Note: Descriptions are shown in the official language in which they were submitted.
APPARATIJ5 AND METHOD FOR HIGHLY
EFFICIENT LAUNDERING OF TEXTILES
Wol~ang U. Spendel
TFCHN I CAL Fl ELD
The preserlt invention has relation to novel apparatus and
prosess ~or laundering of texl:iles usir;g small amounts of water
and energy without substantial soil redeposition. This r~sults in
a superior level of detergency perfiormance.
The pres~nt invention has Purther relation to navei appara-
tU5 and proeess for laundering of mixed textile loads comprised of
. disslmilar fiber and color types without substantial dye trans~er
.~rorn one textile to another
The present invention has still further relation ~o novel wash
iiquor and detergent csmpDsition ~or use in said apparatus and
process.
BACKGROU~ID INFORMATION
The conventional method of washing t~xtiles in an automatic
home-type was5 ing machine in the United States is carried out In
~ither a top loading or front loading machine. The difference
between the two machines is that in a top loader the wash basket
is rotatable around a subs~antially vertical axis and in a front
?5 loader ~he wash baske~ is ro~atable around a substan~ially hori-
zontal axis. Home-type top loading machines are, by ~ar, the
most popular, comprising about g0% of the United States' automa~ic
washing machine market.
The process ~or washing ~ex~iles in a home-type top toader
b~gins by placing the tex~iles in ~he wash baske~, In a normal
~apacity home-type top loader th~ wash bas3<et ean hold up to
about 7 kilograms of textiles. Detergent composition is then
added to the wash basket. Finally, water, which is typically
heated, is added to the wash basket to form a water and deter-
3~ gent soiution known as the wash liquor. Thus, formation of the
wash liquor is c arried out in the wash t: aslcet in the presence of
the textiles to be washed. The washing step is then cornpleted
by applying mechanic~l agitation to the system in order to loosen
and remove the soi l from the texti les .
r f~
2 -
The temperature and level of water and level of detergent
composition used in the wash step can vary. About 609~ of the
wash steps use warm water (typically around 35C~, with th~
balance being evenly split be~ween hot water (typically around
5 50C) and cold water [typically around 15C~. The level of water
and cletergent composition used in this step typical Iy ranges from
about 40 liters to about 90 liters and from about 20 grams to
about 145 grams, respeetively, depending upon the wash basket
size and load size. The resulting detergent composition concen-
~o tration in the wash liquor i from absut 210 parts per million. (ppm) to about 3,60~ ppm.
. - The wash liquor is then remov~d and the :textiles are rinsed.
The rinse step normally comprises adding clear water to the wash
basket~ Mechanical agitation is normally applied during the rinse
15 step to remove th2 detergent comps)~ition from the textiles.
Finaily, the water is drained and the textiles are spun to mech-
anically remove as much water as possible. A cold water rins~ is
used in about 60~ of the rinse steps, with the balance being warm
water rinses. The amount of water used in this step is typical~y
20 the same as that used in the wash step. The rinse step is
generally r~peated one or more times~
The wash cycle of the home-type front loader is very similar
to that of ~he home-type top loader. The temperature of the
water and detergent composition concentration used in the wash-
25 ing step are very similar to a home-type top loader. The basic
difference is that the amount of water used in each of the wash
and rinse step~ typically ranges from about 25 liters to abou~ 35
liters and, thus, the level of detergent composition i~ from about
10 grams to about 70 grarns.
The complete conventional automatic wash process in a home~
type top loader ~ypically uses from about 130 liters to abou~ 265
liters of wat~r. By way of contrast, a home-type front loader,
~hough more efficien~, ~ypically uses about 95 li~ers of water.
This too is a considerable water expenditure for one wash cycle.
35 Also, if the water is heated, there is a considerable energy
expenditure. Both water and energy are c05tly to the consumer.
~2~ 7
-- 3 --
A known drawback normally exhibited by conventional auto-
matic wash process~s of the foregoing type is tha~ soil redeposi-
tion occurs in both the wash and rinse steps. Soil redeposition
is soil that is detached from the textiles and 9025 into the wash
or rinse liquor and is then redeposited onto the textiles. Thus,
soil r~deposition substantially limits the "net" cleaning per-
Formance.
Another known drawback normally exhibited by conventisnal
automatic wash processes of the furegoing type is that dye trans-
10 fer can oscur when dealing with loads of differently coloredtextiles. Dye transfer is the detachm0nt of dye from a textile
into the wash liquor and its subsequent depositiori onto another
~ex~ileO To avoid dye trans~er the consumer has found i~ neces~
sary to perform the additional step of presorting the textiles, not
15 only by textile ~ype but also by color ~ype.
U.!;. Pater)t 4,344,198 issued to Arendt et al on August 17,
1982 claims a process ~or the washing of clothes through a wash
and rinse cycle in a washing machine wi~h a horizontal, perfor~
ated, driven tub arranged inside a hvusing wherein the tub has
20 a~ its rotating periphery a tangentia~ area, in which during the
washing and rir-sing cycle as ~he tub rotates, the clothes are
repeatedly liPted up and then fall in a trajectory path onlto the
lower portion of the tub and are then distributed wi~hout unbal-
ance to the tub, as the tub v~locity is yradually increased. The
25 clothes are then centrifuged as the velocity i5 increased fur~her.
According to Arendt, his improvement comprises the steps of
wetting the clothes with an amount of suds that gives a "doughy"
consistency to the cloth~s by filling the tub wi~h suds u~til the
level of suds does not significantly rise above the tangen~ial area
30 of the tub by maintaining in the tub during washing an aqueous
medium level of at least about 5% of the tub's diameter, whereby
the dry clothes are loaded indivldually into the tub which rotates
at a speed at which the centri~ugal velocity at the tub case is
about 0.3-0.8 g. The tub speed is ~hen increased to about 1 g.
~hen graduaily changed to a spin speed and after ~he spinning,
reduced to a velocity in keeping with the ioading speed. 7-he
process i5 thereaf~er ~ollowed wi~h a rinse cycle which is similar
~o ~he washing cycle. According ~o Arendt, the exchange
5 between "engaged" and "free" medium is achieved not so much by
leaching bu~ by the mechanTcal action of ~he tub. Finally, Arenclt
teaches ~hat water is save~ ~or the most part nolt by using
smaller ratios of total media, but by reducirlg the number of wash
and rinse cycles.
U.5~ Patent 4,118,189 issued to Reinwald et al on Oc~ober 3,
1978 discloses a wash process whieh consists of transforming a
concentrated wash liquor, by the introduction of e~mpressed air,
into 3 foam which is thereafter applied to the soiled textiles. The
te)~tiles are mechanically agitated in the ~am ~r at least ~hirty
15 seconds~ then the foam is des~royed and removed frvm the tex-
tiles by spinning the textiles in a rotary perforated drum. This
cycle is re,oea~ed at least flve ~imes~ followed by conven~ional
rinsingO Reinwald suggests that the dirt detached from the
~extile matcrial and dispersed in a relatively highly concentrated
20 detergent solution is partially deposited again on the textile fiber
during the subsequent rinsing due to a dTlution of the wash
li~u~ .
Still anothar attempt at using more c~ncentrated wash liquor
without encountering redeposition prob`lems of ~he type discussed
25 in the aforementioned patent issued to Reinwald is disclosed in
U.S. Patent 3,650,673 issued to Ehner on March 21, 1972. Ehner
disclose6 a method and apparatus for was~ng ~iles utilizing an
amount of wat~r corresponding to about 50% to 15096 of th~ dry
weight of the tex~iles. - The process consists of placing such
3û quantities of water, the textiies to be laundered and a trans~er
agent, e.g., polyethylene ~oam having a large surfaee area per
unit mass, in a rotatable enclosure similar to those employed in a
front loader type washing machine and tumbling these materials
together for a period of time. Soils removed from the textiles by
35 the tumbling action are distributed over the combined exposecl
. .
surface areas of ~he textiles and the transfer agent, which is
subseguently separated from the tex~iles. Thus, the textiles are
cleansed of the soils distributed onto the transfer agent. Ehner
admits that a quan~ity of soil will be left on the t~xtiles, but
5 teaches that it will be substantially reduced from the originai
quan~ity and will be distributed so as to leave no objectionable
areas of soil concentration. Followin~3 s~paration of ~he soil
carrying transfer agent from the textiles, the tex~iles are sub-
sequently dried in the same rotatable enclosure in whioh they are
10 i'washed" by tumbling them while circL1iating warm dry air there-
through .
UOS. Pa~ent 3,647,354 issued to Loeb on March 7, 19~2
suggests that a wash process such as that disclosed in the afore-
mentioned Ehner patent be followed by a rinse process emp.loying
15 a quantity oF water sufficient only to bring the textiles to a
condition of dampness. According to Loeb, the textiles are
tumbled in a ro~a~ing drum with a clean transfer agent which
functions in a manner similar to the transfer agent used in the
wash process to separate detergent and loosened soils from the
20 texti les .
Despite the advantages al legedly p~ovided by wash processes
of the foregoing type, they have not met with widespread com-
mercial acceptance, particularly in the home laundry market.
Accordinsly, an object of the present invention is ~o provide
25 appara~us and process for laundering textiles using a small
amount of water, yet minimizing soil redeposition and dye trans-
fer, even without presorting of the textiles ~o be laundered.
Another object of the present invention is to provide appara-
tus and process for laundering textiles which makes extr*mely
3û efficient use of ~he detergent composi~ion utilized and, if applied,
extremely efficient use of heat energy.
Another object of the present inventlon is to provide pre-
ferred apparatus and process for laundering textiles using cold
water.
A further objeet of the present invention is to provide
apparatus and proeess ~or laundering textiles which r esul~s in
sup~rior cleaning as welJ as preservation of the textiles' appear-
ance over many laundering eycles.
A still further object in a pre~rred aspect of the present
invention is to provide appara~us and process ~or laundering
textiles wherein mechanical energy can be applied to textiles
whiCh have been contacted with a concentrated wash liquor with-
out creating a suds problem.
A still further object of the present invention is to provide
wash liquor compo5ition5 and detergent compositions fior use in
said apparatus and proCess. - . .
DlSCl~OSlJRE OF THE INVENTION
The present invention cGmprises apparatus and process for
12undePing textiles bas~d upon utilizin~ quantities of an aqueous
iiquid wash liquor in the wash step ranging from, at least, just
enough to be substantially evenly and completely distributed onto
all portions of the textiles to, at most, about S times the dry
weight of the textiles to be laundered. Thi~ resul~s in an
extremely eMcient use of the detergent composition. Nearly all
of the wash liquor, and there~ore nearly all of the detergent
composition contained in the wash liquor, will be in intimate
contact with the textiles throughout the wash step of the present
laundering process. Accordingly, the e~etergent composi~ion is
able to ef~ectively and efficiently interact with the soil. This
step is crucial to the process. Consequently, a superior level of
cleanin~; performance is achieved. However, in order to obtain
such performance for the entire wash load, especially with lower
~mounts of wash liquor, it is ~ssential that the wash liquor be
substantially evenly and completely distributed onto the textiles.
