U.S. patent application number 11/059078 was filed with the patent office on 2005-09-01 for concave composition carrier for multiple use fabric conditioning article.
Invention is credited to Trinh, Toan.
Application Number | 20050192203 11/059078 |
Document ID | / |
Family ID | 34891478 |
Filed Date | 2005-09-01 |
United States Patent
Application |
20050192203 |
Kind Code |
A1 |
Trinh, Toan |
September 1, 2005 |
Concave composition carrier for multiple use fabric conditioning
article
Abstract
Concave composition carrier for multiple use fabric conditioning
article.
Inventors: |
Trinh, Toan; (Maineville,
OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY
INTELLECTUAL PROPERTY DIVISION
WINTON HILL TECHNICAL CENTER - BOX 161
6110 CENTER HILL AVENUE
CINCINNATI
OH
45224
US
|
Family ID: |
34891478 |
Appl. No.: |
11/059078 |
Filed: |
February 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60548374 |
Feb 27, 2004 |
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60550555 |
Mar 5, 2004 |
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60550669 |
Mar 5, 2004 |
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60550557 |
Mar 5, 2004 |
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60555950 |
Mar 24, 2004 |
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60560121 |
Apr 7, 2004 |
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60591032 |
Jul 26, 2004 |
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Current U.S.
Class: |
510/515 |
Current CPC
Class: |
D06M 13/46 20130101;
D06F 58/203 20130101; C11D 17/047 20130101; D06F 39/02 20130101;
D06M 23/02 20130101 |
Class at
Publication: |
510/515 |
International
Class: |
D06L 001/00 |
Claims
What is claimed is:
1. A fabric conditioning article comprising a composition carrier
comprising a first side and a second side, wherein said first side
is capable of releasing a fabric conditioning composition; wherein
said fabric conditioning composition is capable of being
operatively attached to said composition carrier from said first
side; wherein the second side of said composition carrier is
concave at least before a fabric conditioning composition is
operatively attached.
2. The article of claim 1, wherein the second side of said
composition carrier is concave before a fabric conditioning
composition is operatively attached.
3. The article of claim 1, wherein said fabric conditioning
composition comprises a fabric conditioning component, a carrier
component, and optionally a perfume component.
4. The article of claim 1, wherein said fabric conditioning
composition comprises a smaller volume in the solid state than in
the molten liquid state.
5. The article of claim 4, wherein the volume of said fabric
conditioning composition in the solid state is less than about 98%
the volume of said fabric conditioning composition in the molten
liquid state.
6. The article of claim 5, wherein the volume of said fabric
conditioning composition in the solid state is less than about 95%
the volume of said fabric conditioning composition in the molten
liquid state.
7. The article of claim 6, wherein the volume of said fabric
conditioning composition in the solid state is less than about 92%
the volume of said fabric conditioning composition in the molten
liquid state.
8. The article of claim 7, wherein the volume of said fabric
conditioning composition in the solid state is less than about 89%
the volume of said fabric conditioning composition in the molten
liquid state.
9. The article of claim 8, wherein the volume of said fabric
conditioning composition in the solid state is less than about 86%
the volume of said fabric conditioning composition in the molten
liquid state.
10. The article of claim 1, wherein the second side of said
composition carrier has a concavity index of from about 0.001 to
about 0.1.
11. The article of claim 1, wherein the second side of said
composition carrier has a concavity index of from about 0.002 to
about 0.06.
12. The article of claim 1, wherein the second side of said
composition carrier has a concavity index of from about 0.003 to
about 0.04.
13. The article of claim 1, wherein the second side of said
composition carrier has a concavity index of from about 0.004 to
about 0.03.
14. The article of claim 10, wherein the concavity of said
composition carrier has a curvature that is selected from an arc of
a circle, a symmetrical arc of a parabola, a symmetrical arc of a
catenary, an inverted V-shape, or combinations thereof.
15. The article of claim 1, wherein said composition carrier is
made of high melting plastic.
16. The article of claim 1, wherein the first side of said
composition carrier comprises an indicium.
17. The article of claim 16, wherein said indicium is chosen from a
word, phrase, letter, character, brand name, company name, company
logo or symbol, description, logo, icon, perfume name, design,
designer name, symbol, motif, insignia, figure, mark, signal,
color, texture, shape, token, advertisement, and combinations
thereof.
18. The article of claim 17, wherein said indicium is chosen from a
word, phrase, brand name, company name, description, perfume name,
designer name, advertisement, and combinations thereof, and wherein
said indicium is in one or more than one language.
