for example cleaning or garment
treatment, dry-cleaning or water cleaning, etc.) Alternatively, the
user can select pre-set cleaning and/or refreshing cycles. In
another alternative, the apparatus can control the length of the
cycle, based on any number of ascertainable parameters. For
example, when the collection rate of lipophilic fluid reaches a
steady rate the apparatus can be configured to switch off after a
fixed period of time, or initiate another application of the
lipophilic fluid.
[0133] In one embodiment of the present invention, the apparatus of
the present invention may comprise a program selector. This
selector may be in any suitable form, such as a dial, buttons,
touch pads, panel (which would typically include buttons or
assorted selection means) or combinations thereof. Furthermore, the
apparatus of the present invention may include multiple selectors.
For example, a user may use one selector to input load size, and
another selector to input the predominate type of fabric to be
treated (such as, "dry-clean", to indicate the presence of dry
clean only garments in the wash load). Alternatively, all these
functions could be done on one multi-position selector. Such
selector would have at least two selector positions. Possible
combinations of selector positions include:
[0134] 1. at least one selected from "dry-clean", "delicate care
label" and "light soil" and at least one selected from "water
wash", "normal", and "high soil";
[0135] 2. at least one selected from "dry-clean", "delicate care
label" and "light soil" and at least one selected from "refresh",
"deodorize", "fabric treatment" and "rinse/soften";
[0136] In one embodiment any programmable selector would have at
least three selector positions including at least one selected from
"dry-clean", "delicate care label" and "light soil", at least one
selected from "water wash", "normal", and "high soil", and at least
one selected from "refresh", "deodorize", "fabric treatment" and
"rinse/soften".
[0137] The term "machine washable fabric articles", as used herein,
means those fabric articles readily identified by the fabric
industry and consumers as safe for laundering by a conventional
aqueous automatic home laundry process. The term "dry clean only
fabric articles", as used herein, means those fabric articles
readily identified by the fabric industry and consumers as unsafe
for laundering by a conventional aqueous immersive wash automatic
home laundry process, and instead requiring special handling with a
conventional non-aqueous solvent such as Perc (perchloroethylene).
Manufacturer's tags on the fabric article labeling the article as
"machine washable", "dry clean only", or similar description, are
helpful in identifying the fabric types and selecting the proper
laundry process accordingly.
[0138] Additionally, the apparatus of the present invention may
include a control system that is a so called "smart device". This
smart device can include functions/devices such as self diagnostic
system, load type and cycle selection, link to the Internet, remote
access to start the apparatus, signal to inform the user when the
apparatus has finished a fabric article treatment process, or
remote access to diagnose apparatus malfunction by the supplier or
manufacturer when the apparatus breaks down. Furthermore, the
apparatus of the present invention can also be a part of a cleaning
system, the so called "smart system", in which the present
apparatus has the capability to communicate with another laundry
apparatus which performs a complimentary operation (such as a
washing machine or a dryer) to complete the remainder of the
cleaning process.
[0139] The fluid pervious movable chamber in one embodiment of the
present invention has a curved cylindrical surface and a back wall,
and is substantially horizontally mounted. The fluid pervious
movable chamber is a drum, which may be any shape which will allow
for free tumbling and high speed spinning of fabric articles. This
includes, but is not limited to, hexagonal-section "cylinders",
octagonal-section "cylinders" and true cylinders. The drums can be
made of any suitable material. For example, suitable material
includes aluminum, stainless steel, polymeric material and
combinations thereof. The drum may have a uniformly even surface
internally, however, it may also have a variety of raised or
recessed sections on the internal surface of the drum. The raised
sections can include ridges or bumps regularly placed on the
internal surface of the drum. The regular placement is highly
desired as it aids in the rotation of the drum. These ridges or
bumps may optionally run the length of the drum. An illustrative
example of such a drum can be found in FIGS. 1 and 2.
[0140] In another aspect of one embodiment of the present invention
the quantity of the lipophilic fluid within the fluid-pervious
movable chamber at any point in time does not exceed about 5 times
the dry weight of the fabric articles, alternatively, does not
exceed about 1.5 times the dry weight, of said fabric articles.
[0141] In another embodiment of the present invention that any
detachably mounted components, such as traps, filters, storage
means (both cartridge and non-cartridge storage means) are
accessible from positions selected from the top and front faces of
said appliance. An illustration of such an arrangement is
illustrated in FIG. 3.
[0142] The apparatus of the present invention may optionally
contain one or more of:
[0143] (a) at least one trap comprising a filter element, such as,
those traps described previously;
[0144] (b) one or more adjunct storage means for storing
composition(s), optionally, capable of being detachably mounted on
the apparatus;
[0145] (c) a connection to a drain, air outlet or combinations
thereof;
[0146] (d) at least one gas inlet, capable of providing air,
optionally with ozone and/or electrostatic ally treated air, of a
suitable humidity and temperature;
[0147] (e) an ozone source;
[0148] (f) a lipophilic fluid recovery system;
[0149] (g) an outlet vent gas treatment/VOC control system;
[0150] (h) physical static control means; (e.g., corona
discharge)
[0151] (i) an electric motor, such as variable speed, fixed speed
(a clutch and gearing would be used to achieve the different speeds
as required), brushless motor;
[0152] (j) a heater, for heating the gas or heating the lipophilic
fluid;
[0153] (k) a compressor;
[0154] (l) a vacuum pump;
[0155] (m) an inert gas supply means, such as argon, helium, xenon,
etc;;
[0156] (n) a safety interlock, such as locks on any access door to
prevent opening the apparatus while it was in use;
[0157] (o) steam inlet; and
[0158] (p) sensor means, including but not limited to VOC,
vibration, ozone, humidity, temperature and pressure sensor
means.
[0159] In another aspect of the present invention, the apparatus
includes at one least sensor for garment tag detection, for
example, the garment tag detector may be a radio frequency
detector. In this embodiment the fabric articles have a
machine-detectable tag, which is detected by the apparatus enabling
the apparatus to select an appropriate treatment cycle/process
based on the fabric articles fabric type, e.g., silk, denim, wool,
rayon, cotton, "dry-clean only", etc., present in the fabric
articles to be treated.
[0160] The present invention can be performed in an apparatus
capable of "dual mode" functions. A "dual mode" apparatus is one
capable of both washing and drying fabrics within the same drum,
i.e., a dry-to-dry operation. Dual mode apparatuses for
conventional aqueous laundry process are commercially available
particularly in Europe.
[0161] Methods
[0162] One aspect of the method of the present invention involves
multiple spin, spray and tumble cycles in apparatus 70. The chamber
1 is capable of tumbling, agitating, rotating, or otherwise
applying mechanical energy to its content, including the fabric
articles, the lipophilic fluid, and detergent and fabric finishing
compositions, and is capable of evenly distributing the lipophilic
fluid and the compositions onto all the fabric articles in the
chamber 1.