In a preferred embol:liment the upper limit of 1:he quantity of wash
liquor is sush that ther~ is none or minimal amounts of wash
liquor in excess of the absorption capacity of the textiles and
more preferably the wash liquor is not in excess of about 2~ times
the dry weight of the textiles. In the final step or steps of the
process the textlles are rinsed with water to simultaneously
-- 7 --
remove both the soil and the detergent composition. A conven-
tional home-type top loacier or front loader rinse cycle is effec~iv~
~or such a purpose, bu~ the rinse can be accomplished with
reduced quantities of water. ~Nhile the process is particular1y
beneficial when carried out on ~amily-type wash ioads comprised
of mixed fabric and color types, ~he process rnay also be utilized
to advantage on an indus~rial iaundry scale.
In one aspect, the invention resides in laundering
apparatus exhibiting increased detergent efficiency in
removing soils from discre~e loads of assorted soiled
textiles, said apparatus comprising: -
a) a first compartment for xe~aining said soiled
textiles during the laundering processs
b) means for producing a quantity of concentrated
aqueous wash liquor comprising from about 40% to about
99.9% water and at least about 1000 parts per million
of a detergent composition;
c~ non-immersing applicator means for
distributing a quantity of said concentrated aqueous
wash liquor not exceeding about 1-1/2 times the dry
weight of said soiled textiles onto the surface of
said soiled textiles while said textiles are retained
in said first compartmenk and while said soiled
textiles are in a substantially dry state, there being
at most minimal amounts of free wash liquor in sa.id
first compartment after said wash liquor has been
completely distributed;
d) means for delivering said concentrated
aqueous wash liquor to said applicator means;
e) means for exposing the surfaces of
substantially all of said soiled textiles to said
applicator means while said concentrated aqueous
liquid wash liquor is being distributed in said first
compartment, whereby said wash liqucr is
subskantially e~enly and completely distributed onto
~ 7a -
the surfaces of said soiled textiles;
f) rinsing means for contacting said textiles
with a quantity of an a~ueous liquid rinse liquor
after said wash liquor has been allowed to remain in
contact with said soiled textiles for a period of time,
said quantity of rinse liquor being sufficient to
produce enough free water on the surface of the
textiles to adequately ~uspend the soil and detergent
composition; and
g) means for separating said rinse liquor
containing said wash liquor and said soils from said
textiles. This aspect of the invention is also
disclosed, and is claimed, in Canadian Patent
Application No. 415,099 of Wolfgang U. Spendel, filed
November 8, 1982, of which the present application is
a divisional.
The presen invsntion, in another aspect,
resides in a process for laundering a discrete wash
load of assorted soiled textiles comprising the steps
~0 of:
a) producing a quantity of concentxated aqueous
wash liquor comprising from about 40% to about 99.9%
water and from about 1000 ppm to about 600,000 ppm of
a detergent composition,
b) distributing substantially evenly and
completely onto said textiles in their substantially
dry state a quantity of said wash liquor ranging from
about just enough to distribute said wash liquor
substanti~llY evenly and completely onto said textiles
to a quantity of said wash liquor which is about 5 times
the dry weight of the textiles, said wash liquor
containing from about 5 grams to about 200 grams of
said detergent composition per kilogram of said
textiles;
c) allowing said wash liquor to remain in contact
with said soiled textiles for a period of time during
which, if there is more than a minimal amount of free
- 7b -
liquor in excess of the absorption capacity of s~id
textiles, only limited amounts of mechanical energy are
applied to said textiles so as to prevent oversudsing;
d) rinsing said textiles with a quantity of an
aqueous liquid, rinse liquor sufficient to produce
enough free water on the surface of said textiles to
adequately suspend the soil and the detergent
composition; and
e) separating said rinse liquor containing said
wash liquor and said soil from said textiles.
BRIEF DESCRIPTION OF THE DRAWINI~S
While the Specification conc~udes with c3a~T s particular?y
pointing out and distinctly claiming the present invention, it is
believed the present invention wiil be b~er understood from ~he
following description in which:
Figure 1 is a schematic perspective illustra~ion of parti-
cularly preferred apparatus for carrying out the present launder-
ing process;
Figure 2 is a cross-sectional illus~ration of the embodiment
disclosed in Figure 1 taken along section 3ine 2-2 of Fiyure 1;
Fi~ure 2A is an inset of the drive pulley system shown in
Fi~3ure 2 with ~he pulley-actuating cllJtch assembly in its al~er-
native position;
Figure 3 is a cross-sectional segment of the apparatus illus-
trated in Figure 1 taken in a plane which passes through the
center of the wash liquor applicator nozzle and the axis of rota-
tion of ~he movable drum disclosed in Figure l;
Figure 4 is a ~implified cross-sectional illustration of a
particularly preferred wash liguor applicator nozzle; and
Figure 5 is an end view of the wash liqllor applicator nozzle
shown in Figure 4.
DETAILED l)ESCRIPTION OF THE INVENTION
A. PREFERRED APPARATU5
Disclosed in Figure 1 is a schernatic illustration of parti-
cularly preferred apparatus for carrying out a laundering process
97
in accordance with ~he present invention. Figure 1 discloses a
preferred ernbodiment of a washing machine 10 of the present
invention. The apparatus in Figure 1 is ,:aarticularly preferred
when the quan~i~y of wash liquor u~ilized is, at most, abou~ 2~
S times ~he dry weiyht of ~he ~extiles to be iaundered. Such
maximum quantity of wash liquor approaches the maximum absorp-
tion capacity of an average wash load. For purposes of clari~y,
none of the details of the cabinet nor the access door is shown in
Figure 1.
1 0I n the embodiment of Figure 1, the washing machine l û
ccmprises a stationary drum 15 of generaliy cylindrical construc~
tion and having a horizontal access opening 20. The centerline of
the cylindrical stationary drum 15 coincides with the axis of
rotation 300 of a movable drum 40 (sometimes referred to in the
15 prior art as a wash basket) mounted within stationary drum 15.
As is more clearly illustrated in the cross-sectional views of
Fiyures 2 and 3, stationary drum lS comprises a peripheral wall
16, a back wall 17 secured to one sdge of the peripheral wall, a
front wall 1 B secured to the opposite edye of the peripheral wall,
20 said front wall having a tubular-shaped extension 19 having an
access opening 20 used to load and unload laundry from the
washing machine 10. Acoess opening 2D forms a seal with pliable
sealing gasket 210 which Is secured about its outermost periphery
to the front wall 200 of the washing machine cabinet. When the
25 washing machine lo is in operatiorl, the washing machine's access
door 2~0 is in the closed po~ition shown Tn Fiyure 2 and forms a
water~ight seal against the outermost portion of pliabJe sealing
gasket 210. These latter elemerits are illustrated only in the
cross-section of Figure 2 to ensure maximum clarity in the
30 remaining drawing figuresO The lowermost portion of stationary
drum 15 is provided with a drain c:onnection 21 located in peri
pheral wall 16. The drain connection 2t is connected by means of
a flexible connecting line 142 to the suction side of a rinse liquor
discharge pump 140 which is secured ~y means of support 141 to
07
_ 9 _
the base of the washing machine cabine$ (not shown~. Connect-
ing line 143 conveys rinse liquor discharged from the pump 140 to
a sewer drain (not shown).
As can also be seen in Figures 1 and 2, stationary drum 15
5 is supported by means of four suspension springs 66 which are
connected at one end to anchor means 65 secured to the upper-
most portion of ~he stationary drum 15 and at their other end t
fixed anchor means 67 which are securad to the washing machine
cabinet ( not shown ) .
Extending from the lowermos~ portion of peripheral wall 16
are four support members 70, the lowermost ends of which are
secured to motion limiting damper pads 71.. A vertical guide plate
72 passes between the two sets of motion limiting damp~r pads 71.
Sufficient clearance is provided between the motion limiting
damper pads 71 and the guide plate 72, which is secured ~o the
base of the washing machine cabinet (not shown3, so that the
stationary dPLIm 15 may undergo limited up-and down and side-to-
side movement while access opening 20 and tubular extension 19
remain in sealed engagement with pliable sealing gasket 210. The
resilient moun~ing of stationary drum 15 minimizes the transmis-
~ion of vibration which occurs during moments of imbalanced
loading to the washing machine cabinet (not shownl.
Located inside stationary drum 15 i5 a movable drum 40
comprising a per~orated peripheral wall 41, a substantially imper-
forate back w311 42 secured to one edge of said peripheral wall
and a substantially imperforate front wall 43 secured to the
opposite edge thereof. Extending from the front wall 43 of the
movable drum 40 is a tubular-shaped extension 44 which ~ermi-
nates in an access opening 45 which is cuncentrically a!igned with
the access openiny 20 in stationary drum 15. Equally spac~d on
the inner circumference of peripheral wall 41 are three lifting
vanes 47 of substantialiy triangular cross-section. The innsarmost
edge of lthe side walls 48 of the triangular-shaped vanes 47
preferably terminate to form an innermost land area 49. 3n a
-- 10 --
par~icularly preferred embodimen~, each of the vanes is
symmetrically-shaped about a radially extending line originating a~
~he axis of rotation 300 of movable drum 40 and passing through
its al~i~ude. This perrnits rotation of movable drum ~0 in opposite
5 directions with equal lifting ef~ect on the articles being iaun
dered .
I n an exempiary embodiment of a washing machine 10 of the
present invention, ~he movable ~rum 40 measured approximately
21~" f54.6 cm. ) in diame~er by approa~imately 12" 130~5 cm. ) in
10 depth, while the trians~ular-shaped lifting vanes 47 exhibited a
base of approximateiy 2" t5.1 cmO) in width by 9" (22~9 cm.) in
qepth, an .overall altitude of approximateiy 3" 17.6 cm. ) and a
land ar~a 49 measuring approximately 1'1 t2~5 cm.) in width by 7"
(17.8 cm. ) in depth. The inner movable drum 40 exhi~ited
approximately 750 uniformly spaced perforations 46, each perfora-
tion having a diameter of approximately 1/4" (0.635 cm. ) . The
stationary drum 15 enclosing the aforementioned movable drum 40
measured approximately 24" (61 cm.) in diameterO
As will be apparent from an inspection of Figure 2, movablé
20 drum llO is rotatably secured to stationary drum 15 by means of
driveshaft 29. The innermost end of driveshaft 29 incorporates
. an integral flange 30 which is secured by means of c~mpanion
flange 31 and a multiplicity of ~asteners, such as rivets 32, to
the back wall 42 of movable drum 40. The shaft portion of
25 driveshaft ~g passes ~hrough a clearance hole 51 in the back wall
42 of movable drum 40 and is supported by means of a pair of
bearings 25 secured to the b~ck wall 17 of stationary drum 15.