19. The article of claim 2, wherein said article comprises at least
one of adhesive, glue, double sided tape, hook and loop or
reclosable fastener type device, screws, bolts, magnets, and
combinations thereof, for operably connecting to an inside surface
of a clothes dryer.
20. The article of claim 1, further comprising a docking member
comprising a first side and a second side, wherein said composition
carrier is operatively attached to said first side of said docking
member, and wherein said second side of said docking member is
releasably attached to an inner surface of a clothes dryer.
21. The article of claim 20, wherein said composition carrier
comprises a mating member to operably connect to said docking
member.
22. The article of claim 20, wherein said first side of said
docking member comprises a connecting member to operably connect to
said second side of the composition carrier, wherein said
connecting member comprises at least one of: lip, hole plug,
segment, securing tap, or combinations thereof.
23. The article of claim 20, wherein said docking member comprises
two securing tabs at both ends of the docking member.
24. The composition of claim 1, wherein the fabric conditioning
composition comprises at least one of methyl
bis(tallowamidoethyl)-2-hydr- oxyethyl ammonium methyl sulfate, and
methyl bis(hydrogenated tallowamidoethyl)-2-hydroxyethyl ammonium
methyl sulfate, methyl bis (stearyloyloxyethyl)-2-hydroxyethyl
ammonium methyl sulfate, dimethyl bis (stearyloyloxyethyl) ammonium
methyl sulfate, and/or methyl bis (hydrogenated
tallowoyloxyethyl)-2-hydroxyethyl ammonium methyl sulfate.
25. The composition of claim 1, wherein said composition carrier
comprises at least one of ethylene bisamides, primary alkylamides,
alkanolamides, polyamides, alcohols containing at least 12 carbon
atoms, alkoxylated alcohols containing at least 12 carbon atoms,
carboxylic acids containing at least about 12 carbon atoms,
derivatives thereof, and mixtures thereof.
26. The composition of claim 1, further comprising at least one of:
soil release agent, chelant, dye transfer inhibitor, dye fixative
agent, chlorine scavenging agent, optical brightener, odor control
agent, antimicrobial agent, fungicide, wrinkle control agent,
anti-oxidant, preservative, insect repellent, moth repellent,
processing aid, plasticizer, mold release agent, and mixtures
thereof.
27. A process of making the fabric conditioning article of claim 1
comprising the steps of (a) providing a composition carrier
comprising a second side comprising a concave configuration; and
(b) casting or extruding the multiple use fabric conditioning
composition onto said composition carrier.
28. A fabric conditioning article comprising a fabric conditioning
block comprising a solid fabric conditioning composition and a
composition carrier; wherein said composition carrier comprises a
first side and a second side; wherein said fabric conditioning
composition is operatively attached to said composition carrier
from said first side; wherein said fabric conditioning composition
comprises a smaller volume in the solid state than in the molten
liquid state, and wherein the second side of said composition
carrier comprises a concave configuration before said composition
carrier is attached to said fabric conditioning composition.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit to the following U.S.
Provisional Patent Applications: 60/548,374, filed Feb. 27, 2004;
60/550,555, filed Mar. 5, 2004; 60/550,669, filed Mar. 5, 2004;
60/550,557, filed Mar. 5, 2004; 60/555,950, filed Mar. 24, 2004;
60/560,121, filed Apr. 7, 2004; and 60/591,032, filed Jul. 26,
2004, the disclosures of which are all hereby incorporated by
reference.
FIELD OF THE INVENTION
[0002] The invention relates to an improved fabric conditioning
article and to methods using and manufacturing the same.
BACKGROUND OF THE INVENTION
[0003] Dryer-added fabric conditioning products provide a better
convenience to the consumer as compared to the rinse-added fabric
conditioning products because they spare the consumer the
requirement of having to be present at the beginning of the rinse
cycle.
[0004] There are two main types of dryer-added fabric conditioning
products, namely, single use products and multiple-use products.
Single use products, most commonly in the sheet form coated with a
fabric conditioning composition, calls for adding a single sheet
into an automatic clothes dryer containing a wet laundry load at
the beginning of the drying cycle. Examples of this type of product
are disclosed in U.S. Pat. No. 3,442,692 to Gaiser and U.S. Pat.
No. 3,686,025 to Morton et al.