[0163] The amount of lipophilic fluid which is dispensed into the
chamber 1 is typically, less than about 5 times the dry weight of
the fabric articles to be cleaned, or less than about 2 times the
dry weight of the fabric articles, or less than about 1 1/2 times
(i.e., {fraction (3/2)} times) to about 0.2 times the dry weight of
the fabric articles, or from about 20% to about 150%, or about 20%
to about 90%, by weight of the dry fabric load. In one embodiment,
the quantity of lipophilic fluid is such, that there is none or
minimal amounts of lipophilic fluid in excess of absorption
capacity of the garments, which is typically about 150%, by weight
of the dry fabric. For example, in a single application of
lipophilic fluid to clean a typical 5 kilogram load of assorted
soiled fabric articles, the apparatus of the present invention can
use as little as from about 5 kg to about 10 kg of lipophilic
fluid. It is understood that the fluid reservoirs in the appliance
can in general be stocked with much more fluid than is used in a
single treatment cycle, and the apparatus may fully or partially
recycle fluid from cycle to cycle and/or have multiple cycles).
Typically, in a domestic situation the amount of fluid is based on
weight, type of garments, soil amount, and can be controlled by
user-selectable interface choosing the most appropriate cycle, much
in the same fashion as a consumer would on a conventional washing
machine.
[0164] It is understood that the present invention also includes
the "immersive" washing method wherein a large quantity of a
lipophilic fluid is pumped into the chamber 1 such that the fabric
articles are submerged in the wash liquor. The total amount of
lipophilic fluid can be from about 550% to about 1500% by weight of
the dry fabric in the chamber.
[0165] The time taken for applying the lipophilic fluid will depend
upon the precise method(s) used for applying the lipophilic fluid
and on the number of cycles of lipophilic cleaning fluid through
the fabric articles and can vary quite widely. For example, this
can take from about 30 seconds to about 30 minutes. More generally,
a complete cleaning or fabric treatment operation from start to end
(at which time the fabric articles are ready to wear with the
exception of optional ironing) can take from about 5 minutes to
about three hours, or even longer, for example, if a low-energy
overnight mode of operation is contemplated or if a cleaning
operation is to be followed by additional fabric treatment. The
total processing time will also vary with the precise appliance
design, for example appliance variations having reduced pressure
(vacuum) means can help reduce cycle time. Typical operations,
including the wash and rinse cycles and the drying cycle, would
take about 20 minutes to about two hours in total. Fabric treatment
operations involving longer times may be less desirable for the
consumer but may be imposed by energy-saving requirements, which
can very from country to country.
[0166] The lipophilic fluid is then at least partially removed from
the fabric articles by non-distillative removal. One example of
non-distillative removal employs, an inflatable bladder, not shown
in the figures, which expands from the back wall of the inner drum
66, along the axis of rotation of the inner drum 100, and presses
the fabric load against the inner wall of the chamber 1. The
pressure applied by the inflated bladder forces the lipophilic
fluid out of the fabric through the perforations in the inner drum
46 into the outer chamber 2 and collected in tank 8 via conduit 7.
During this non-distillative removal the chamber 1 may be
stationary, rotating at speed sufficient to tumble the fabrics or
rotating at sufficient speed to fix the fabrics in place on the
inner wall of the chamber 1. The expansion and deflation of the
bladder may be performed and in combination with redistributing the
fabric load by rotating the chamber 1.
[0167] Another example of non-distillative removal involves the use
of capillary action, such as that supplied by a sponge or the like.
In this embodiment, the lipophilic fluid treated fabric articles
are pressed against a sponge or the like to remove the lipophilic
fluid. The sponge may be, for example, located in the rear wall 66
of the inner chamber 1, or in one of the lifting vanes 60. The
sponge would be prevented from contacting the fabric until
appropriate by means of a movable cover.
[0168] Yet another example of non-distillative removal involves
high speed rotation of chamber 1, which is referred to as the spin
cycle in a conventional appliance. The lipophilic fluid treated
fabric articles are subjected to high centrifugal acceleration,
typically of the order of about 4,450 m/s.sup.2 (about 450G).
Typically, the fabric load is subjected to the high centrifugal
acceleration for about 30 seconds to about 5 minutes. The
lipophilic fluid removed by the high centrifugal acceleration is
collected in tank 8, and the assorted pumps and delivery conduits
3-7 as shown in FIG. 1 illustrates one possible way of recovering
the fluid removed from the fabric articles.
[0169] Following the partial removal of lipophilic fluid by
non-distillative methods, air is introduced to the chamber 1 to
complete the drying of the fabric articles without the need for an
additional or separate drying apparatus. Alternatively, the fabric
articles can be transferred to another compartment or chamber
within the same apparatus for the drying cycle. A suitable transfer
means is exemplified in a "tunnel-type" washing machine, wherein
fabric articles are transferred internally from one compartment to
another compartment via a conveyor device. Examples of tunnel-type
washing machines are disclosed in EP 0,914,511 B1 and WO 98/48094
(to Electrolux).
[0170] Typically, the non-distillative step removes at least about
70 wt %, or at least about 80 wt % of the lipophilic fluid. The
removal of the remaining lipophilic fluid is achieved in the drying
step, during which the fabric articles is tumbled in the chamber
under moving air. The air is optionally heated to less than about
100.degree. C., or between from about 30 to about 80.degree. C., or
between from about 40 to about 65.degree. C., and at a flow rate of
about 15 l/s to about 272 l/s, or from about 20 l/s to about 200
/s. Alternatively, a gas (e.g., nitrogen) may be used in place of
air. In another alternative, gases (such as steam, ozone) could be
added to the air. Optionally, the air may be ionized.
[0171] In another optional embodiment, surface actives or inert
fabric care substances can be added to the air or gas stream to
obtain additional fabric care benefits, such as static removal,
pleasant odor, disinfection, softening etc.
[0172] Exhaust air can be filtered or cleaned by other means to
ensure that minimal amount of solvent vapor is discharged from the
system, for example, through the exhaust systems. A gas sensor may
be located near the exhaust to monitor the solvent vapor
concentration in air stream exiting the apparatus. Another gas
sensor may be included in the apparatus to monitor the solvent
vapor level in chamber 1. In another aspect of the method of the
present invention, a fabric finishing step is included in the
drying cycle. After the lipophilic fluid is at least partially
removed from the treated fabric article, a fabric finishing
composition is delivered into the chamber 1 such that it contacts
the fabric article and delivers fabric finishing benefits, such as
fabric softness, fluffiness, odor, anti-static, wrinkle resistance,
and the like.
[0173] In one embodiment, the finishing composition is applied to
the fabric articles via spraying, while the fabric articles are in
motion such as tumbling or low speed rotation (e.g., spun at a
centrifugal acceleration about 9.8 m/s.sup.2, which is just enough
force to hold the garments against the chamber 1. Alternatively,
the finishing agent is applied to the fabric articles by spraying
in multiple stages with tumbling of the fabric articles in between
to achieve more uniform distribution of the composition on the
fabric surface.
[0174] In another embodiment, the fabric finishing composition is
applied in the drying cycle when the chamber 1 is at a temperature
of less than about 100.degree. C., or from about 20.degree. C. to
about 80.degree. C., or from about 35.degree. C. to about
60.degree. C. In yet another embodiment, in order to deliver
enduring perfume odor to the treated fabric article, a fabric
finishing composition comprising perfume as the primary ingredient
(i.e., no other ingredient has a higher percentage in the
composition) is applied during the cool-down operation of the
drying cycle. As used herein, the "cool-down operation" refers to
the part of the drying cycle when heat is no longer supplied to the
chamber 1, though heat may continue to be applied to the finishing
composition to help dispensing the composition.