Bearings 25 are secured in position by means of bearis~g retainers
22 which are joined to one another and to the back wall 17 by a
30 multiplicity of conventional fasteners, such as rivets 33. The
shaft portion of driveshaft 29 passes through a clearance hvle 26
in back wall 17 of sta~ionary drum 15.
Power to rotate rnovable drum 40 is transmitted to the exter
nal portion of driveshaft 29 either by means of an eccentrically
35 mounted driven pulley 2~ or by means of a concentrically mounted
driven pulley 34 which are both secured in fixed relation to
drivesha~t 29. As will be explained in greater detail hereinafter,
the eccelltrically mounted driven pulley 28 is used ~o vary the
speed of rotation of the movable drun 1~0 throughout each revolu-
tion of the drum, while the concentrically mounted driven puliey
5 34 is used to drive the movable drum l~O at a constant speed of
rotation ehroughou~ each revolution.
Th~ clrive system for the movable drum 40 pre~erably com~
prises a v~riable speed drive motor 60 secured by means of
support 61 to the peripheral wall 16 of stationary drum 15,
Because the drive motor 60 i5 5~eUrQd ~0 the stationary drum 15,
any movement of ~he stationary cirum 15 does not affect the speed
of rotation of movable drum 40. The output.shaft. 62 of drive: .
motor 60 has secured thereto a concentrically mounted drive
pu!ley 38 and a eoncentrically mounted drive pulley 36. A two-
lS position, pulley-actuating clu~ch assembly 37 Ts positioned inter-
mecliate pulleys 36 and 38. Drive pulleys 36 and 38 are both of
two-piece construction so as to permit engagement or disengage-
men~ of l~heir respective drive bel~s by puiley-actuating clutch
assembly 37. The housing of clutch assembly 37 ~hrough which
20 drive motor shaft 62 freely passes is preferably secured to the
housing of drive motor 6~ by means of a laterally extending
support 63, as generally shown in Figures 1 and 2.
Concentrically mounted drive pulley 38 is connected to
eccentrically mounted driven pulley 28 by means of a conventional
25 clrive ~elt 27. Likewise, concentrically mounted drive pulley 36 is
connected to concentrically mounted drive puliey 34 by means of a
conventional drive belt 35. When clutch assembly 37 Is in its
flrs~ positlon, the ciistance between ~he opposing ~aces of drive
pulley 36 is sufficiently grea~ that drive belt 35 is allowed to
30 freely slip therebetween when driveshaf~ 29 revolves. When
clutch assembly 37 is ac:tlJated into its second position, the
opposing faces of drive pulley 36 are brought sufficiently close
together that drivs belt 35 is driven by pulley 36. Simuitane-
ously, the distance between the opposing ~ces of driYe pulley 38
35 is increased to a distance which is sufficiently great that drive
belt 27 is allowed to freeiy slip therebetw2en when driveshaft 29
.
-- 12 --
revolves. Figure 2 depic~s ~rive pulle~y 36 in the engaged posi-
tion, while the inset of Figure 2A depicts drive pulley 38 in the
engaged position.
In 3 particularly preferred embodiment of ~he present inven-
tion, drive motor 60 is not only variable speed, but is also
reversible so that rnovable drum 40 may be rotated first in one
direction and th~n in the opposite direction ~hroughout ~he vari-
ous portions of the laundering cycle. It is believed that revers-
ing the direction of drum rotation several times during the
laundering cycle will provide more uni~orm appllcation of the wash
liquor, more uni~orm agitation and more uniform heat.trans~er to
the textiles being laundered, and h~nce more effective cleansing.
In the exemplary washlng machine embodlment described
earlier herein, th~ eceentrically mounted driven pulley 28 was
used to provide rotation of the movable drum 40 at a speed which
varied from about 48 to abuu~ 58 revolutions per rninute during
each complete revolution of the drum, while the concentrically
mounted pulley system ~omprising pulleys 36 and 34 was used to
provide rot3tion of the movable drum at a constant speed Gf about
544 revolutions per minute.
Referring again to the ,e~articulai ly pre~erred em~odiment of
Figure 1, there is shown an air circulating blower 160, preferably
of the centrifugal variety, secured by means of a support 162 to
an upper portion of peripheral wall 16 of 1:he stationary drum 15.
The air circulating blower 160 is preferably powered by variable
speed drive motor 11;1. A connecting duct 163 conveys air from
the blawer discharge to a heater 164. The heater 164 includes a
heating element 165 over which the air must pass prior to enter
ing connecting duct 166 which conveys heated air frsm the hea~er
164 to an inlet opening 180 located in the peripheral wall 16 of
the stationary drum 15. In the embodiment disclosed in Figures
1-3, heated air is introduced intermediate the peripheral wall 16
of stationary drum 15 and the peripheral wall 41 of m~vable drum
40. The bulk of the heated. air introduced in this area is ~orcecl
to enter movable drum 40 via perforations 46 located in peripheral
wall 41. As pointed out earlier herein, the movable drum 40 is
9~
caused to rotate at varying speed during the laundering portion
of the cycle via the eccentrically mounted pulley 28. Since the
artic!es being laundered are normally loca~ed at or adjacent the
innermost surface of peripheral wall 41 of movable drum 40 during
S the laundering cycle, the heatec~ air introduced between the
stationary and movable drums is caused ~o penetrate the textiles
being laundered on its way to return opening 190 located in
tubular extension 19 of stationary drum 15.
Return opening 190 is connected to a diverter valve 168 by
means of connecting duct 167. Diverter valve 168 has ~wo posi-
tions. In its first posi~ion, connecting ducts 170 and 171 are
blocked off and all of th~ humid air withdrawn from stati~ary
drum 15 is returned to the suction side of air circulating blower
160 via connecting duct 172~ As will be explain~d in greater
detail in the ensuing preferred process description, diver~er
valve 168 remains in its first position during the laundering
portion of the cycle described herein. The temperature of ~he
returning air is sensed in connecting duct 167 by means of a
sensin~ element 173 mounted in the duct. The sensing element
173, which is preferably of the thermistor type, sends a signat to
temperatlJre controller 175 Yia signal transmission line 174. The
temperature control3er 175, which is preferably adjustable, trans-
mits a signal via signal transmission line 176 to ~he heating
element 165 in heater 164 to either raise, lower or maintain the
temperature of the air being introduced into connecting duct 166.
Thus~ the heated air employed during the launciering portion of
the cycle is continually recirculated by means of the afore nen
tioned closed loop system, and its temperature is continuously
monitoreci and maintained at a predetermined levei.
In a particularly preferred embodiment of the present inven-
tion, the washing machîne 10 may also be employed as a clothes
ciryer. This is accomplished by manTpulation of diverter valve
168. Advancing control lever 169 from the a~orementioned first
position of the diverter valve to a second position connects air
duct 171 with return air duct 172 and air duct 170 with return
air duct 167. Since air ducts 170 and 171 are both vented to
~2~9~7
-- 14 --
atmosphere, the ef~ect of adYancing ~he diverter valve 168 to i~s
second position is to convert the closed loop recirculation system
described earlier herein in conjunc~ion with ~he laundering cycle
to a non-recirculating vented sys$em. In the vented mode of
op~ration, fresh air is drawn into duct 171 and routed through
the heater as before to provide warm dry 3ir ~or drying the
laundered tex~iles contained within movable drum 40. Similarly,
the moist air withdrawn from stationary drum 15 is discharged to
the atmosphere via connecting duct 170 rather than being recir-
culated to the suction side of the air circulating blower 160.
During the drying portion of the cycle, movable drum 40 is
rotated, as during the laundering cyole, by driv~ motor 60 oper-
ating through the ecc~ntrically mounted pulley and drive belt
system described earlier her~in. T~mperature of the air used
durins3 the drying cycle is also monitorecl and controlled by
sensing element 173 and temperature controller 175. However,
the temperature sel~cted during the drying cycle may differ from
that employed during the laundering cycle~ Aoc~rdingly, the
temperature controller 175 preferably has two independently
adjustable set points which may be preadjusted to dif~erent tem-
- perature levels ~or the iaundering and drying cycles.
As wlll be readily apparent to those skilled in the art,
diver~er valve control ~ver 169 may be automatically ~ctua~ed
rather than manually actuated, as disclo~ed in the present illus-
trationsO This may be accomplished utilizing solenoids or similar
control apparatus well known in the art and therefore not shown.
In the exemplary washing machine embodiment desoribed
earliar herein, the air circulating blower 160 utilized to reoir-
culate the humid air during the laundering portion of the ~ycle
had a rated capaci~y of 460 Cubic feet tl3.03 cubic meters) of air
per minute at a pressure of 0.25" (~.635 cm. ~ of water, and the
connecting ducts used to construct the recirculation loop w~re
sized to permit recirclJlation of the air a~ rat~d flow. The heater
1 fi4 e!nployed on the exemplary machine contained a heating ele
ment 7 65 comprising a 240 volt AC:, 5200 watt, spiral wound,
'Nichr~*coil~ The temperature 5ensing element 173 comprised a
* Trademark for a series of nickel-chromium alloys
containing by weight- from 54-B0% n1ckel, 10-20%
chromium, 7-27~ iron, 0-11% copper, 0-5~ manganese,
0.3~4.6~ silicon, and sometimes 1 percent molybdenum,
. and 0.25% titanium. They are used as electrical
r~sistance alloys.
-- 15 --
thsrmistor inserted into return air duct 167. Temperature con-
troller 175 comprised a 0-2Q0F (-17.ô - 93.3Cl adjustable unit
having a set point accuracy of 3% of range and a s~t point
stability of 29~ of span from the nominal setting. A high limit
5 snap disc-type thermostat [not ~hown) having a range of
1~00-450F (204.4 - 232.2C) was also utilized ts protect the
system.
Referring again to Figures 1-3, preferred wash liquor and
rinse liquor addition systems are disclosed. In particular, the
10 wash liquor utilized during the laundering portion of the cycle is
prepared in wash liquor reservoir 89 which is schematically i!lus-
~rated in Figure 1. In a particularly pre~rred ~orm of the
present invention, the cycle i initiated by introduciny a
predetermined amount of detergent composTtion, which may be in
15 granular, paste, gel or lic~lJid in form, in~o the wash liquorreservoir 89. Water froTI supply line 80 passes lthrough pressure
regulator 81, connecting line 101 and control valves 82, 84 and
87, which are in the open position, into ghe side of wash liquor
reser~oir 89 via conrlecting lines 96, 94 and 99. Control valves
20 85 and 88 are closed a~ ~his point in time to prevent the water
from escaping via delivery lines 95 and 98. Located within wash
liqwor reservoir 89 is a l~vel sensing probe ga which is connected
at its uppermost end to a level sensor 91. The level of the liquid
Introduced into the wash liquor reservoir rises along probe 92.