[0005] Multiple use fabric conditioning products are placed in the
interior of the dryer to release the fabric conditioning active to
successive laundry loads. Each multiple-use product lasts many
drying cycles, from a few cycles to about 50 or more cycles. Said
product can either be an unattached article that is added to an
automatic clothes dryer and is tumbled along with a wet laundry
load, or an article that is releasably attached to the interior of
an automatic dryer drum. An example of an unattached multiple use
fabric conditioning article is disclosed in U.S. Pat. No. 3,676,199
issued Jul. 11, 1972 to Hewitt et al.
[0006] The products can be attached to the interior of the dryer,
as disclosed in U.S. patent application Publ. No. 2003/0192197 A1
published Oct. 16, 2003 to Griese et al., and U.S. patent
application Publ. No. 2003/0195130 A1 published Oct. 16, 2003 to
Lentsch et al. The softener active, which is preferably solid at
room temperature, can soften or melt under the clothes dryer
operating temperature, such as those disclosed in U.S. Pat No.
3,696,034, or only softens at a temperature above the clothes dryer
operating temperature, such as those disclosed in U.S. patent
application Publ. Nos. 2003/0192197 and 2003/0195130 A1. In use,
this type of article is attached to the inside wall of a dryer,
such as on a dryer fin, and a wet laundry load is tumbled in the
presence of said article while being dried in order to receive the
conditioning benefits. After drying, the laundry is removed but the
article is left in place and is ready for the next load of wet
laundry for drying. This article provides increased convenience to
the consumer as its use requires less effort to use than single use
products while eliminating searching for unattached multiple use
products after each drying cycle.
[0007] It is surprising that the multiple use solid fabric
conditioning compositions, such as those disclosed in U.S. patent
application Publ. No. 2003/0195130 A1, reduce their volume as they
cool to transition from the molten state to the solid state. Due to
the shrinkage, it is found that when the fabric conditioning
composition is fixedly cast or extruded onto the first side of the
composition carrier, the second side of the composition carrier,
which is originally flat, becomes warped in a manner that the
second side of the composition carrier is bent in a concave
fashion. This warping not only conveys a poor quality impression of
the product, but also can make the connecting elements such as lips
of the composition carrier and mating members of the docking member
to either fit too tightly and can make the placement and/or
replacement more difficult, or the end of the composition carrier
raised too high such that the fabric composition dispenser unit can
easily slip out of the docking member.
[0008] The present invention relates to improvements to solve this
unexpected problem.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention may take form in various components and
arrangements of components, and in various steps and arrangement of
steps. The drawings are only for purposes of illustrating the
preferred embodiments and are not to be construed as limiting the
invention.
[0010] FIG. 1 is a perspective view of a multiple use fabric
conditioning block, a composition carrier, and a docking
member;
[0011] FIG. 2a is a cross sectional view of one embodiment of a
free composition carrier;
[0012] FIG. 2b shows the concavity of the second side of the free
composition carrier of FIG. 2a;
[0013] FIG. 3a is a cross sectional view of another embodiment of a
free composition carrier; and
[0014] FIG. 3b shows the concavity of the second side of the free
composition carrier of FIG. 3a.
SUMMARY OF THE INVENTION
[0015] A first aspect of the present invention relates to a fabric
conditioning article comprising a composition carrier comprising a
first side and a second side capable of releasing a fabric
conditioning composition; wherein said fabric conditioning
composition is capable of being operatively attached to said
composition carrier from said first side; wherein the second side
of said composition carrier is concave at least before a fabric
conditioning composition is operatively attached. In one
embodiment, the second side of said composition carrier is concave
before a fabric conditioning composition is operatively attached.
In one embodiment, the fabric conditioning composition comprises a
fabric conditioning component, a carrier component, and optionally
a perfume component. In another embodiment, the fabric conditioning
composition comprises a smaller volume in the solid state than in
the molten liquid state.
[0016] In one embodiment, volume of said fabric conditioning
composition in the solid state is less than about 98% the volume of
said fabric conditioning composition in the molten liquid state. In
another embodiment, the volume of said fabric conditioning
composition in the solid state is less than about 95% the volume of
said fabric conditioning composition in the molten liquid state. In
yet another embodiment, the volume of said fabric conditioning
composition in the solid state is less than about 92% the volume of
said fabric conditioning composition in the molten liquid state. In
still another embodiment, the volume of said fabric conditioning
composition in the solid state is less than about 89% the volume of
said fabric conditioning composition in the molten liquid state. In
yet another embodiment, the volume of said fabric conditioning
composition in the solid state is less than about 86% the volume of
said fabric conditioning composition in the molten liquid
state.