[0175] Suitable finishing compositions comprise fabric care agents,
including but not limited to, finishing polymers, fabric softening
agents, perfumes, wrinkle control agents, anti-static agents, water
and mixtures thereof. In a specific embodiment, water vapor or
water mist can be used as the finishing composition. The
composition can be a liquid or gel at room temperature, and can be
heat activated. That is, the viscosity of the composition needs to
drop to less than about 50 centipoises (50 mPa-s) at a temperature
of 100.degree. C. or lower. In a typical embodiment, the viscosity
of the composition is from about 0.5 to about 20 centipoises (about
0.5 to about 20 mPa-s) at about 37.degree. C. Viscosity
measurements can be determined with a Brookfield LVF
viscometer.
[0176] Other applicators or dispensing devices, for example,
atomizers, nebulizers, and like devices, can also be used. A
typical applicator of this type is capable of providing droplets
having average particle size less than about 100 microns, typically
from about 0.1 to about 60 microns, or from about 0.5 to about 40
microns, or from about 1 to about 20 microns. Due to the small
particle size, the droplets are more susceptible to air movement in
the chamber 1. An air circulation device, such as a fan, may be
used to direct the droplets towards the walls 65, 66, 67.
Alternatively, the air circulation system or the gas/air vent can
be closed while the finishing composition is being dispensed into
the chamber, thus, the droplets of the finishing composition are
not lost through the vent. Optionally, to ensure contact between
the dispensed finishing composition and the fabric article, the air
circulation system or the vent can remain closed for about 5
minutes to about 30 minutes after the finishing composition is
completely dispensed.
[0177] Nebulizers, atomizers and like devices are well known to
those skilled in the art. A suitable device for use herein is a
nebulizer that has at least one ultrasonic sonotrode, or ultrasonic
vibrating cell. Typical of such nebulizer is commercially available
under the tradename Acu Mist.RTM. from Sono Tek Corporation,
Milton, N.Y. Still other examples of such devices are available
from Omron Health Care, GmbH, Germany; and from Flaem Nuove, S.P.A,
Italy. Likewise, aerosol delivery systems, which are well known to
the art, can be used to deliver the detergent and/or finishing
compositions. Electrostatic dispensing devices can also be used to
dispense the compositions to the chamber 1. Exemplary of such
electrostatic dispensing devices are described in U.S. patent
application Ser. No. 10/418,595 (P&G Case 8903) and PCT
Publication WO 03/02291.
[0178] Other dispensing devices can be removably attached to the
front door 59 are described in U.S. patent application Ser. Nos.
10/697,735; 10/697,685; and 10/697,736 (P&G Cases 9397, 9398,
and 9400); U.S. Patent Application No. 2003/0200674A1; PCT
publications WO 03/087285 and WO 03/087461. It is understood that
these dispensing devices can be used to deliver the detergent
composition, the finishing composition, and even the lipophilic
fluid.
[0179] In another aspect of the method of the present invention, a
detergent composition is mixed with the lipophilic fluid to form a
diluted wash liquor, prior to contacting the fabric articles. The
mixing can take place outside the apparatus, and the diluted wash
liquor is stored in one of the tanks of the apparatus.
Alternatively, the detergent composition and the lipophilic fluid
are stored in separate tanks and mixed in the apparatus to form the
wash liquor. After the wash liquor is dispensed into the chamber 1,
the fabric articles are tumbled for about 1 to about 20 minutes to
redistribute the fabric articles and to ensure an even distribution
of the lipophilic fluid on the fabric articles. A further portion
of lipophilic fluid is applied to the fabric article, which are
optionally tumbled for about 1 to about 20 minutes. The final
portion of the lipophilic fluid is applied to the fabric articles
while the fabric articles are tumbled or spun at a low speed (about
9.8 m/s.sup.2). The lipophilic fluid used in different steps herein
may include the same or different compositions, the same or
different lipophilic fluids, in the same or different amounts, or
combinations thereof.
[0180] The lipophilic fluid used in different steps herein may also
include water or other polar solvents (e.g., diols, glycols);
methods that uses mixed fluids in the wash liquor (referred to as
the "bi-modal" cleaning methods) are described in U.S. patent
application Ser. No. 10/612,106 (P&G Case 8121C). In one
embodiment of the bi-modal cleaning method, at least one step
therein uses the lipophilic fluid as the dominant fluid. The
dominant fluid is the fluid that is present at a level higher than
any other fluid in the wash liquor. The dominant fluid is typically
at least about 50% by weight of the wash liquor, though it is not
required to be. For example, component A in a wash liquor
comprising a liquid mixture of A:B:C at 45:30:25 weight ratio is a
dominant fluid. In another embodiment, instead of a mixture, the
lipophilic fluid, water and/or polar solvents are applied
individually, in a concurrent or sequential manner.
[0181] In yet another aspect of the method of the present
invention, a detergent composition may be applied directly (i.e.,
without being diluted into a wash liquor) to the fabric article in
the washing cycle. The detergent composition can be delivered by a
spray nozzle, an atomizer, a nebulizer, and the like. The fabric
articles may be tumbled while the detergent composition is being
applied; this tumbling redistributes the fabric articles and
ensures an even deposition of the detergent composition on the
fabric article. Since the cleaning agents are not loss due to
dilution in a wash liquor, this direct deposit method of undiluted
composition is more effective in delivering cleaning agents to the
fabric article and a smaller amount of cleaning agent is used to
deliver the same benefit. Additional portions of lipophilic fluids
can be applied to the fabric articles and the fabric articles are
tumbled or spun at low speed; and the steps can be repeated, if
desired.
[0182] Optionally, a finishing composition can be applied to the
fabric article in the washing cycle in any step of the washing
cycle. The finishing composition can be applied directly to the
fabric article or as a premix with a lipophilic fluid and/or a
detergent composition. In a specific embodiment, the finishing
composition and the detergent composition are premixed and applied
to the fabric article as a "two-in-one" composition.
[0183] In another aspect of the present invention, the consumable
and/or recyclable lipophilic liquids, detergent compositions and/or
finishing compositions are provided in a tank, a container, a
cartridge or the like, that is removably attachable to the
apparatus via a "lock and key" system such that they can be easily
and conveniently replaced by the user.
[0184] The method of the present invention may optionally comprise
the step of forming in-situ an emulsion or micro emulsion
comprising two or more fluid streams, such as the lipophilic fluid
and water (optionally, fabric treating agents, polar solvents)
immediately prior to evenly distributing the lipophilic fluid on a
retained load of fabric articles within the apparatus of the
present invention.
[0185] Oil-in-water emulsion formation can be brought about by any
number of suitable procedures. For example, the aqueous phase
containing an effective amount of surfactant package can be
contacted with the solvent phase by metered injection just prior to
a suitable mixing device. Metering can be maintained such that the
desired solvent/water ratio remains relatively constant. Mixing
devices such as pump assemblies or in-line static mixers, a
centrifugal pump or other type of pump, a colloid mill or other
type of mill, a rotary mixer, an ultrasonic mixer and other means
of dispersing one liquid in another, non-miscible liquid can be
used to provide sufficient agitation to cause emulsification.
[0186] These static mixers are devices through which the emulsion
is passed at high speed and in which said emulsion experiences
sudden changes in direction and/or in the diameter of the channels
which make up the interior of the mixers. This results in a
pressure loss, which is a factor in obtaining a correct emulsion in
terms of droplet size and stability.