25 When the liquid level within reservoir û9 reaches a predetermineel
point, level sensor 91 transmits a signal ~o level controller 93 Vi3
signal transmission ITne 105. Level controller 93 sends a si~nal
Yia signal transmission line 106 to close off controi valve 82.
After control valve 82 ~as been closed, pump 86 is started to
30 initia~e recirculation, mixing and ~ormation of a wash liquor within
reservoir 89. Control valves 85 and 38 remain closed during the
mixing cycle. Pump 86 withdraws liquid from the bottom o~ wash
liquor reservoir 89 via connecting lines 99 and 97 and discharges
the liquid withdrawn back into the reservoir via connecting lines
35 9~ and 96. Recirculation of the liquid is carriecl out until such
time as the detergent composition Ts substantially dissolved or
.,
~2~ 7
-- 15 --
dispersed in the water. The time required will of course vary,
depending upon such variables as the solubility characteristics of
the particular detergent composition employed, the concentration
of det~rgent composition, the temperature of the incoming water
5 and like. To rninimize the mixing time, it is generally preferred
to design the liquid recirculation loop to maximize th~ turbulence
of flow during recirculation.
As will be explained in greater de~ail in conjunc~ion wi~h the
ensuing preferred process description, the present laundering
10 process may be carried out without the addition of heat energy
via heating element 165. However, experience to ~ate has demon-
strated tha.~ it is gene~ally preferable that wash liquor and rinse
liquor temperatures be in ~he range cf about 25C. or higher to
maximize the benefits afforded by th~ present process. To
15 achieve this objective when the heat energy addition option is not
employed during the laundering cycle, a water preheating unit
~not showni may be utilized on the incoming water supply line to
er~sure that the temperature of the incoming water does not fal3
below about 25~::, even during cold weather conditions.
~o As polnted out earlier herein, a relatively small amount of
wash liquor is utilized during the present laundering process
when compared to prior art laundering processes. Accordingly,
the method of applying the wash liquor to ghe textiles to be
laundered must be highly ef~ctive in order to provicle substan-
tially even and complet2 distribution, especially when very
reduced quantities of wash liquor are utilized. One particularly
. pre~erred means of accomplishing this objective has been to 3pply
~he wash liquor by means of a high pressure spr3y nozzle t00 as
the movable drum 40 rotat~s. During the wash liquor application
step control valves 82 and 88 are closed and control valves 84, 85
and 87 are opened. Wash liquor 230 is withdrawn from reservoir
B9 by means of pump 86 and is conveyed via flexible delivery line
95 to high pressure spray nozzle 100 which, in the illustra~ed
embodiment, is mounted in the tubuiar-shaped extension 19 of
stationary drum 15. A small amount of wash liquor is also per-
mittecl to flow through valve 84 and delivery line 96 back into
:
reservoir 89 to provide some recirculation and mixing durin9 the
wash liquor application cycle. As can be seen from Figure 3,
whi~h is a simpliFied diametral cross-section taken through spray
nozzle 100 and ~he axis of rotation 300 of movable drum 1~0, high
5 pressure nozzle 100 i5 located at approximateiy the 8 o'clock
position and a substantially flat, fan shap~d spray of wash liquor
230 is targeted ~o strike peripheral wall l~1 and back wall 42 of
the movable drum 40 which, in the illustrated embodiment, is
rota~ing in a counterclockwise orientation, at appro3timately the 2
1~ o'clock position.
. In order to distribute the textiles to be laundered subctan-
tia-lty uniformiy about the periphery of the mo~able drum 40, the
textiles are initially tumbled at low speed via eccentrically
mounted driven pulley 28. Movable drum 40 is thereafter acceler-
15 ated by concentrically mounted driven pulley 36 to a speed whichis sufficient to hold the substantially uniformly distribL~ted
articies against peripheral wall 1l1. The wash liquor application
step is initiated while the articles are held against peripheral wall
1. However, after several revolutions of movable drum 40, the
speed of drum rotation is redueed by trans~rring the input
driving force from roncentrically mounteci driven pulley 36 back
to escentrically mounted driven pulley 38. The slower speed of
rotation, which varies throughout each revolution of movable drum
40, causes the ~extiles within the drum to be carried by lifting
25 vanes 47 to approximately the 1 o'clock position, at which point
they tend to fall away from peripheral wall 41 an~ pass through
the substantially flat, fan-shaped spray of wash liquor 230 on
their return to the bottom of the drum.
While in the illustrated embodiment, the drum rotation is
30 oriented in a counterclockwise direetion, it has also been iearned
that the drum may, if desired, be rotated in a clockwise direc-
tion. In the latter case the textiles which fall away from the
peripherai wall 41 at approximately the 11 o'clock position still
pass through the fan-shaped spray of wash liquor 230 on their
35 return to the bottom of the drum.
~2~
-- 18 ~
The wash liquor appiication step is carried out until all or a
predetermined amoun~ of the wash liquor contained in reservoir 89
has been applied to the textiles being laundered. The quantity
of wash liquor applied l'or a given laundering cyele will vary,
S depending upon such factors as the cluantity of textiles being
laundered, their materials of construction, and the soil type and
level of soil loading, as rnore fully described in the accompanying
detaiied process description. When the wash liquor application
s~ep has been completed, even with the smallest quantities of
wash liquor within the invention, the wash liquor is substanSially
evenly and completely distributed on~o the textiles being sub-
jected to the present launderin~3 process.
To further er,hance distribution, wash liquor application may
be carried out in ~everal stages, with ~he movable drum 40 being
momentarily stspped and restarted between each stage to allow the
articles to ~ompletely redistribute themselves prior to each stage
of wash liquor application. Similarly, multlple spray noz71es may
be employed.
Figures 4 and 5 disclose the internal configura~ion of the
spray nozzle 100 employed in the exemplary washing maohine
embodiment described @arlier herein. In particular, an
irregularly-shaped orifice 1~00 is formed by intersection of a
V-shaped groove 410 having an included angle o~ approximately
45~ extending across the nozzle's face 430 and a cylindrical
passageway 420 passing through its longitudinal axis. A cross-
seotional vTew of this exemplary nozzle 100 is generally disclosed
in Figure 4, and an end view ~aken along view line 5-5 is shown
Tn Figure 5. The maximum width W of the a~orementioned groove
410 was approximately 0.075" ~0.19 cm.), as measured at the ~ace
430 of the nozzle. The diame~er D2 of the nozzle face 430 was
approximately 0.40" (1.02 cm. ~. The diameter D1 of passayeway
420 was approximately 0.125" (0.32 em. ~ alor;g i~s length, con-
verging at an included angle R of approx~mat~ly 120 adjacent the
nozzle face 430. In~ersec.tion of groove 410 and passageway 420
produced the irregularly shaped orifice 40û genera31y shown in
Figure 5. Wash liguor was fed by means of a pump 86 having a
- 19 -
rated capac;ty of 50û gallons per hour at 7 psi connected to
nozzie 100 via a 1/4" (0.635 cm. ) diameter flexible delivery line
954 The nozzle 100 was installed in tubular shaped ex~ension 19
at approximately the R o'clock posi~ion with its spray oriented so
5 as to strike peripheral wall l~1 and back wall 42 of movable drum
40, as generally shown in Figure 3. Drum rotation was oriented
clockwise when viewed from its front wall side.
While spraying has been found to be a par~icularly pre~erred
method of wash liquor application, other application means, e.g.,
10 atomizers, which will produce a similar distr3bution of wash liquor
throughout the textiles to be laundered, as described in the
accornpanying detailed process s:iescrip~iont may be employ~c~ with
equal suecess.
After the wash liquor application has been compîeted, pre-
15 ferably mechanical energy is applied to the textiles by rota~ingmovable drum 40 at relatively low speed such ~hat the textiles
being laundered are continually lifted by vanes 1~7 secured within
the movable drum and caused to mechanically tumbl~ back toward
the bottom of the drum. As poin~ed out earlier herein, the
20 turnbling action is accentua~ed by varying the speed of rotation of
~he movable drum 40 throughout each revolution of ~he drum.
This is aceoMplished In the machine embodiment disclosed in
Figure 1 by driving the movabl~ drllm 40 via ecc~ntrically
mounted driven pulley 28. In a particularly preferred embodiment
25 of the invention, the direc~ion of ro~ation of movable drum 40 is
reversed several times throughout ~h~ laundering cyele. This
provides more thorough mechanical agitation of the textiles being
laundered and, hence, more unifiorm heat transf~r ~hroughout the
~extiles. In addition, it minimizes ~he tendency of textiles,
30 particularly long ~nd thin appendages on textiles, e.g., sleeves
on shirts, from beçoming knotteJ up.
Heat energy is preferably supplied to the textiles being
laundered during the aforementioned mechanical agitation process.
In th~ machine embodiment disclosed in Figure 1 this is acoom-
35 plished by recirculating moist humid air through heater 164 usingair handling blower 160. Preferred air temperature ranges and
~l2~
~ 20 --
cycle times are specifled in the aceompanying detailed process
description .
Followin~g the mechanical andlor hea~ energy application
phase of the present laundering process, ~he textiles ~:ontained
S within the movable drum 40 are rinsed with an aqueous rinse
liquor 240, which in a particularly pre~erred embodiment com-
prises water. This is supplied from water supply line 80 via
controi valve 83 whieh is opened to permit delivery of rinse water
to movable drum 40 via flexible delivery line 110 and applicator
nozzle 120. Appliça$or nozzle 120 i also pre~erably mounted in
. the tubu~ar shaped extension 19 of stationary drum. 15. Appli-
ea-~or nozzl~ 12û need not, however, be~ a high pressure spray
nozzle sueh as that utilized to apply wash liquor. Because free
standing liquor is employed in movable drurn 40 during the rinse
15 portion of ~he present laundering cycle, it is believed that the
particular manner of applying the rinse liq~Jor to the laundered
text;les is much l~ss critical than the manner of applying the
wash liquor. Accordingly, the rinse liquor may be added by any
of several means weil known in ~he art, ~.9O, directly into
20 ~tationary drum 15 via an orifice in peripheral wall 16.
The textiles b~ing laundered are pr~ferably sl~bj~cted to
mechanical agitation during both the rinse liguor addition and the
rinse cycles. Thls is preferably done by rotating movable drum
40 at relatively iow speed via eccentricaily mounted driven pulley
25 28. As with the mechanicat energy and heat energy application
phase of the laundering cycle, the direction of rotation of movable
drum 40 is preferably changed several times during the rinse
cycle to ensure more un;~rm rinsing.
In a particularly preferred embodimen~, several relatively
30 short rinse cyeles are employed to remove the loosened soil and
detergent from the textiles being 7aundered.