[0017] In one embodiment the second side of said composition
carrier has a concavity index of from about 0.001 to about 0.1. In
another embodiment, the second side of said composition carrier has
a concavity index of from about 0.002 to about 0.06. In yet another
embodiment, the second side of said composition carrier has a
concavity index of from about 0.003 to about 0.04. In still another
embodiment, the second side of said composition carrier has a
concavity index of from about 0.004 to about 0.03.
[0018] In one embodiment, the concavity of said composition carrier
has a curvature that is selected from an arc of a circle, a
symmetrical arc of a parabola, a symmetrical arc of a catenary, an
inverted V-shape, or combinations thereof.
[0019] In one embodiment, the composition carrier is made of high
melting plastic. In another embodiment, the first side of said
composition carrier comprises an indicium. In yet another
embodiment, the indicium is chosen from a word, phrase, letter,
character, brand name, company name, company logo or symbol,
description, logo, icon, perfume name, design, designer name,
symbol, motif, insignia, figure, mark, signal, color, texture,
shape, token, advertisement, and combinations thereof. In still
another embodiment, the indicium is chosen from a word, phrase,
brand name, company name, description, perfume name, designer name,
advertisement, and combinations thereof, and wherein said indicium
is in one or more than one language.
[0020] In one embodiment, the article comprises at least one of
adhesive, glue, double sided tape, hook and loop or reclosable
fastener type device, screws, bolts, magnets, and combinations
thereof, for operably connecting to an inside surface of a clothes
dryer.
[0021] In one embodiment, the article further comprises a docking
member comprising a first side and a second side, wherein said
composition carrier is operatively attached to said first side of
said docking member, and wherein said second side of said docking
member is releasably attached to an inner surface of a clothes
dryer.
[0022] In one embodiment, the composition carrier comprises a
mating member to operably connect to said docking member. In
another embodiment, the first side of said docking member comprises
a connecting member to operably connect to said second side of the
composition carrier, wherein said connecting member comprises at
least one of: lip, hole plug, segment, securing tap, or
combinations thereof In yet another embodiment, the docking member
comprises two securing taps at both ends of the docking member.
[0023] In one embodiment, the fabric conditioning component
comprises at least one of methyl
bis(tallowamidoethyl)-2-hydroxyethyl ammonium methyl sulfate, and
methyl bis(hydrogenated tallowamidoethyl)-2-hydroxyethyl ammonium
methyl sulfate, methyl bis(stearyloyloxyethyl)-2-hydroxyethyl
ammonium methyl sulfate, dimethyl bis(stearyloyloxyethyl) ammonium
methyl sulfate, and/or methyl bis(hydrogenated
tallowoyloxyethyl)-2-hydroxyethyl ammonium methyl sulfate. In
another embodiment, the carrier component comprises at least one of
ethylene bisamides, primary alkylamides, alkanolamides, polyamides,
alcohols containing at least 12 carbon atoms, alkoxylated alcohols
containing at least 12 carbon atoms, carboxylic acids containing at
least about 12 carbon atoms, derivatives thereof, and mixtures
thereof. In yet another embodiment, the composition further
comprises at least one of soil release agent, chelant, dye transfer
inhibitor, dye fixative agent, chlorine scavenging agent, optical
brightener, odor control agent, antimicrobial agent, fungicide,
wrinkle control agent, anti-oxidant, preservative, insect
repellent, moth repellent, processing aid, plasticizer, mold
release agent, and mixtures thereof.
[0024] In one embodiment, the process of making the fabric
conditioning article comprises the steps of (a) providing a
composition carrier comprising a second side comprising a concave
configuration; and (b) casting or extruding the multiple use fabric
conditioning composition onto said composition carrier.
[0025] A second aspect of the present invention relates to a fabric
conditioning article comprising a fabric conditioning block
comprising a solid fabric conditioning composition and a
composition carrier; wherein said composition carrier comprises a
first side and a second side; wherein said fabric conditioning
composition is operatively attached to said composition carrier
from said first side; wherein said fabric conditioning composition
comprises a smaller volume in the solid state than in the molten
liquid state, and wherein the second side of said composition
carrier comprises a concave configuration before said composition
carrier is attached to said fabric conditioning composition.
DETAILED DESCRIPTION OF THE INVENTION
[0026] While the specification concludes with the claims
particularly pointing and distinctly claiming the invention, it is
believed that the present invention will be better understood from
the following description.