[0187] In one embodiment of the method of the invention, the mixing
steps are sequential. The procedure consists in mixing the solvent
and emulsifier in a first stage, the premix being mixed and
emulsified with the water in a second stage. In another embodiment
of the invention, provision is made for carrying out the above
mixing steps in a continuous mode. The mixing typically takes place
at room temperature, with the fluids, water and cleaning agent
supplied at room temperature as well.
[0188] A batch process such as an overhead mixer or a continuous
process such as a two fluid coextrusion nozzle, an in-line
injector, an in-line mixer or an in-line screen can be used to make
the emulsion. The size of the emulsion composition in the final
composition can be manipulated by changing the mixing speed, mixing
time, the mixing device and the viscosity of the aqueous solution.
In general, by reducing the mixing speed, decreasing the mixing
time, lowering the viscosity of the aqueous solution or using a
mixing device that produces less shear force during mixing, one can
produce an emulsion of a larger droplet size.
[0189] In a further aspect of the present invention, the lipophilic
fluid or the wash liquor are at least a portion of the extraction
process is conducted concurrently with fluid/wash liquor
distribution. In this embodiment, the even distribution is
accomplished by spraying said lipophilic fluid or wash liquor
through at least one spray nozzle while the fabric articles are
moving in said fluid-pervious movable chamber at the time of
spraying. Some lipophilic fluid can be extracted by centrifugal
forces or gravity. In a further embodiment, P&G Case 9540 37 a
pattern of speed changes and/or reversal in the movement direction
is used to redistribute the fabric in the fluid-pervious movable
chamber, thereby achieving even wetting.
[0190] Another embodiment of the present invention method for
treating fabric articles in an apparatus of the present invention.
In one embodiment of this aspect of the present invention the
method comprises
[0191] (I) one or more steps of prespotting, soaking or pretreating
a fabric article or a load of fabric articles by any conventional
process; and
[0192] (II) at least one step of treating said fabric article or
load of fabric articles in an appliance according to any of the
foregoing appliance claims.
[0193] By "one or more steps of prespotting, soaking or pretreating
a fabric article or a load of fabric articles by any conventional
process" it is meant that the fabric article or load is pretreated,
prespotted or soaked exactly as if they were to be treated before
being cleaned or treated either a conventional domestic or
commercial aqueous laundry apparatus, or commercial dry cleaning
apparatus. For example, the fabric article or load is let soak
overnight immersed in an aqueous bath containing a bleach solution
and then treated in the apparatus of the present invention; or a
pretreated solution is applied to stain on a fabric article which
is then treated in the apparatus of the present invention, etc.
[0194] In another embodiment of this aspect of the present
invention the method comprises
[0195] (I) at least one step of treating a fabric article or load
of fabric articles in an appliance according to any of the
foregoing appliance claims and
[0196] (II) one or more steps of posttreating said fabric article
or a load of fabric articles by any conventional process.
[0197] By "one or more steps of posttreating the fabric article or
a load of fabric articles by any conventional process" it is meant
that the fabric article or load is posttreated exactly as if they
were to be posttreated after being cleaned or treated in a
conventional domestic or commercial water laundry apparatus, or
commercial dry cleaning apparatus. For example, the fabric article
is contacted with a fabric softener after being treated in the
apparatus of the present invention, etc.
[0198] The apparatus of the present invention may be used for
refreshing and/or cleaning a fabric article. Furthermore, the
apparatus of the present invention may be used for alternately
cleaning loads of fabric articles in any of said garment cleaning
or garment treatment modes.
[0199] The apparatus of the present invention may be used in a
service, such as a dry cleaning service, diaper service, uniform
cleaning service, or commercial business, such as a Laundromat, dry
cleaner, linen service which is part of a hotel, restaurant,
convention center, airport, cruise ship, port facility or
casino.
[0200] In another embodiment of the present invention the apparatus
of the present invention may be used for treating an unsorted load
of fabric articles without substantial damage or dye-transfer
between said articles. By "unsorted fabric articles" it is meant
that the fabric articles to be treated comprise two or more
articles selected from the group consisting of articles having "dry
clean only" care labels. In other words, it is one embodiment of
the present invention that an apparatus and method of treating
using the same apparatus, which clean dry clean only fabrics at the
same time, and in the same apparatus, as fabrics which can be water
washed.
[0201] In another embodiment of the present invention is directed
to a fabric article which has been treated in an apparatus
according to the present invention. Typically, any such treated
fabric article comprise an analytically detectable amount of at
least one compound (e.g., an organosilicone) having a surface
energy modifying effect but no antistatic effect; or an
analytically detectable amount of at least one compound having a
surface energy modifying and/or feel-modifying and/or
comfort-modifying and/or aesthetic effect and at least one
antistatic agent other than said at least one compound.
[0202] Water, if any, used in the apparatus and methods of the
present invention can be treated to soften, filter, disinfect,
heat, cool, and the like prior to being used in the apparatus and
in the methods.
[0203] Lipophilic Fluid
[0204] "Lipophilic fluid" as used herein means any liquid or
mixture of liquid that is immiscible with water at up to 20% by
weight of water. In general, a suitable lipophilic fluid can be
fully liquid at ambient temperature and pressure, can be an easily
melted solid, e.g., one that becomes liquid at temperatures in the
range from about 0.degree. C. to about 60.degree. C., or can
comprise a mixture of liquid and vapor phases at ambient
temperatures and pressures, e.g., at 25.degree. C. and 1 atm.
pressure.
[0205] Typically, the suitable lipophilic fluid is non-flammable
or, has relatively high flash points and/or low VOC
characteristics, these terms having conventional meanings as used
in the dry cleaning industry, to equal to or exceed the
characteristics of known conventional dry cleaning fluids.
[0206] Non-limiting examples of suitable lipophilic fluid materials
include siloxanes, other silicones, hydrocarbons, glycol ethers,
glycerine derivatives such as glycerine ethers, perfluorinated
amines, perfluorinated and hydrofluoroether solvents,
low-volatility nonfluorinated organic solvents, diol solvents,
other environmentally-friendly solvents and mixtures thereof.
[0207] "Siloxane" as used herein means silicone fluids that are
non-polar and insoluble in water or lower alcohols. Linear
siloxanes (see for example U.S. Pat. Nos. 5,443,747, and 5,977,040)
and cyclic siloxanes are useful herein, including the cyclic
siloxanes selected from the group consisting of
octamethyl-cyclotetrasiloxane (tetramer),
dodecamethyl-cyclohexasiloxane (hexamer),
decamethyl-cyclopentasiloxane (pentamer, commonly referred to as
"D5") and mixtures thereof. In one embodiment, the siloxane
comprises more than about 50% cyclic siloxane pentamer, or more
than about 75% cyclic siloxane pentamer, or at least about 90% of
the cyclic siloxane pentamer. In another embodiment, the suitable
siloxane is a mixture of cyclic siloxanes having at least about 90%
(or at least about 95%) pentamer and less than about 10% (or less
than about 5%) tetramer and/or hexamer.
[0208] The lipophilic fluid can include any fraction of
dry-cleaning solvents, especially newer types including fluorinated
solvents, or perfluorinated amines. Some perfluorinated amines such
as perfluorotributylamines, while unsuitable for use as lipophilic
fluid, may be present as one of many possible adjuncts present in
the lipophilic fluid-containing composition.