It i5 believed preferable to remove the rinse water from
movable drum 40 ~uring the init3al rinse cycles witllout resorting
~o hi~h sPeed centrifugation, i.e., high speed ~otation of movable
35 dr~n 40. ~ile n~t wishing to be bound by ~cheory, it is ~elie~ed Jchat
avoidanc~ of centrifugation during the early rinse cycles minimizes
-- 21
the chance of redepositing suspended soils onto the ~extiles bein~
laundered, since the rir-se liquor is no~ forced ~hrough the ~ex-
~iles being laundered on its way to the per~orations 46 in peri-
pheral wall 41 of movable drlJm 40~ Accordingly, centrifugation
S to remove as much moisture as possible from ~he laundered and
rlnsed ~ex~iles i5 preferably de~erred until the last rinse cycle.
As will be clear from an inspection of Figures I and 2, rinse
wat~r which is removed frorn movable drulTI 40 ei~her by gravity
or by centrifugation is ultimately removed from s~ationary drum 15
through drain connection 21 by means of discharge pump 140 from
whence it is pref~rably conveyed to the-sewer.
If desired~ laundry additives of various types, e.g., fabric
sof~eners, may be employed in conjunction with ~he laundering
process described her~in. If desired, such additives may be
15 applied to the articles being laundered by conventional gravity
addition (not shown) or via pressure spray nozzle 100~ In the
latter instance, one or more secondary reservoirs 90 may be
employed. The discharge of these secondary reservoirs may be
connected, as by delivery line 98 and control valve 88, to the
20 wash liquor mixing system.
Dependin~ upon the nature of ~he additive, it rnay be desir-
able to flush the wash li~uor reservoir 89 with water prior to
introducing the additive into the reservoir. This may be done by
refilling the reservoir with water and recirculating the solution
25 via pump 86 prior to discharging it into one of the rinse cyeies.
After wash liquor reservoir 89 has been flushed, control valve 88
may be opened to permit delivery of an additive fro~n reservoir 90
to the wash liquor reservoir via ,sump 86. When a predetermined
quantity of the additive has been trans~erred to wash liquor
30 reservoir 89, a water dilution cycle may, if desired, be carried
out in a manner similar to that employed ~or mixing the wash
liquor, i.e., wa1:er from the supply line is added to reservoir 89,
eontrol valves 82, 85 and 88 are closed, and the additive solution
is recirculated via pump 86 to the wash liquor reservoir 89 until
35 such time as the additive is ready ~or application to the articles
being laundered. Application of the mixed additiv2 solution may
-- 22 --
th~reafter be carried out ~uriny one or more of the rinse cycles
employed in the present prooess in a manner generally similar to
that employed ~or ~he application of the wash liquor.
Followil13 centrifugation by high speed rotation of movable
5 drum 40 ~o mechanically remove as much rinse liquor as is
feasible, the washing mac~,ine 10 may be operated as a conven-
tional clothes drying apparatLIs by actuating diver~er valve 168
from its first position to its second position. In its second
position, diverter valve 1~8 permits ~resh air to be drawn into
connecting ciuct 171 via suotion from blower 160, heated to a
predetermined temperature by heater 164, circulated through the
laundered and rinsed textiles contained in- rotating drum 40 and
vented from stationary drum 15 to the atm~sphere via connet~ting
duct 170. As will be appreciated by those skilled in the art,
movable drum 4~ is preferably operated at low speed via eccentri-
cally mounted driven pulley 28 throu~;hout the drying cycle to
provide more uniform air flow and heae transfer through the
laundered and rinsed textiles contained therein.
PREFERRED PROCESS
Another aspect of this invention oomprises a proeess for
laundering textiles, hereinafter re~erred to as the Qconcentrated
laundering process". The pro~ess lltiiizes quantities of an
aclueous liquid wash li~uor in the wash s~ep ranging from, at
least, about just enough to be substantially evenly and completely
distributed onto all portions of the textiles ~o, at most, about 5
times the dry weight of the textiles to be laundered. The quan~
tities of` wash liquor are applied to the textiles during the wash
step. It is essential that the wash liquor be substal-tiaily evenly
and eompletely clistributed onto the textîles. In the final step or
steps of the process the textiles are rinsed with water to remove
bo~h the soil and detergent composition.
The quantities of wash liquor that can be used in the wash
step range fr~m, at leas~, about just enough to be substantially
evenly and completely distributed onto all portions of the t~xtiles
to, at most, about 5 times the dry weight of the texltiles to be
laundered. The quantities of wash liquor in the rang~ of the
.
~2~ 7
-- 23 --
lower limit approach what is equivalent to directly applying a
conventional level of a typical cnmmercially avai3able heavy duty
liquid detergent composition to the textiles. Surprisingly, the
addition of more wash liquor, i.e., adding both water and deter-
S gent compositior; to the wash liquor s~lch tha~ the wash liquor
cor-centration remains constant, so that the upper limit is
exceeded results in essentially no additional 50il removal and no
less 50il redeposition. It should be noted that depending on the
nature of the textiles, soil types, soil levels, detergent compo-
sTtion levels and detergen~ compositiorl formulations that the upper
limit can vary slightiy. When quantities of wash liquor exceeding
the absorption capacity of the textiles are uti.lized,. only limited
amounts of mechanical energy should be applied to the textiles
during the wash step in order to prevent ov~rsudsing. ~ut,
surprisingly, a good level of cleaning performance is achieved
nonetheless. Also, with quantities of wash lic3uor exceeding the
absorption capacity of the textiles, though possible, it is not
essential that the preferred apparatus be utilizedO
MORE PREFER~ED QUANTITIE5 OF WASH LIQUOR
Therefore, in a more pre~erred embodiment the quantity of
wash I iguor that can be used in the wash step ranges from about
just enough to be substantially evenly and completely distributed
onto all portions of the textiles to, at most, none or minimal
amounts of wash liquor in excess o- the absorption capacity of the
~ex~iles. With such quantities there is at most minimai amoun~s of
"free" wash liquor. Thus, essentially ~11 of the wash liquor and,
therefore, essentially all of the detergent composition contained in
~he wash liquor, will be in intimate contact with the textiles
throughout the wash step. This permits the application of a
substantial amount of mechanical agitation to the textiles during
the wash step, as discuss~d below, without any oversudsing.
Surprisingly, numerous other benefits are obtained when the
quantities of wash liquor of this more preferred embodiment are
utilized. For example, since essentially ali of the detergent
composition is in intimat2 contaet with the textiles, the detergent
composition is being utilized extremely e~iciently. Also, there is
- 24
essentially no wash liquor for ~he dye of ~he textiles to be
relea~ed into and subsequently deposited onto ano~her textile.
Thus, dye transfer during the wash step is minimized and,
therefore, it is generally not necessary for the consumer to
presort the textile~. This is particularly signi ficant if the
laundry load contains the type of t~xtile commonly known as a
dye bleeder, i.e., one that contains e~cessive amoun~s of highly
soluble dyes. Another benefit is that the addition of more wash
liquor , i ~ ~., adding both watér and detergent composition to the
wash liguor such that the wash liquor concentration remains
o~nstant, to approach the upper limit of about S tim~s ~he dry
weight of the textiles to be launder~d provi~es . minimal additional
50il removal in view of the sost of th~ additional detergent com-
position utilized.
t5 In a more pre~erred embodiment, the quantity of wash liquor
that can be used in the wash step is from about just enough to
~e substantial Iy evenly and cnnipletely distributed onto the tex-
tiles to about 2~ times the dry weight of the textiles and
preferably from abou~ 3/4 to about 1~ tim~s the dry w~ight of the
~extiles. These ranges provide the most efficient use of a deter-
gent compositionO That is to say, in these ranges, ~or a given
quantity of detergent composition, there is the most ssil removal
and least soil redqposition. Surprisingly, the addition of more
water to-the wash liquor, i.e., diluting the wash liquor, so as to
exc~ed this upper limit, results in less soil remov31 from the
textiles and more soil redeposition. Also, with this preferred
limit, contact dyeing is minimized~ Contac~ dyeing is the trans~er
of dye from the surface of one eextile directly to that of another.
These preferred ranges can also vary depending on the nagllre of
~he textiles, 50il types, soil levels, cletergent composition levels
and deterg~nt compssition formulations.
THE WASH LIQUOR
The wash liquor contains frorn about 40~ to about 99 . 9~,
preferably from about ~596 to about 99 . 5~ and most 'pre~rably
from about 959~ to about g8.7~ of water ~nd from about 1,000 ppm
to about ~00,000 ppm, preferably from about 5,000 ppm to about
~7
-- 25 -
150,000 ppm and most pref~rabiy from about 13,000 ppm to about
50,000 ppm of ~ detergent c~mposition. Wash ~iquor con~entra
tions of d~tergen~ composition below about 1,000 ppm result in
subs~antially Jess soil removal from the textiles and above 600,000
5 ppm do not provide suMcient additional benefit to jus~ify the
addition of more detergent composition. However, in absolu~e
terms, the wash liquor should contain from about five grams of
detergent compo~ition to aboult 2ao grams per kilogram of wash
load. As u~ilized here:in the wash load refers ~o the dry weight
10 of the textiles, unless o~herwise specified. Pre~rabiy, the
absolute amount of det~rgent composition in the wash. Iiquor is
from about 10 grams~o abou~ ~0 grams per kilogram of wash lo~d.
How2ver, the most pre~erable detergent composition leYels are
heavily dependent on the det~rgent composition ~ormulation. It
15 shouid be no~ed that the wash liguor of the presen~ inven~ion is
much more conc~ntrated than the wash liquor ut11ized in the
eonventional autornatic home~type top loader washing machines~
although simiiar quantities of detergent composition are used.