[0027] The compositions of the present invention can include,
consist essentially of, or consist of, the components of the
present invention as well as other ingredients described herein. As
used herein, "consisting essentially of" means that the composition
or component may include additional ingredients, but only if the
additional ingredients do not materially alter the basic and novel
characteristics of the claimed compositions or methods.
[0028] All percentages and ratios used herein are by weight of the
total composition and all measurements made are at 25.degree. C.,
unless otherwise designated. An angular degree is a planar unit of
angular measure equal in magnitude to {fraction (1/360)} of a
complete revolution.
[0029] All measurements used herein are in metric units unless
otherwise specified.
[0030] As used herein, "Multiple use" describes the ability of the
fabric conditioning block to be used to deliver a desired amount of
fabric conditioning composition to the laundry during at least two
cycles for drying laundry. In one embodiment, multiple use includes
at least about 10 cycles, in another embodiment, multiple use
includes at least about 20 cycles, in another embodiment, multiple
use includes at least about 30 cycles, in another embodiment,
multiple use includes at least about 40 cycles, in another
embodiment, multiple use includes at least about 50 cycles, and in
another embodiment, multiple use includes at least about 60 cycles,
before the fabric conditioning composition needs to be
replaced.
[0031] As used herein, a "Dryer" describes any type of laundry
dryer that uses heat and agitation to remove water from the
laundry. An exemplary dryer includes a tumble-type dryer where the
laundry is provided within a rotating drum that causes the laundry
to tumble during the operation of the dryer.
[0032] As used herein, "Laundry" refers to any textile or fabric
material, e.g., garment, that is laundered.
[0033] It has now surprisingly been discovered that a composition
carrier having a first side and a second side wherein the
composition carrier is concave at least before a fabric
conditioning composition is operatively attached provides the
benefit of producing a substantially planar or flat composition
carrier after the addition of a fabric conditioning composition.
Such a composition carrier may be utilized to form a fabric
conditioning article having a fabric conditioning block having a
fabric conditioning composition and a composition carrier.
[0034] The composition carrier is an object that is capable of
being operably connected to a solid multiple use fabric
conditioning composition. The composition carrier includes a first
side and a second side. In one embodiment, the fabric conditioning
composition is operably connected to the composition carrier by
fixedly casting or fixedly extruding the composition onto the
carrier, or in another embodiment, fixedly casting or fixedly
extruding in such a way that the portion of the composition coming
into contact with laundry is located on the first side of the
composition carrier. In the unattached state, viz., before the
fabric conditioning composition is attached to the composition
carrier, the second side of the composition carrier of the present
invention includes a concave configuration with a curvature
selected from an arc of a circle, a symmetrical arc of a parabola,
a symmetrical arc of a catenary (a hyperbolic cosine curve), a
V-shape curve, a curve containing one or more cusps, or
combinations thereof. Without wishing to be bound by theory, it is
believed that after the molten fabric conditioning composition is
cast onto the first side of the composition carrier and let cool,
the solidifying composition pulls the ends of the composition
carrier toward the side of the composition. It is believed that the
intentionally designed concavity on the second side of the
composition carrier of the present invention will compensate for
the warping of the composition carrier, and make the second side
substantially planar and/or flat, and thus improving the ease of
placing and/or replacing the fabric conditioning block on the
docking member, and/or preventing the block from accidental
slipping out of the docking member.
[0035] The composition carrier can be constructed from a variety of
materials. Materials of construction include metals, ceramics,
woods, laminates, plastics, and combinations. In one embodiment,
the composition carrier is made of one or more plastics. In yet
another embodiment, the composition carrier is made from of a high
melting plastic, including, but not limited to nylon,
polypropylene, polyethylene, and combinations thereof. One of
ordinary skill in the art would readily know how to select a
material suitable for use in a dryer. The composition carrier, if
made of plastic, may be molded, extruded, or blow molded. In one
embodiment, the first side of the composition carrier is flat or
arced. In another embodiment, the first side of said composition
carrier is neither flat nor arced.
[0036] In a preferred embodiment, the composition carrier
additionally includes an indicium. Suitable indicia that can be
used in the present invention are disclosed in the co-filed U.S.
Provisional Application No. 60/548,374, filed Feb. 27, 2004,
entitled "IMPROVED MULTIPLE USE FABRIC CONDITIONING ARTICLE WITH
REPLACEMENT INDICIUM" to Trinh et al., and references cited
therein. The indicium is preferably chosen from a word, phrase,
letter, character, brand name, company name, company logo or
symbol, description, logo, icon, perfume name, design, designer
name, symbol, motif, insignia, figure, mark, signal, color,
texture, shape, token, advertisement, and combinations thereof,
more preferably said indicium is chosen from a word, phrase, brand
name, company name, description, perfume name, designer name,
advertisement, and combinations thereof, and wherein said indicium
is in one or more than one language.