[0209] Other suitable lipophilic fluids include, but are not
limited to, diol solvent systems e.g., higher diols such as C.sub.6
or C.sub.8 or higher diols, organosilicone solvents including both
cyclic and acyclic types, and the like, and mixtures thereof.
[0210] Non-limiting examples of low volatility non-fluorinated
organic solvents include for example OLEAN.RTM. and other polyol
esters, or certain relatively nonvolatile biodegradable mid-chain
branched petroleum fractions.
[0211] Non-limiting examples of glycol ethers include propylene
glycol methyl ether, propylene glycol n-propyl ether, propylene
glycol t-butyl ether, propylene glycol n-butyl ether, dipropylene
glycol methyl ether, dipropylene glycol n-propyl ether, dipropylene
glycol t-butyl ether, dipropylene glycol n-butyl ether,
tripropylene glycol methyl ether, tripropylene glycol n-propyl
ether, tripropylene glycol t-butyl ether, tripropylene glycol
n-butyl ether.
[0212] Non-limiting examples of other silicone solvents, in
addition to the siloxanes, are well known in the literature, see,
for example, Kirk Othmer's Encyclopedia of Chemical Technology, and
are available from a number of commercial sources, including GE
Silicones, Toshiba Silicone, Bayer, and Dow Corning. For example,
one suitable silicone solvent is SF-1528 available from GE
Silicones.
[0213] Non-limiting examples of suitable glycerine derivative
solvents for use in the methods and/or apparatuses of the present
invention have the following structure: 1
[0214] wherein R.sup.1, R.sup.2 and R.sup.3 are each independently
selected from: H; branched or linear, substituted or unsubstituted
C.sub.1-C.sub.30 alkyl, C.sub.2-C.sub.30 alkenyl, C.sub.1-C.sub.30
alkoxycarbonyl, C.sub.3-C.sub.30 alkyleneoxyalkyl, C.sub.1-C.sub.30
acyloxy, C.sub.7-C.sub.30 alkylenearyl; C.sub.4-C.sub.30
cycloalkyl; C.sub.6-C.sub.30 aryl; and mixtures thereof. Two or
more of R.sup.1, R.sup.2 and R.sup.3 together can form a
C.sub.3-C.sub.8 aromatic or non-aromatic, heterocyclic or
non-heterocyclic ring.
[0215] Non-limiting examples of suitable glycerine derivative
solvents include 2,3-bis(1,1-dimethylethoxy)-1-propanol;
2,3-dimethoxy-1-propanol; 3-methoxy-2-cyclopentoxy-1-propanol;
3-methoxy-1-cyclopentoxy-2-propanol; carbonic acid
(2-hydroxy-1-methoxymethyl)ethyl ester methyl ester; glycerol
carbonate and mixtures thereof.
[0216] Non-limiting examples of other environmentally-friendly
solvents include lipophilic fluids that have an ozone formation
potential of from about 0 to about 0.31, lipophilic fluids that
have a vapor pressure of from about 0 to about 0.1 mm Hg, and/or
lipophilic fluids that have a vapor pressure of greater than 0.1 mm
Hg, but have an ozone formation potential of from about 0 to about
0.31. Non-limiting examples of such lipophilic fluids that have not
previously been described above include carbonate solvents (i.e.,
methyl carbonates, ethyl carbonates, ethylene carbonates, propylene
carbonates, glycerine carbonates) and/or succinate solvents (i.e.,
dimethyl succinates).
[0217] "Ozone Reactivity" as used herein is a measure of a VOC's
ability to form ozone in the atmosphere. It is measured as grams of
ozone formed per gram of volatile organics. A methodology to
determine ozone reactivity is discussed further in W. P. L. Carter,
"Development of Ozone Reactivity Scales of Volatile Organic
Compounds", Journal of the Air & Waste Management Association,
Vol. 44, Pages 881-899, 1994. "Vapor Pressure" as used can be
measured by techniques defined in Method 310 of the California Air
Resources Board.
[0218] In one embodiment, the lipophilic fluid comprises more than
50% by weight of the lipophilic fluid of cyclopentasiloxanes,
("D5") and/or linear analogs having approximately similar
volatility, and optionally complemented by other silicone
solvents.
[0219] Compositions
[0220] The cleaning agents and the fabric care agents can vary
widely and can be used at widely ranging levels. Typically, for a
given fabric treating agent, when present in the composition,
comprises from about 0.1% to about 80%, or from about 1% to about
60%, or from about 5% to about 50% by weight of the composition. In
some embodiments, water is included in the composition as the
carrier; water can be present at a level from about 0.1% to about
99%, or from about 1% to about 90%, or from about 10% to about 80%
by weight of the composition.
[0221] When the composition is diluted with the lipophilic fluid,
water and/or polar solvents to form the wash liquor, a given fabric
treating agent, when present, typically comprises from about 0.01%
to about 50%, or from about 0.1% to about 30%, or from about 1% to
about 20% by weight of the wash liquor.
[0222] However, certain agents are used in much lower level in the
compositions. For example, detersive enzymes such as proteases,
amylases, cellulases, lipases and the like as well as bleach
catalysts including the macrocyclic types having manganese or
similar transition metals all useful in laundry and cleaning
products are typically used in a composition at very low levels,
typically from about 0.01% to less than about 5%, by weight of the
composition.
[0223] Some suitable cleaning agents include, but are not limited
to, soil release polymers, surfactants, bleaches, enzymes,
perfumes, and mixtures thereof.
[0224] Suitable fabric care agents include, but are not limited to,
finishing polymers, softening agents, perfumes, finishing agents,
wrinkle control agents, shrinkage reducing agents, anti-static
agents, and mixtures thereof.
[0225] Some of these cleaning or fabric care agents are described
in detail below.
[0226] One class of suitable soil release polymers includes
fluorine-containing soil release polymer (fluoro-SRPs),
specifically, copolymers derived from perfluoroalkyl monomers and
alkyl methacylate monomers, commercially available under the
tradename ZONYL.RTM. from E. I. du Pont de Nemours and Company of
Wilmington, Del. Also commercially available is REPEARL F35.RTM.,
which contains fluoro-SRP in an aqueous suspension form from
Mitsubishi. Other suitable fluoro-SRPs are disclosed in WO
01/98384, WO 01/81285; JP 10-182814; JP 2000-273067; WO 98/4160213,
and WO 99/69126.
[0227] Another class of suitable soil release polymers includes
silicone-containing soil release polymer (Si-SRPs). Exemplary
Si-SRPs are commercially available as DF104, DF1040, SM2125,
SM2245, SM2101, SM2059 from GE, and Dow Corning 75SF.RTM.
Emulsion.
[0228] Also suitable for use as soil release polymer in the present
invention are water soluble modified celluloses which include, but
are not limited to: carboxymethylcellulose, hydroxypropylcellulose,
methylcellulose, and like compounds. These compounds, and other
suitable compounds, are described in Kirk Othmer Encyclopedia of
Chemical Technology, 4.sup.th Edition, vol. 5, pages 541-563, under
the heading of "Cellulose Ethers", and in the references cited
therein.