The detergent composition c~n contain al3 of the standard
20 ingredients of detergent compositions, i.e., detergent surfactants
and detergency builders. Suitabie ingredien1:s include those set
fiorth in U.S. Patents 3,~36,537, Baskerville et al, February 3,
1976; 3,664,961, Norris, May 23, 1972; 3,919,678, Laughlin et al,
December 30, 19750 4,222,905, Cockrell, September 16, 1980; and
~s 4,239,659, Murphy, December 16, 1980~
The wash liquor should preferably contain from about 400
ppm to about 150,000 ppm, more preferably from about 1 ,SOû ppm
to about 10~000 ppm of detergent surfactant and, in abso3ute
30 terms, preferably from about 1 gram to about 45 grams per
kilogram of wash 7Oad. The wash liquor rhould also contairl
preferably from 0 ppm to about 1 Oû ,300 ppm, more preferably
from 1,000 ppm to about 50,000 ppm of a detergency builder and,
in absolute terms, preferably lFrom about 10 grams to about 50
35 grams per kilogram of washload. It should be noted that ano~her
benefit of the concentrated laundering process is that, due to the
9~7
-- 26 -
small quantities of water utilized, water hardness control is not as
critical as in a convenîional wash process. Suitable detergent
surfactants and detergency builders ~or use herein are disclosed
in ~he U. S. patents cited immediately hereinbefore. The wash
liquor can also con~ain inorganic salts other than detergency
builders, enzymes and bleaches. The levei of inorganio salts in
the wash liquor Is from about 0 ppm ~o about ~50,000 ppm and
preferably from about 11,500 pplT to about 5~,000 ppm. The
pre~erred enzymes for use herein are selected fram the group
consisting of proteases, amylases and mixtures thereof. The ievel
of enzymes pr~sent in the wash liquor is from 0 ppm ~o about
3,000 ppm, pref~rably from. 0 ppm to about 1,5û0 ppm. The level
of prol:eases present in the wash liquor is from 0 Anson Units per
liter (A.U./L.) to about 1.0 A.U./L. and preferably from 0.03
A.U./L. to about 0.7 A.U./L. The leYel of amylases present in
the wash liquor i5 from about 0 Amylase Units/liter o~ wash liquor
to about 26,000 Amylase Units/liter of wash liquor and pre~erably
from about 200 Amylase Units/liter of wash liquor to about 13,000
Amylase Units/liter of wash liquor wherein Amylase Units are as
defined in UoK~ Patent 1,275,301 E~esfiDrges (Published May 24,
1972 ) . Bleach levels in the
wash liquor are from 0 ppm ~o a5~out 5 ,oon ppm and preferably
from about 500 ppm to about 2,000 ppm. Also, bleaeh levels in
the wash liquor are from 0 ppm to about 2 ,000 ppm, preferably
from about 20 ppm to about 1,000 ppm and moct preferably from
about 50 ppm to about ~50 ppm of available chlorine when a
chlorine bleach is utilized and from about 0 ppm to abou~ 1,500
pplr, preferably from about 50 ppm to about 750 ppm .and most
preferably from about 100 ppm to about 500 ppm when an oxygen
bleaeh is utilized.
Other parameters of the wash liquor are pH, viscosity,
oil/water interfacial tension and parti le size. The pH range for
the wash liquor is from abou~ 5 to about 12, preferably from
abollt 7 to about 10.5 and most preferably from about 9 to- about
3~ 10.5. It has been generally observed that superior cleaning can
be achieved in the concentratecl launderirlg process without the
use of highly alkaline detergent compositions. The vi5c:osity of
the wash liquor can range pref~rably from about the v;scosity of
water to about 250 centipoise and more pre~rably from sbout the
viscosity of water to abou~ 50 centipoise. Also, i~ is preferred
5 that the oil/water interfacial tension is no greater than about 10
dynes and more pr~ferably no s3rea~er than about 5 dynes and
preferably that no solid ingredient is larger than about 50
microns and more prefPrably no larger than abou~ 10 misrons.
Typically, the ~uantity of wash liajuor utilized in the concentrated
10 laundering process when utilized for home-type laundry loads will
- range from about 1 liter to abou~ 20 liters and preferably from
about 2 liters to abou~ S liters.
The detergent compositions utiliz~d in the ccncentrateci
laundering process can be in any form, such as granules, pastes,
15 gels or liquids. Iiowever, based upon ease of prepa-ration of the
wash liquor, liquid detergent compositions and rapidiy dissolving
granular detergent compositions are desirable.
The conditions anai detergent compositions for the present
concentrated launciering process can be miid and safe ~or the mos~
20 delicate ~abrics cleaned by the leas~ experienced consumer without
unduly sacrificing cleaning.
WASH LIQUOR APPLICATIC)N 5TEP
The wash liquor for the present proc~ss can be prepared by
mixing the detergent composition and wa~er. in the case of
25 granular detergent compositions, the granules must be dissolved
and/or dispersed before the resulting wash liquor can be applied
to the textiles. In the illustrated embodiment~ such predissolu-
tion and/or predispersion occurs by placing a predetermined
quantity of granules in wash liquor reservoir 89 which is then
30 filled from the water supply line 80 via control valve 82 and
delivery line 96. If a highly concen~rated liquid detergent com
position is used, then a flow-throlJgh mlxing cell, e.g., a static
mixer, can be used as an alternative to the wash liquor reservoir
to mix the detergent composition and water. However, in -ranges
35 of the minimal quantity of water, an appropriate concentrated
aqueous liquid detergent composition can be applied "as is" with~
out further dilution.
.
- 2B -
The wash liquor is applied as an aqlueous liquid directly onto
the textiles. Preferably, the textiles are dry when the wash
liquor is applied. It is also desirable that the application of the
wash liquor, especially when ~here is no free wash liquor, is such
S that it is substantial Iy eompletely and evenly distributed onto the
textiles. That is to say, that if the wash liguor is not evenly
distributed over substantially all of the textilQs, then the
untreated portions wiil not be eleaned as well and/or those por-
tions of the textiles which are treated with more than their pro-
10 portionate share of the wash liquor may appear as "ciean" spotsafter the concentrated laundering process has been carried out.
It should be noted that with the larger quantities of wash liquor
within the invention it is easier to make such a distribution.
This jc especially true with quantities of wash liquor exceeding
lS the absorption capacity of the textiles.
The foregoing detai led description of a preferred rnachine
embo~iment to accomplish such an application where there is no
free wash liquor will be used in the following discussion.
I n a home-type front loading automatic washing maehine of
20 the type deseribed hereinbefore and illustrated in Figures 1-5,
îhe wash liquor is pumped from either the wash liquor reservoir
89 or mixing cell ~not shown) through a delivery line 95 which
has a high pressure spray nozzle iûO attached at the end of it.
The nozzle should be situated inside of the machine in such a
25 position so 25 to optimize the even and complete application of the
wash liquor onto the textiles. This can be accomplished by
attaching the nozzle 100 in the tubular shaped extension 19 of the
statiorlary drum 15, as generally shown in Figure 1~ As an
option, more than one nozzle can be used. Such multiple nozz!es
30 may be positioned so tl;~ey will e~feetiYely increase the area of the
drum that would be sprayed by the nozzles and, ther~fore,
ensur~ a more oomplete application of lthe wash liquor onto the
textiles. As an alternative to a nozzle, an atomizer (not shown~
can be used. An- atomizer i5 believed to be particutarly desirable
35 when rninimal ~uantities of water are used because the wash liquor
mus~ be extremely finely divided ~o ensure uniform distribu~ionO
-- 29 ~
It should be noted that with quantities of wash li~uor exceeding
the absorption capacity of the textiles, but within the invention,
l~ss sophisticated means may be utilized to ensure good distribu-
tion of the wash liquor onto the textiles.
As generatly described in the foregoing apparatus descrip-
tion, before the wash liqLJor is pumped through the delivery line
95 and ou~ the nozzle lO0, the movable drum 40 is prefer2bly
rotated. The purpose of the rotation is to clear the textiles from
~he center of the drum so that they are not blocking ~he field of
spray of the nozzle lO0, ~0 distribute them substantially uniformly
along the peripheral wall 4û, ~nd to expose as much of their
surf~ce area to the initiai spray as is ~easible. This is pre-
f~rably accomplished by initially driving movable drum 40 via
concentrically mounted driven puliey 34 at a constant speed which
is sufficien~ ~o ~orce the textiles against the peripheral wall 41 of
the movable drurn 40 and thereaf~er driving movable drum 40 via
eccentrically moun~ed driven pulley 28 at a r~duced varying speed
which allows the textiles to tumble continuously through the
spray.
The pressure in the delivery line 95 should be high enough
to produce a substantially flat ~an-shaped spray of the wash
liquor 23~ through the noz~le lO0, said spray preferably covering
the entire depth clf the movable drum 40, as generally shown in
Figure 3.
This particularly preferred method of wash liquor application
pQrmits the textiles to be substantially completely and evenly con-
gacte~ by the wash liquor. Thls permits the very ef~ective
det~rgent/soil interaction of the concentrated laundering process
to occur. Additionally, such a methocl of wash liquor ~pplication
is extremely efficient becaus2 when the quantil:y of wash liquor
utilized do2s not exc~e~ the a~sorption capacity of the textiles
~ssentially all of the wash liquor is on the textiles.
A benefit of the concentrated laundering process is that
effectiv~ el~aning results can be obtained over . a wide range of
wash liquor ~emperatures. The temperature of ~he wash iiquor
can range from about 2C to about 90C, pre~erably from about
9~7
- 30 --
15C to about 70C and most preferably from about 25C to about
50C. Surprisingly, the eleaning performance achieved at tem-
peratures from about 25C to about 50C Is as good as that
achieved at temperatures above about 50C. AISD~ such low
temperatures are especially sa~e for dyed and/or synthetic tex-
tiles. Dye transfer is minimized at such temperature, especially
when there is no free wash lic~uor. If it is desired to perform
the wash liquor application s~ep at tempera~ures above ambient
temperature, either the wash liquor or the incoming water from
supply line 80 c~n be heated before the wash liquor is applied to
the textiles . I lowever, it j5 pre~erred that the temperature of
the textiles not exceed about 7ût:, as this may result in exces-
sive wrinkling and shrinkage. Furthermore, temperature-
sensi~ive synthe~ic textiies should not be hea~ed above ~heir
manufacturer-res:ommended washing temperatures.
APPLICAl!ION OF ENERGY AFTER TEXTILES
HAVE BEEN CONTACTED WITtl WASH LIQUOR
Irt a pre~erred embodiment, energy can be applied to the
textiles a~ter they have been sontacted by the wash liquor. It
may be in the form of heat energy andtor mechanical energy,
albeit they are not completely interchangeable, for a period
ranging from about 1 to about 30 minutes, preferably from about
5 to about 15 minutes.
The application of heat energy permits the consumer to
obtain excellent bleaching per~ormance from bleaches such 3S
sodium perborate, sodium percarbonate and hydrogen peroxide
which are generally more effective at higher ~empera~ures. This
is not economical in a conventional home-type automatic wash
process due to the cost of heating such large quantities vf wash
3n liquor. Further, since small quantities of water are used in the
concentrated laundering process, conventional levels of bleach wlll
have a higher ef~ective concentration. This too contributes to
the ef~ective and/or efficient use of bleach in the concentrated
laundering process.
In a preferred embadiment, heat energy is applied by recir-
culating moist air which is heated via heating element 165 to raise
~he ~emperature of the textiles ~o about 60C:, ~he ternpera~ure at
which hydrogen peroxide based bleaches become particularly
reactive. In addition to the c~osed loop rn~ist air recircula~ion
system disclosed in Figure 1, numerous other methods may be
5 used for the application of healt energy. Nonlimiting examples are
microwaves, steam and solar energy.
As an alternative ~o ~he ~pplication of heat energy ~o acti-
vate the bleach, inorganic peroxide sal~ activators or low tem-
perature active bleach~s such as peroxyacids can be used. Such
10 activated bleaches are ef~ective below about 5b :;. Organic
pero~ide . salt activators are well known in the art and are
described extensively in the li~erature. For example, see U . S.