[0037] Fabric Conditioning Composition
[0038] The fabric conditioning composition of the present invention
includes a fabric conditioning component, a carrier component, and
optionally a perfume component, that is preferably substantially
solid at the operating temperature of household and/or commercial
clothes dryers (e.g., at about 90.degree. C. or higher). Exemplary
fabric conditioning components, carrier components, and perfume
components are described in U.S. patent application US 2003/0195130
and references cited therein, co-filed U.S. Provisional Application
No. 60/550,555 filed Mar. 5, 2004, entitled "MULTIPLE USE FABRIC
CONDITIONING COMPOSITION WITH IMPROVED PERFUME", to Trinh et al.,
and references cited therein; and co-filed U.S. Provisional
Application No. 60/550,557 filed Mar. 5, 2004, entitled "MULTIPLE
USE FABRIC CONDITIONING COMPOSITION WITH BLOOMING PERFUME", to
Morgan et al, and references cited therein. The fabric conditioning
component provides fabric conditioning properties to laundry such
as fabric softening or antistatic benefit. Non-limiting examples of
the fabric conditioning component include methyl
bis(tallowamidoethyl)-2-hydr- oxyethyl ammonium methyl sulfate, and
methyl bis(hydrogenated tallowamidoethyl)-2-hydroxyethyl ammonium
methyl sulfate, methyl bis (stearyloyloxyethyl)-2-hydroxyethyl
ammonium methyl sulfate, dimethyl bis (stearyloyloxyethyl) ammonium
methyl sulfate, methyl bis (hydrogenated
tallowoyloxyethyl)-2-hydroxyethyl ammonium methyl sulfate, and
mixtures thereof. Other fabric conditioning components and other
optional ingredients may include one or more of sanitizer,
deodorizer, odor control agent, soil repellant, soil release agent,
dye-transfer inhibitor, dye fixative agent, chlorine scavenging
agent, chelant, fiber protecting polymer, fiber smoother,
antimicrobial agent, fungicide, antioxidant, preservative, insect
repellent, moth repellent, Uv light absorber, optical brightener,
wrinkle control agent, processing agent, and/or mold release
agent.
[0039] The fabric conditioning composition of the present invention
shrinks in volume as it solidifies from the molten liquid state.
Thus said fabric conditioning composition has a smaller volume in
the solid state than in the molten liquid state, with the volume in
the solid state typically being less than about 98%, less than
about 95%, less than about 92%, less than about 89%, or less than
about 86% the volume in the molten liquid state.
[0040] The carrier component mixes with the fabric conditioning
component and helps the fabric conditioning component resist
transfer to laundry by melting during the drying operation. The
carrier component is chosen so that the fabric conditioning
composition exhibits a melting point or softening point that is
above the operating temperature of the dryer. In most dryer
operations, this means that the melting temperature of the fabric
conditioning composition is above about 90.degree. C. The melting
temperature or the softening temperature of the fabric conditioning
composition can be above about 95.degree. C., above about
100.degree. C., above about 110.degree. C., or above about
120.degree. C. The melting temperature of the fabric conditioning
composition can be below 200.degree. C. Non-limiting examples of
the carrier component include ethylene bisamides, primary
alkylamides, alkanolamides, polyamides, alcohols containing at
least 12 carbon atoms, alkoxylated alcohols containing at least 12
carbon atoms, carboxylic acids containing at least about 12 carbon
atoms, derivatives thereof, and mixtures thereof.
[0041] The melting temperature of the fabric conditioning
composition refers to the temperature at which the composition
begins to flow under its own weight. As the fabric conditioning
composition reaches its melting point, one will observe the
composition undergoing a transfer from a solid discreet mass to a
flowable liquid. Although a differential scanning calorimeter (DSC)
measurement of the composition may reveal that certain portions or
phases of the composition may exhibit melting at temperatures that
are within the operating temperatures of a dryer, it should be
understood that what is meant by the melting temperature of the
composition is not the melting temperature of certain portions or
phases within the composition, but the melting temperature of the
composition as demonstrated by the composition being visibly
observed as a flowable liquid. It is expected that the fabric
conditioning composition may be provided as a solid mixture
including multiple phases or as a solid solution including a single
phase.