[0229] Another class of suitable soil release polymers may comprise
block copolymers of polyalkylene terephthalate and polyoxyethylene
terephthalate, and block copolymers of polyalkylene terephthalate
and polyethylene glycol. These compounds are disclosed in details
in are discussed in U.S. Pat. Nos. 6,358,914 and 4,976,879.
[0230] Another class of soil release polymer is a crystallizable
polyester comprising ethylene terephthalate monomers, oxyethylene
terephthalate monomers, or mixtures thereof. Examples of this
polymer are commercially available as Zelcon 4780.RTM. (from
DuPont) and Milease T.RTM. (from ICI). A more complete disclosure
of these soil release agents is contained in EP 0 185 427 A1.
[0231] The surfactant suitable for use in the present invention has
the general formula:
Y.sub.u-(T.sub.t-X.sub.v).sub.x-Y'.sub.w (I)
T.sub.y-(X.sub.v-Y.sub.u).sub.x-T'.sub.z (II)
[0232] and mixtures thereof;
[0233] wherein T and T' are solvent compatibilizing (or lipophilic)
moieties, which are independently selected from:
[0234] (a) C1-C22 alkyl or C4-C12 alkoxy, linear or branched,
cyclic or acyclic, saturated or unsaturated, substituted or
unsubstituted;
[0235] (b) siloxanes having the formula:
M.sub.aD.sub.bD'.sub.cD".sub.d (III)
[0236] wherein a is 0-2; b is 0-1000; c is 0-50; d is 0-50,
provided that a+c+d is at least 1;
[0237] M of formula (III) is R.sub.3-e.sup.1X.sub.eSiO.sub.1/2
wherein R.sup.1 of formula (III) is independently H, or an alkyl
group, X of formula (III) is hydroxyl group, and e is 0 or 1;
[0238] D of formula (III) is R.sub.2.sup.4SiO.sub.2/2 wherein
R.sup.4 of formula (III) is independently H or an alkyl group;
[0239] D' of formula (III) is R.sub.2.sup.5SiO.sub.2/2 wherein
R.sup.5 of formula (III) is independently H, an alkyl group, or
(CH.sub.2).sub.f(C.sub.6Q.sub.4).sub.gO--(C.sub.2H.sub.4O).sub.h-(C.sub.3-
H.sub.6O).sub.i(C.sub.kH.sub.2k).sub.j-R.sup.3, provided that at
least one R.sup.5 of formula (III) is
(CH.sub.2).sub.f(C.sub.6Q.sub.4).sub.gO--(C.s-
ub.2H.sub.4O).sub.h--(C.sub.3H.sub.6O).sub.i(C.sub.kH.sub.2k).sub.j-R.sup.-
3, wherein R.sup.3 of formula (III) is independently H, an alkyl
group or an alkoxy group, f of formula (III) is 1-10, g of formula
(III) is 0 or 1, h of formula (III) is 1-50, i of formula (III) is
0-50, j of formula (III) is 0-50, k of formula (III) is 4-8;
C.sub.6Q.sub.4 of formula (III) is unsubstituted or substituted
with Q of formula (III) is independently H, C.sub.1-10 alkyl,
C.sub.1-10 alkenyl, and mixtures thereof.
[0240] D" of formula (III) is R.sub.2.sup.6SiO.sub.2/2 wherein
R.sup.6 of formula (III) is independently H, an alkyl group or
(CH.sub.2).sub.l(C.sub.6Q.sub.4).sub.m(A).sub.n-[(L).sub.o-(A').sub.p-].s-
ub.q-(L').sub.rZ(G).sub.s, wherein l of formula (U') is 1-10; m of
formula (III) is 0 or 1; n of formula (III) is 0-5; o of formula
(III) is 0-3; p of formula (III) is 0 or 1; q of formula (III) is
0-10; r of formula (III) is 0-3; s of formula (III) is 0-3;
C.sub.6Q.sub.4 of formula (III) is unsubstituted or substituted
with Q of formula (III) is independently H, C.sub.1-10 alkyl,
C.sub.1-10 alkenyl, and mixtures thereof; A and A' of formula (Ell)
are each independently a linking moiety representing an ester, a
keto, an ether, a thio, an amido, an amino, a C.sub.1-4
fluoroalkyl, a C.sub.1-4 fluoroalkenyl, a branched or straight
chained polyalkylene oxide, a phosphate, a sulfonyl, a sulfate, an
ammonium, and mixtures thereof; L and L' of formula (III) are each
independently a C.sub.1-30 straight chained or branched alkyl or
alkenyl or an aryl which is unsubstituted or substituted; Z of
formula (III) is a hydrogen, carboxylic acid, a hydroxy, a
phosphato, a phosphate ester, a sulfonyl, a sulfonate, a sulfate, a
branched or straight-chained polyalkylene oxide, a nitryl, a
glyceryl, an aryl unsubstituted or substituted with a C.sub.1-30
alkyl or alkenyl, a carbohydrate unsubstituted or substituted with
a C.sub.1-10 alkyl or alkenyl or an ammonium; G of formula (III) is
an anion or cation such as H.sup.+, Na.sup.+, Li.sup.+, K.sup.+,
NH.sub.4.sup.+, Ca.sup.+2, Mg.sup.+2, Cl.sup.-, Br.sup.-, I.sup.-,
mesylate or tosylate;
[0241] Y and Y' are hydrophilic moieties, which are independently
selected from hydroxy; polyhydroxy; C1-C3 alkoxy; mono- or di-
alkanolamine; C1-C4 alkyl substituted alkanolamine; substituted
heterocyclic containing O, S, N; sulfates; carboxylate; carbonate;
and when Y and/or Y' is ethoxy (EO) or propoxy (PO), it must be
capped with R, which is selected from the group consisting of:
[0242] (i) a 4 to 8 membered, substituted or unsubstituted,
heterocyclic ring containing from 1 to 3 hetero atoms; and
[0243] (ii) linear or branched, saturated or unsaturated,
substituted or unsubstituted, cyclic or acyclic, aliphatic or
aromatic hydrocarbon radicals having from about 1 to about 30
carbon atoms;
[0244] X is a bridging linkage selected from O; S; N; P; C1 to C22
alkyl, linear or branched, saturated or unsaturated, substituted or
unsubstituted, cyclic or acyclic, aliphatic or aromatic,
interrupted by O, S, N, P; glycidyl, ester, amido, amino,
PO.sub.4.sup.2-, HPO.sub.4, PO.sub.3.sup.2-, HPO.sub.3.sup.-, which
are protonated or unprotonated;
[0245] u and w are integers independently selected from 0 to 20,
provided that u+w>1;
[0246] t is an integer from 1 to 10;
[0247] v is an integer from 0 to 10;
[0248] x is an integer from 1 to 20; and
[0249] y and z are integers independently selected from 1 to
10.
[0250] Nonlimiting examples of surfactants having the above formula
include alkanolamines; phophate/phosphonate esters; gemini
surfactants including, but are not limited to, gemini diols, gemini
amide alkoxylates, gemini amino alkoxylates; capped nonionic
surfactants; capped silicone surfactants such as nonionic silicone
ethoxylates, silicone amine derivatives; alkyl alkoxylates; polyol
surfactants; and mixtures thereof.