Patents 4,248,928, âpadini et al, issued Fe~ruary 3, 1981, and
4,220,562, Spadini et al, issued September 12, 1980,
Active bleaches such
as organic peroxyacids and water soluble salts thereof are well
known in the art. For a more del:ailed description of such
bleaches see U~st Patents 4,126,573, Johnston, issued November
21, 1978 and 4,100,095, Hutchins et ai, issued June 11, 1978r
Other benefits of the application of heat enersy are the
assistance in the distribution of wash liquor onto ths textiles and
lîpid/oily soil removai. If during the wash liquor application step
the wash liquor was not substantial Iy evenly and compietely
2; distributed ~nto the textiles, then the application of heat energy
does provide some additional distribution. Also, experimental
evidence indicates that heat energy does assist somewhat in the
removal of lipid/oily soil. Some other potential benefits ~f the
application of heat energy are the effective use of enzymes and
30 the creation of desirable detergent surfactant phases. Different
enzymes are most ef~ective 3~ different ternperatures. ThereP~re,
the textiles couid be heated through certain temperature ranges
to maximize enzyrne effectiveness. However, as discussed herein-
be~ore, heat energy does not provide a major performance bene-
3s fit, except as discussed hereinbefore with respect to bleaches, tothe concentrated laundering process. It is pre~erred ~hat heat
- 32 --
energy be applied such that the t~mperatur~ of the textiles is
pref~rably from about 15C to about 70C and more preferably
from about 25C to abou~ 5ûC.
The appiication of mechanicai energy provides numerous
benefits. Mechanical energy helps to distribute the wash liquor
so that it is more evenly and completely dlstribute~l onto the
textiles. Thus, if during the wash liquor application step the
wash liquor was not substantially evenly and completely distri-
bu~ed on~o the ~ax~iles, then the input of mechanical energy will
enhance such distribution. Mechanical energy also minimizes the
~eriod of tlme that the same textiles will remain in intimate con-
tact with each other. Consequently, contact dyeing is minimi~ed.
Also, it is believed that mechanical energy contributes to
improved cleaning efficacy. How~ver, with quantities of wash
liquor exceeding the absorption capaeity of the textiles, only a
limited amount of mechanic~l energy shou3d be applied in order to
prevent oves slJdsing. 13ut, this is dependent on the conc~ntra-
tion and nature of the detergent composition in the wash liquor.
In the embodiment illustrated in Figures 1-5, mechanical
energy can be applied by con~inuing rotation of the movable drum
40 at the last speed at which the wash liquor was applied. This
creates a tumbling act30n by the textiles in movable drum 40 and
results in the textiles being mechanically agitatecl.
THE RINSE
After the foregoing steps have been completed, the textiles
are rinsed in a rinse l;quor which preferably comprises clear
water. Unlike a conventional automatic wash process wherein the
goai of th~ rinse is to remove primarily the residual detergent
composition, the goal of the present rinse is to remove the entire
detergen~ composition and the soil. Thus, the present rinse s~ep
simultaneously per~rms the soil and detergent eomposition trans-
por~ functions normally performed sequentially in conventional
washing and conventional r3nsing steps. 5urprisingly, it has
been observed that, during the rinse step, soil redeposition and
dye transfer are minimal. Also, it has been observed that the
r inse liquor contains stable emulsion particles whereas the rinse
~ .
.
~'bUr~ ~
-- 33 --
liquor in a conventional automatic wash process does not contain
such emulsion par~icles.
In the preferred launclering apparatus illustra~ed in Figures
1-5, rinse liquor i5 introdus~d to the interior of movable drum 40
5 from water supply line Ro via control valYe 83, delivery line 110
and applicator nozzle 120~ Movable drum 40 i5 preferably ro~ated
at varying speed via eccentrically moun~ed driven pulley 28 so
that the textiles being rinsed are caused to tumble in a manner
similar to the wash liquor application step. For more completg
10 agitation of the articles b~ing rinsed movable drum 40 may be
stopped and its direction of rotation revers2d seYeral times
thr~u~hout the rinse tycle. After the initial rinse has been
complet~d, the rinse liquor is preferably remov@d from movable
drum 40 by pumpin~ it out via purnp 140 without accelerating the
15 rotation of ~he movab~e drum. This procedure can be repeated
several times until the detergent eomposition and soil are
removed. However, the textil~s need not be pun out by high
speed rotation o~ movable drum 40 between rinses. This mini-
mizes the potential fior wrinl<lins~ if lthe textiles are warm and also
20 minimize~ tlle potential for 50il redeposition due to the rinse water
being "filtered" through the tex~iles. If desired, acijuvan~s such
as cptical brighteners, fabs~ic so~teners and p~rfumes can be
added to the rinse or applied, via the applicator nozzle 120, a~er
the last rinse and distributed by tumblingO Bodying agents,
25 such as s~arch, can also be added by spraying after the last
rinse. Following the last rinse the textiles can be spun out by
high speed ro$ation of movable drum 40.
. An ef~ective rinse can be accomplished in accordance with
the present invention with reduced wat~r consumption and, there-
30 fiore, if heated water is used, reduced energy consumption. ThealTount of rinse liquor per k~logram of wash load is from about 4
liters to about 32 liters, pre~erably from about 5 liters to about
10 liters per rinse cycle. Rins~ liquor levels below this amount
would not produce enough free water on the surface of ~he tex-
35 tiles to adequately suspend the soil and detergent composition.Generally more than one rinse cycle is necessary to remove ~ll of
~2~ 7
-- 3~ ~
the soil and detergent composition from the textiles. The use of
such small ~uantities of rinse liquor permits ~he consumer to
perform an entire laundering cycle of the present invention with
about 25 liters or less of wa~er per kilogram of wash load. The
5 rinse liquor temperature i5 from about 75C to about 55C and
preferably from about 25C lto about 4~C.
In a particularly pre~erred embodiment of the present inven-
tion carried out in the apparatus of Figures 1-5, the complete
rinse comprises two or three cycles which can be carri@cl out in
10 either eold or warm clear water. Each cycle can be from about 1
to about 10 minutes with each cycle not necessarily being the
same length of time.
In a particularly preferred embodiment of the present inven-
tion, the weight of the dry wash load is determined by an auto-
15 matic weight sensor lnot shown3 and lthe quantities of washliquor, d@tergent composition, and rinse liquor are automatically
regulated thereafter by control means known in the art and
therefore not shown.
After the final rinsin~ step the laundered texgiles can, if
20 desired, be dried in the appara~us illustrated in Figures 1-5.
- This is done by positioning diverter valve 168 so that atmospheric
air i5 drawn into connecting duct 171 by Iblower 160, heated by
heating element 165, circulated through the tumbling textiies
contained in the moving drum 4û, withdrawn from drum 40 in a
25 hurnid condition via ~onnecting duct 167 and vented to atrr)osphere
via connecting duct 170. Exercising this option enables the
consumer to perform the en~ire laundering and drying process in
a single apparatus and in continuous ~ashion.
The present concentrated laundering process can be
30 employed to clean up even the dingiest of ~extiles and especiall
synthetic textiles in a number of laundering cycles. When an
effective bleach i employed, the number of la~lndering cycles
re~uired for such purposes is reduced. This is believed to be
due to the eomblnation of excellent soil removal and substantial
35 avoidance of excessive dye trans~er and soil redeposi~lonO Also,
it has been observed that the present concentrated laundering
process extends the useful "life" of textiles. This is believed to
be due to the wash liquor 3ubricating the textile fibers.
Another aspect of the present invention is a granular paste,
gel or liquid detergent composition packaged in association with
S instructions for use in the concentrated laundering process.
When such detergent c~mposition is combined with water it pro-
duces from just enough wash liquor to be substantially evenly and
completeiy distributed onto a wash load of textiles to about 5 kiio-
grams of a wash liquor per kilogram of wash load of textiles, said
wash liqusr con~aining from about 10 grams to about 60 grams of
the detergent composition per kilogram of wash load of textiles.
~The process of this Invention is primarily directed to house-
hold laundry which consists of wash loads essentially made up of
textiles, i.e., the process is a small batch process, that typicaily
cleans less than about 10 kilograms of soiled textiles which are a
mixture of textile types andlor colors. While the present ccncen-
trated laundry process has been described in detail in conjunction
with a preferred hsme laundering apparatus, it will be appre
ciated by those skilled in the art that the process can also be
carried out on an industrial scale i~ provision is made fior proper
distribution of the wash Jiquor over the textiles and avoidance of
appreciable amounts of free wash liquor in eontact with the tex-
tiles .
The following examples are illustrative of the invention.
EXAMPLE I
Three sets of polyester and polycotton swatches con~aining
the ~ollowing soil types w~re prepared: artificial sebum, triolein,
CRlSe:O oil and a mix~ure of inorganic particulate sotl and lipid
soil. The three sets of swatches, wit5~ three clean sw~tehes used
to measure soil redepo ition, were then sprayed with wash liquor
con~aining 1.92 grams of ARIEL 7a commercial detergent composi-
tion containing about 10P~ surfactarlt~ about 45~ sodium tripoly-
phosphate detergency bullder, a~out 12% sodium perborate bleach,
and about 1/4~ of an enzyme composition) in a miniature launder-
Tng apparatus which mimics the acti~n of the exemplary iaundering
apparatus disclosed in the preferred apparatus description. This
* Trademark for a vegetable oil.
** Trademark
,
~2~
-- 36 ~
quantity of ARIEL corresponds to about 32 grams of detergent
composition per kilogram of wash 3Oad. The movable drum in the
minia~ure laundering app~ratus ha~ a nine inch diameter and a
nine inch depth. The swatches were then mechanically agitated
5 at room temperature for seven minutes by rotating the movable
drum. The swatches were ~hen rinsed in another miniature
laundering ~p,oara~us having a six inch diameter and four inch
depth movable drum wi~h O 462 liters tap water ~or two minutes .
(The size of the movable drum used for the rinse was selected to
10 be proportional to the textile load ai~hough the size o~ the mov
able drum used for the wash liquor application was larger because
spray-ori was not ~asible in the small six inch drum. ~ The rinse
step was performed three times. Th~ above procedure was
repeatsd with wash liquors comprising various quan~îties of water
15 and 1.92 grams of ARIEL. The swatches were then measured to
obtain the dif~erence in Hunter Ulhiteness Units Filtered (~HWUF).
This measurement corresponds to the amount of soil removed from
the swatches, with the higher number signifying grea~er soil
removal. HWUF measurements exclude the ef~ect of brightener,
20 therehy measuring only soil removal. The results were as
fol lows:
~HWUF
Weight ratio of wash
iquor to swatches
~5 1:1 2.5:1 3.5:1
Artificial sebum polyester9.4 6.9 4.6
Artificial sebum polycotton 20.1 14.7 12.0
CRISCO polyester 6.1 3.7 2.5
C R I S CO polycotton 8 . 7 6 . 2 . 9
Triolein polyester 8 . 9 5 .1 5 . 3
Triolein polycotton 16 . 3 6 . 6 6 . 4
Soiled polyester 27.4 20.5 12.0
Soiled polycotton 33.1 23.8 19.4
Polyester redeposition -9, 0 -11 . 5 -17 . 2
Polycotton redeposition-2.7 -4.0 -7~3
- 37 --
The data indicate that as the quantity of wa~er in the wash
liquor i5 inereased above the wash liquor to swatches ratio of
about 2.5:1, there is iess soil removal and more soil redeposition.