[0042] The softening temperature of the composition refers to the
temperature at which the solid mass becomes easily deformable. For
many exemplary compositions according to the invention, it is
expected that the softening temperature will be a few degrees below
the melting temperature.
[0043] Non-limiting examples of suitable fabric conditioning
composition are described in U.S. 2003/0195130 A1 published Oct.
16, 2003 to Lentsch et al., and any continuation-in-part
applications thereof.
[0044] The fabric conditioning composition is preferably operably
connected to the composition carrier by fixedly casting or fixedly
extruding the composition onto the carrier, more preferably fixedly
casting or fixedly extruding in such a way that the portion of the
composition coming into contact with laundry is located on the
first side of the composition carrier. To facilitate this casting
or extrusion, the composition carrier may include a plurality of
apertures to allow molten fabric conditioning composition to better
adhere to the composition carrier. In one embodiment, the apertures
of the composition carrier have hexagonal shapes and are arranged
in a nonlinear, honeycomb fashion. In this embodiment, this
arrangement of apertures, without wishing to be bound by theory,
strengthens the casting or extruding of the fabric conditioning
compositions onto the composition carrier thereby preventing the
composition from breaking and shearing from the composition
carrier. In a preferred embodiment, the plurality of apertures are
countersunk on a second side of the composition carrier to allow
the solid fabric conditioning composition to be fixedly cast or
extruded onto said composition carrier.
[0045] Docking Member
[0046] The fabric conditioning article is operably connectable to
an inside surface of a dryer. In a preferred embodiment, the
article further includes a docking member to operably connect to
the inside of a dryer. Other non-limiting ways of operably
connecting the article to the inside surface of the dryer includes
the use of adhesive, glue, double sided tape (e.g., 3M, part number
4084), VELCRO.RTM. or any other suitable hook and loop or
reclosable fastener type device, screws, bolts, magnets, or other
connecting means known in the art.
[0047] In turn, a "docking member" may have a first side and/or a
second side. The composition and/or composition carrier may be
releasably affixed to the first side of the docking member and/or
the inside surface of the dryer. In one embodiment, the docking
member, preferably the first side of the docking member, includes a
connecting member to affix, preferably releasably affix, the
composition carrier, preferably the second side of the composition
carrier, to the first side of the docking member. In another
embodiment, the docking member, preferably the second side of the
docking member, includes a connecting member to affix, preferably
releasably affix, the docking member to the inside surface of a
dryer. Non-limiting examples of a connecting member include: lips
to secure mating members or mating member to secure lips; hole plug
and segment, wherein the segments releasably engage the holes; a
securing tap (e.g., "snap tap"); or combinations thereof. An
example of a docking member is described in U.S. patent application
Publication 2003/0192197 A1.
[0048] The fabric conditioning article may be operably connected on
a fin, door, or barrel of the dryer. Docking member(s) may be
angled, relative to the surface of attachment to decrease or
increase efficacy.
[0049] In one embodiment, the docking member can have the same
color as the composition carrier, or, optionally have a different
color than the composition carrier, and optionally have an
off-white color.
[0050] The docking member can be made from a variety of materials.
Materials of construction include metals, ceramics, woods,
laminates, plastics, and combinations. In one embodiment, the
docking member is made of one or more plastics. In yet another
embodiment, the docking member is made from a high melting plastic,
including, but not limited to nylon, polypropylene, polyethylene,
and combinations thereof. One of ordinary skill in the art would
readily know how to select a material suitable for use in a dryer.
The docking member, if made of plastic, may be molded, extruded, or
blow molded.
EXAMPLES
[0051] The following are intended to be non-limiting examples
further exemplifying various aspects of the present invention.
[0052] FIG. 1 is a perspective view of a multiple use fabric
conditioning block 10 and a docking member 20. The fabric
conditioning block 10 is made of a composition carrier 30 and a
solid fabric conditioning composition 40. The composition carrier
has a first side 31, a second side 32, and a circumferential third
edge 33. The fabric conditioning composition 40 is operably
connected to the composition carrier 30 by being fixedly cast or
fixedly extruded to the composition carrier 30 such that the
portion of the composition 40 coming into contact with laundry is
located on the first side 31 of the composition carrier. The
circumferential third edge 33 includes a connecting member in the
form of mating members 35 that protrude laterally out. When the
solid fabric conditioning composition 40 is connected to the
composition carrier 30, the second side 32 of the composition
carrier is flat and planar.