[0251] Yet another class of suitable surfactants are
organosulfosuccinates, with carbon chains of from about 6 to about
20 carbon atoms. In one embodiment, the organosulfosuccinates
contain dialkly chains, each with carbon chains of from about 6 to
about 20 carbon atoms. IN another embodiment, the
organosulfosuccinates have chains containing aryl or alkyl aryl,
substituted or unsubstituted, branched or linear, saturated or
unsaturated groups. Nonlimiting commercially available examples of
suitable organosulfosuccinate surfactants are available under the
trade names of Aerosol OT.RTM. and Aerosol TR-70.RTM. (ex.
Cytec).
[0252] Nonlimiting examples of suitable bleaches are selected from
the group consisting of catalytic metal complexes, activated
peroxygen sources, bleach activators, bleach boosters,
photobleaches, free radical initiators and hyohalite bleaches.
[0253] Examples of suitable catalytic metal complexes include, but
are not limited to, manganese-based catalysts such as
Mn.sub.2.sup.IV
(u-O).sub.3(1,4,7-trimethyl-1,4,7-triazacyclononane).sub.2(PF.sub.6).sub.-
2 disclosed in U.S. Pat. No. 5,576,282, cobalt based catalysts
disclosed in U.S. Pat. No. 5,597,936 such as cobalt pentaamine
acetate salts having the formula [Co(NH.sub.3).sub.5OAc] T.sub.Y,
wherein "OAc" represents an acetate moiety and "T.sub.Y" is an
anion; transition metal complexes of a macropolycyclic rigid
ligand--abbreviated as "MRL". Suitable metals in the MRLs include
Mn, Fe, Co, Ni, Cu, Cr, V, Mo, W, Pd, and Ru in their various
oxidation states. Examples of suitable MRLs include:
dichloro-5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexadecane
manganese(II),
dichloro-5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexad- ecane
manganese(III) hexafluorophosphate and
dichloro-5-n-butyl-12-methyl--
1,5,8,12-tetraaza-bicyclo[6.6.2]hexadecane manganese(II). Suitable
transition metal MRLs are readily prepared by known procedures,
such as taught for example in WO 00/332601, and U.S. Pat. No.
6,225,464.
[0254] Suitable activated peroxygen sources include, but are not
limited to, preformed peracids, a hydrogen peroxide source in
combination with a bleach activator, or a mixture thereof. Suitable
preformed peracids include, but are not limited to, compounds
selected from the group consisting of percarboxylic acids and
salts, percarbonic acids and salts, perimidic acids and salts,
peroxymonosulfuric acids and salts, and mixtures thereof. Suitable
sources of hydrogen peroxide include, but are not limited to,
compounds selected from the group consisting of perborate
compounds, percarbonate compounds, perphosphate compounds and
mixtures thereof. Suitable types and levels of activated peroxygen
sources are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and
6,326,348 B1 that are incorporated by reference.
[0255] Suitable bleach activators include, but are not limited to,
perhydrolyzable esters and perhydrolyzable imides such as,
tetraacetyl ethylene diamine, octanoylcaprolactam,
benzoyloxybenzenesulphonate, nonanoyloxybenzenesulphonate,
benzoylvalerolactam, dodecanoyloxybenzenesulphonate.
[0256] Suitable bleach boosters include, but are not limited to,
those described U.S. Pat. No. 5,817,614.
[0257] Nonlimiting examples of suitable enzymes include proteases,
amylases, cellulases, lipases, and others. Suitable proteases
include subtilisins from Bacillus [e.g. subtilis, lentus,
licheniformis, amyloliquefaciens (BPN, BPN'), alcalophilus,] under
the tradenames of Esperase.RTM., Alcalase.RTM., Everlase.RTM. and
Savinase.RTM. (from Novozymes), BLAP and variants (from Henkel).
Other suitable proteases are described in EP130756, WO 91/06637, WO
95/10591 and WO 99/20726. Suitable amylases (.alpha. and/or .beta.)
are described in WO 94/02597 and WO 96/23873. Nonlimiting examples
of commercially available amylases include Purafect Ox Am.RTM.
(from Genencor) and Termamyl.RTM., Natalase .RTM., Ban.RTM.,
Fungamyl.RTM. and Duramyl.RTM. (from Novozymes). Suitable
cellulases include bacterial or fungal cellulases, such as those
produced by Humicola insolens, particularly DSM 1800 [commercially
available as Carezyme.RTM.]. Other suitable cellulases are the
EGIII cellulases produced by Trichoderma longibrachiatum. Suitable
lipases include those produced by Pseudomonas and Chromobacter
groups. Nonlimiting examples of commercially available lipases
include Lipolase.RTM., Lipolase Ultra.RTM., Lipoprime.RTM. and
Lipex.RTM. from Novozymes. Also suitable for use herein are
cutinases [EC 3.1.1.50]; esterases; carbohydrases such as mannanase
(U.S. Pat. No. 6,060,299); pectate lyase (WO 99/27083)
cyclomaltodextringlucanotransferase (WO 96/33267); and
xyloglucanase (WO 99/02663). Additionally, nonlimiting examples of
bleaching enzymes include peroxidases, accases, oxygenases, (e.g.
catechol 1,2 dioxygenase, lipoxygenase (WO 95/26393), (non-heme)
haloperoxidases.
[0258] As used herein the term "perfume" refers to any odoriferous
material. Suitable perfumes include but are not limited to one or
more aromatic chemicals, naturally derived oils and mixtures
thereof. Chemical classes for such aromatic chemicals and essential
oils include but are not limited to alcohols, aldehydes, esters,
ketones. Perfume is commonly provided with a perfume delivery
system.
[0259] Suitable perfume delivery systems include but are not
limited to perfume loaded cyclodextrins, amine assisted delivery
compositions, polymer-assisted perfume systems,
reactive/pro-perfume systems and inorganic carrier systems. Perfume
loaded cyclodextrin delivery compositions comprise perfume
materials or blends complexed with cyclodextrin type materials--a
majority of the cyclodextrin may be alpha-, beta-, and/or
gamma-cyclodextrin, or simply beta-cyclodextrin. Processes for
producing cyclodextrins and cyclodextrin delivery compositions are
further described in U.S. Pat. Nos. 3,812,011, 4,317,881, 4,418,144
and 5,552,378.
[0260] Amine assisted delivery systems comprise one or more
perfumes and a polymeric and/or non-polymeric amine material that
is added separately from the perfume to the finished products. Such
systems are described in WO 03/33635 and WO 03/33636.
[0261] Polymer-assisted delivery systems use physical bonding of
polymeric materials and perfumes to deliver perfume materials.
Suitable polymer assisted systems, include but not limited to,
reservoir systems (coacervates, microcapsules, starch
encapsulates), and matrix systems (polymer emulsions, latexes).
Such systems are further described in WO 01/79303, WO 00/68352, WO
98/28339, and U.S. Pat. Nos. 5,188,753 and 4,746,455.
[0262] Reactive/pro perfumes systems include, but are not limited
to, polymeric pro-perfumes that comprise perfume materials,
typically aldehyde or ketone perfumes, reacted with polymeric
carriers, typically nitrogen based carriers, prior to addition to a
product; non-polymeric pro-perfume systems that comprise perfume
materials reacted with non-polymeric materials for example, Michael
adducts (.beta.-amino ketones), Schiff bases (imines),
oxazolidines, .beta.-keto esters, orthoesters and photo
pro-perfumes. Such systems are further described in WO 00/24721, WO
02/83620 and U.S. Pat. Nos. 6,013,618 and 6,451,751.
[0263] Inorganic carrier systems that comprise inorganic materials
(porous zeolites, silicas, etc.) that are loaded with one or more
perfume materials. Such systems are further described in U.S. Pat.
Nos.: 5,955,419, 6,048,830 and 6,245,732.
[0264] Suitable odor control agents include agents include,
cyclodextrins, odor neutralizers, odor blockers and mixtures
thereof. Suitable odor neutralizers include aldehydes, flavanoids,
metallic salts, water-soluble polymers, zeolites, activated carbon
and mixtures thereof.
[0265] Other cleaning agents suitable for use herein include, but
are not limited to, builders including the insoluble types such as
zeolites including zeolites A, P and the so-called maximum aluminum
P as well as the soluble types such as the phosphates and
polyphosphates, any of the hydrous, water-soluble or
water-insoluble silicates, 2,2'-oxydisuccinates, tartrate
succinates, glycolates, NTA and many other ethercarboxylates or
citrates; chelants including EDTA, S,S'-EDDS, DTPA and
phosphonates; water-soluble polymers, copolymers and terpolymers;
soil release polymers; optical brighteners; processing aids such as
crisping agents and/fillers; anti-redeposition agents; hydrotropes,
such as sodium, or calcium cumene sulfonate, potassium
napthalenesulfonate, or the like, humectant; other perfumes or
pro-perfumes; dyes; photobleaches; thickeners; simple salts;
alkalis such as those based on sodium or potassium including the
hydroxides, carbonates, bicarbonates and sulfates and the like; and
combinations of one or more of these compositions.
[0266] Suitable finishing aids includes, but are not limited to,
finishing polymers, fabric softening agents, anti-static agents,
odor control agent, odor neutralizers, perfume, insect and/or moth
repelling agents and mixtures thereof.
[0267] The finishing polymers can be natural, or synthetic, and can
act by forming a film, and/or by providing adhesive properties. For
example, the present invention can optionally use film-forming
and/or adhesive polymer to impart shape retention to fabric,
particularly clothing. By "adhesive" it is meant that when applied
as a solution or a dispersion to a fiber surface and dried, the
polymer can attach to the surface. The polymer can form a film on
the surface, or when residing between two fibers and in contact
with the two fibers, it can bond the two fibers together.
[0268] Nonlimiting examples of the finishing polymer that are
commercially available are: polyvinylpyrrolidone/dimethylaminoethyl
methacrylate copolymer, such as Copolymer 958.RTM., molecular
weight of about 100,000 and Copolymer 937, molecular weight of
about 1,000,000, available from GAF Chemicals Corporation; adipic
acid/dimethylaminohydroxypropyl diethylenetriamine copolymer, such
as Cartaretin F-4.RTM. and F-23, available from Sandoz Chemicals
Corporation; methacryloyl ethyl betaine/methacrylates copolymer,
such as Diaformer Z-SM.RTM., available from Mitsubishi Chemicals
Corporation; polyvinyl alcohol copolymer resin, such as Vinex
2019.RTM., available from Air Products and Chemicals or
Moweol.RTM., available from Clariant; adipic acid/epoxypropyl
diethylenetriamine copolymer, such as Delsette 101.RTM., available
from Hercules Incorporated; polyamine resins, such as Cypro
515.RTM., available from Cytec Industries; polyquaternary amine
resins, such as Kymene 557H.RTM., available from Hercules
Incorporated; and polyvinylpyrrolidone/acrylic acid, such as
Sokalan EG 310.RTM., available from BASF.
[0269] Additional examples of suitable finishing polymers include
but are not limited to starch carboxymethyl cellulose,
hydroxypropyl methyl cellulose, and mixtures thereof.
[0270] Suitable fabric softening agents or actives typically
comprise a cationic moiety, such as a quaternary ammonium salt,
which may be selected from the group consisting of:
N,N-dimethyl-N,N-di(tallowyloxyeth- yl) ammonium methylsulfate,
N-methyl-N-hydroxyethyl-N,N-di(canoyloxyethyl) ammonium
methylsulfate and mixtures thereof. Additional examples of fabric
softening agents include but are not limited to silicone or
silicone emulsions (e.g., aminosilicones, cationic silicones),
polyol polyesters (e.g., sucrose ester derivatives, and mixtures
thereof.
[0271] Exemplary anti-static agents include fabric softeners which
have a fatty acyl group which has an iodine value of above 20, such
as N,N-di(tallowoyl-oxy-ethyl)-N,N-dimethyl ammonium methylsulfate.
However, it is to be understood that the term antistatic agent is
not to be limited to just this subset of fabric softeners and
includes all antistatic agents.
[0272] Exemplary insect and moth repellent agents useful in the
present invention can include perfume ingredients, such as
citronellol, citronellal, citral, linalool, cedar extract, geranium
oil, sandalwood oil, 2-(diethylphenoxy)ethanol, 1-dodecene, etc.
Other examples of insect and/or moth repellents useful in the
composition of the present invention are disclosed in U.S. Pat.
Nos. 4,449,987; 4,693,890; 4,696,676; 4,933,371; 5,030,660;
5,196,200; and in "Semio Activity of Flavor and Fragrance Molecules
on Various Insect Species", B. D. Mookherjee et al., published in
Bioactive Volatile Compounds from Plants, ASC Symposium Series 525,
R. Teranishi, R. G. Buttery, and H. Sugisawa, 1993, pp. 35-48, all
of said patents and publications being incorporated herein by
reference.
[0273] Kit
[0274] A kit comprising a plurality of components is another aspect
of the present invention. The components of the kit include, but
are not limited to:
[0275] (a) a fabric finishing composition and/or a detergent
composition as described herein;
[0276] (b) a reservoir for storing the composition;
[0277] (c) a dispensing device for dispensing the composition;
[0278] (d) attachment means for removably attaching the reservoir
and/or the dispensing device to a fabric treatment apparatus;
[0279] (e) packaging or container for containing components
(a-d).
[0280] The kit may further comprise a set of instructions, in
association with the reservoir or the packaging, on how to use the
kit. In one embodiment, the instruction may comprise two subsets of
instructions. One subset instructs the user to assemble the
components of the kit such that the dispensing device is in fluid
communication with the composition in the reservoir. The other
subset instructs the user how to attach and detach the reservoir
and/or the dispensing device to the fabric treatment apparatus. In
another embodiment where the dispensing device and the reservoir
form an integral unit, the instructions need only to instruct the
user how to attach and detach the integral unit to the fabric
treatment apparatus.
[0281] While particular embodiments of the present invention have
been illustrated and described, it would be apparent to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
[0282] All percentages stated herein are by weight unless otherwise
specified. It should be understood that every maximum numerical
limitation given throughout this specification will include every
lower numerical limitation, as if such lower numerical limitations
were expressly written herein. Every minimum numerical limitation
given throughout this specification will include every higher
numerical limitation, as if such higher numerical limitations were
expressly written herein. Every numerical range given throughout
this specification will include every narrower numerical range that
falls within such broader numerical range, as if such narrower
numerical ranges were all expressly written herein.
[0283] All documents cited are, in relevant part, incorporated
herein by reference; the citation of any document is not to be
construed as an admission that it is prior art with respect to the
present invention.
* * * * *