[0053] In this embodiment, the composition carrier 30 is operably
connectable to a docking member 20. The docking member 20 has a
first side 21, a second side 22, and a perimeter 23. The second
side 22 of the docking member 20 provides a surface onto which an
adhesive or another docking member (not shown) or other means of
operably connecting the docking member 20 to an inside surface of a
dryer. The perimeter 23 of the docking member 20 includes a rail
portion 24 bordering the docking member 20 along two sides, which
may protect the corresponding edges of the fabric conditioning
block 10, when the fabric conditioning block 10 is operably
connected the docking member 20. The docking member 20 also
includes lips 25 and one or two securing tabs 26 as connecting
members. The lips 25 extend from the rail portion 24 along two
sides. The securing tab(s) 26 is at the end(s) of the docking
member 20. When the fabric conditioning block 10 is slid into the
docking member 20 from either end, the securing tab 16 is pushed
downward and then snaps into place to border the corresponding edge
of the composition carrier 30 when operably connected to the first
side 21 of the docking member 20. The mating members 35 are
arranged similarly as the lips 25 on the docking member 20.
Therefore, the block 10 does not have to be slid into the docking
member 20 all the way from an end of the block 10. Rather, the
mating member 35 and the corresponding lips 25 are simply placed in
the spaces between the lips 25 thereby depressing the securing tab
26 concurrently. As the block 10 is slid in the docking member 20
so the lips 25 align with the mating members 35, the securing tab
26 engages the end of the block 10 thereby snap locking it into
place. This provides a shorter distance to connect the block 10 to
the docking member 20 should; for example, the walls of the dryer
prevent the block 10 from being slid into place from the end of the
docking member 20. To disengage the block 10 from the docking
member 20, the securing tab 26 is pushed downward and then the
block 10 is slid away from the lips 25 of the docking member 20.
When the mating members 35 of the composition carrier 30 no longer
align with the lips 25 of the docking member 20, the block 10 may
be removed from the docking member 20. In one embodiment, the
docking includes one securing tap 26 at one end of the docking
member, while the rail portion 24 is extended to the other end to
protect one end of the composition carrier 30. In the preferred
embodiment depicted in FIG. 1, the docking member 20 includes two
securing taps 26 situated at both ends of the docking member. This
arrangement allows block 10 to be attached from both ends of the
docking member 20.
[0054] FIG. 2a is a cross sectional view of one embodiment of a
free composition carrier 30, taken along line 1-1 of FIG. 1,
including a first side 31 and a second side 32, showing the
concavity of the second side 32. In this embodiment the concavity
of the second side 32 has a curvature that is chosen from, e.g., an
arc of a circle, a symmetrical arc of a parabola, a symmetrical arc
of a catenary (hyperbolic cosine curve), or combinations thereof.
FIG. 2b shows the concavity of the second side 32 of the free
composition carrier 30 of FIG. 2a, said concavity is characterized
by a concavity index, defined as the ratio h/2R wherein h is the
deviation from planarity of the each end of the second side 32, and
2R is the length of the composition carrier 30. The concavity index
of the composition carrier of the present invention is typically
from about 0.001 to about 0.1, preferably from about 0.002 to about
0.06, more preferably from about 0.003 to about 0.04, and even more
preferably from about 0.004 to about 0.03.
[0055] FIG. 3a is a cross sectional view of another embodiment of a
free composition carrier 30, taken along line 1-1 of FIG. 1,
including a first side 31 and a second side 32, showing the
concavity of the second side 32. In this embodiment the concavity
the second side has an inverted V-shape configuration. FIG. 3b
shows the concavity of the second side 32 of the free composition
carrier 30 of FIG. 3a, said concavity is characterized by a
concavity index, defined as the ratio h/2R wherein h is the
deviation from planarity of the each end of the second side 32, and
2R is the length of the composition carrier 30. The concavity index
of the composition carrier of the present invention is typically
from about 0.001 to about 0.1, preferably from about 0.002 to about
0.06, more preferably from about 0.003 to about 0.04, and even more
preferably from about 0.004 to about 0.03.
[0056] The disclosure of all patents, patent applications (and any
patents which issue thereon, as well as any corresponding published
foreign patent applications), and publications mentioned throughout
this description are hereby incorporated by reference herein. It is
expressly not admitted, however, that any of the documents
incorporated by reference herein teach or disclose the present
invention.
[0057] Except as otherwise noted, the articles "a", "an", and "the"
mean "one or more".
[0058] 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.
[0059] While particular embodiments of the present invention have
been illustrated and described, it would be obvious 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.
* * * * *