EXAMPLE I I
A washload was prepared in the minia~ure laundering appara-
tus of Example I consis~ing of the following textiles: 20 3~11 x
3~11 white polycotton swatches, 15 4" x 4" white polyester
swatches, four 6" x 6" white ~erry clo~h towels. One 6" x 6" red
terry cloth towel, which is an excessive dye bleed~r, was used as
a dye source~ The dry weight of the texgiles was as ~ollows:
Dry weight of ~ex~iles
lGrams)
white terri@s 36
1 red terry ~9
15 white polyester swatches 32 . 2
20 white polycotton swatches 26.4
Total 3103.6
The wash liquor was prepared by dissolving 3.3 grams of
ARIEL in 200 ml. of tap water. The rnovable drum was ~hen
20 rotate~ and the wash liquor was sprayed onto the textiles until
contact dyeing was first visually observed. The weight of the
wash liquor absorbed onto the textlles was caiculated. The
results were as followso
Weight of wet Weight of wash
textiles (grams3liquor absorbed hy
texti les ~ g rams )
4 white terries 108.3 72,3
red terry ~27 O 1 ~18 O l
15 white polyes~er swatches 82.2 S0.0
3020 white polycotton swatches 50 . 8 24, 4
Total ~2~.8 ~16502
Then the ratio of the weight of wash liquor absorbed by the
textiles to the dry weight of the textiles was calculatedO
9~2~
- 38 -
Ratio of weight o~ wash
iiquor absorbed to dry
weight of textiles
4 white terries 2.0
1 red terry ~2.0
~5 whi~e polyester swatches ï.6
2û white polycottons 9
Total ~1.6
These data indicat~ that when excessive dye bleeders are
10 included in a typical wash load, contact dyeing occurs when the
weight of the wash liquor exceeds albout 1~ times the total weight
of the textiles..
E~XAI~1PLE l l l
Two sets of cotton swatches were prepared with each swatch
15 containing On2 of the follnwing four stains: brown gravy, cof~ee,
grape and tea. Two sets of polyester and polycotton swatches
were prepared with each swatch containing one of the ~ollowing
soil types: artiflcial sebum, artificlal s~bum plus particulate soil
and triolein. Then 24 dingy swatch~s were prepared in which
20 half were made from a cotton T-shirt and half were made from a
polycotton sheet. All of the abov~ swatches were pinn~d to two
cotton towels for a combined weight of 1/~ pound~ A 5-l/2 pound
"dummy" load consisting of clean temperature-sensitive synthetic
textiles and the swatch~s were placed in an appara~us similar to
25 that shown in Figure 1. The te~tiles were then rotated and a
wash liquor consisting of 96 ~rams of ARIEL dissolved in 2.84
liters of tap water which was sprayed onto the textiles. The
textiles were then rotated at room temperature for 10 minutes and
then subsequentOy rinsed in about 20 liters of water. The rinse
30 step was repeated twice. The above procedure was repeated
three more times with only the temperature of the wash load
during the 10 minute rotation period being varied.
The data were obtained in ~E units and ~HWUF unlts. ~E
units are a measurement of the change in color of tha swatch
35 resulting from the wash cycle. Change in color is proportional to
the amount of soil removal, with a higher ~E value corresponding
3g --
~o greater 50il removal. The above proc~dure was repea~ed and
the average of the results o~ the two replic2tes is as follows:
~E
45* Rm 120 150 180
(Temperature F.)
(7.2C)(49C) (65.5~ Z.2l~
Brown gravy 2.2 4.9 4.9 8.6 7.6
Coffee 3.8 5.8 6.5 6.2 6.3
Grape 3.7 6.4 7.9 1û.6 10.6
Tea 2.0 5.5 7.2 8.9 8.4
Artiflcial sebum
poiyester . .6.4 13.1 11.4 14.6 12~4
Artifisial sebum
polycotton 6 . 5 11 . 2 11 . 01~ . 6 î 0. 3
Triolein polyester 4 . 7 S . 0 7 . 0 6 . 0 7 . 3
Triolein polycotton 6.3 7.6 8.6 7.5 8.5
~HlIIUF
Soiled polyester 27.3 42.9 43.9 1~4.1 1~0.3
Soi led polycotton 35 . 2 48 . 6 48 . 6 48 . 0 48 . 5
*Same laundry loaci as in ExaJnple V and only one replicate.
The data indicate that the concen~rated laundering process is
only slightly temperature dep~ndent. Higher tempera~ures were
significant ~or stain removal, but that i5 primarlly due to the
bleach in ARIEL which becomes more effec~ive at higher tempera-
tures.
It was visually observed that at temperatures of 150~F
(65.5VC~ and 1~0aF (82.2C) that the sensitive synthetic textiles
suffered much wrinkling and shr inkage. It is surprising that the
leval of cleaning at "cool" temperatures, e.g., less than about
~0 40C~ lc extremely good. Prior to this invention it was beiieved
impossible to obtain this level of cleaning at these temperatures.
EXAMPLE IV
Twelve old dingy T-shirts and pillow cases were washed
alon~3 with a family bundle according to the same procedure as
outlined in Example lll. The temperature oF the wash loacl during
the ten minute rotation period was 145F. (62.8C). The
~2~
4~ -
T-shirts and pillowcases were used normally in between wash
cycles. I lunter Whiteness Units were measured before and a~ter
the indioated number of wash cycles to obtain the difference in
Hunter Whiteness Units (~HWU). The results were as follows:
5Pillowcase ~HWU No. of wash cycles
26.1 15
2 37.0 16
3 5~.6 6
4 ~5.1 6
51.0 6
49.0 6
7 1309. 7 .-
8 12.8 7
9 11.3 3
10.0 3
11 39.6 9
12 q1.6 9
T-shirt ~HWU No. of wash cycles
14.2 17
2 13.9 17
3 34.2 11
4 27.8 11
17.6 . 12
6 17,5 1
7 18.3 15
8 14.2 lS
9 19~5 6
14.9 7
11 î6.3
12 17.5 5
The data indicate that there was considerable soi l removal
from the pillowcases and T-shirts and their clean condition was
maintained. This level of performance cannot be achieved with a
conventional automatic wash proc~ss.
- 4i -
EXAMPLE V
A six pound wash load was prepared ~hat ~onsisted of a 5~
pound load of ac~ual household laundry and ~ pound load made up
of cotton, poly~ster, polycotton swatches pinned to two cotton
5 towels. Each ootton swatch con~ained one of the following stains:
brown graYy, coffee, grape and ~eaO Each polyester and polycot-
ton swatch contained one of the ~ollowing soils: artiflcial sebum,
triolein and a mixture of inorganic particulate soil and lipid soil.
The wash load was then washe~ accor~ing ~u ~he sam2 procedure
10 as ouelined in Example lll. The temperature of the wash load
during the ten minute rotation period was abou~ 1 45F. (62 . 8C) .
. The above prooedure was rep~ated two more time~ with reduced
quantaties of ARIEL.
The above wash procedure was repeated with the following
15 deterslent compositions: TOP (a commercial detergent composition
containing en~ymes) and ZAB (a built eommercial detergent com-
position containin~ enzymes). This procedure was also repeated
with reduced quantities of detergent compositions.
The data were obtained in ~E units and ~HWUF units. The
20 results were as t'ollow5:
~E
ARIEL
~6 118 24
(Grams of detergent)
Brown gravy 14.5 7.0 5.0
Coffee 12 O fi 5 . 66 . 2
~irape 14.8 2.8 5.3
Tea 14.3 5.7 2.5
Artificial sebum polyester 9 . 08 . 0 3 . 9
Artificial sebum polycot~on 8.2 6.9 4.3
Triolein polyester 7. 6 5 . 33 . 8
Triolein polycol:ton 10 . 8 7 . 23 . 7
~HWUF
Soiled polyester 45.2 17.2 4.0
Soiled polycotton . 51.3 34.8 21.7
* Trademark
.
9~
-- 42 --
~E
~OP
95 ~8
lCrams of detergent~
Brown gravy 8.8 6.2
Coffee 8.1 5.1
Grape 7.8 2.3
Tea 4.4 2.9
Artificial sebum t~olyester 9.3 5,4
1û Artificial sebum polycot~on10.5 8.2
Trio5ein polyester 5 . 7 4 . o
Tri~lein polyco~ton - 10.5 8.2 . - .
~i~lWUF
Soiled polyester 38.3 21.0
Soiled polycotton ~3.7 34.2
~E
ZAB
~6 48
(Grams 3f detergent composition) .
Brown gravy 9.6 6.1
~::offee 8 . 4 5 . 3
Grape 5.8 2.t
Tea 5.2 2.7
Artificial sebum polyester 6.2 4.0
Artificial sebum polycotton 7.7 4.2
Triolein polyester 8 . 3 4 .1
Triolein polycotton 10.2 6.7
~HWU F
Soiled polyester 34.7 19.B
Soiled polycotton 41.3 30.9
The data indicate that as the quantity of detergent in the
wash liquor is reduced, the amount of soil removal from the
swatches was also reduced.
~XAMPLE Vl
3s The foltowing typical granular detergent composition was
prepa red:
- 43
Sodium C~6 18 alkyl sui~ate 5,5
Sodium C12 linear alkylbenzene sul~onate 3.5
C1 4-1 ~ a l ky l polyethoxy late 5 . 5
Sodium tripolyphosphate 24.1l
~eolite A 17,6
Sodium carbonate 1005
Sodium silicate ~2.û r) 1.9
Sodium sul~ate 21.0
Water 8.9
Miscellaneous 1.2
Two sets of poiye5ter and polycotton swatches containing the
following soil types were prepared: artificial sebum, triolein,
CRISC:0 oil, beef ta310w and a mixture of inorganic particulate soil
15 and lipid soil. The two sets of swatches, with two clean poly-
ester swatches and two clean polycotton swatches used to measure
soil redeposition, and 14 polyester and 15 polycotton clea
swatches which constitute a ~Idummy~ load were then placad in a
miniature launderins apparatus which mimics the action of the
2û ~xemplary laundering apparatus disclosed in the pre~erred appar-
atus description. The swatches were then sprayed with wash
liquor containing 2.29 grams ~f the above granular detergent
composition. The quantity of wash liquor corresponded to about
twice the dry weight of ail of the swatches and the quantity of
25 detergent ccmposition corresponded ~o about 17.6 grams per
kilogram of swatches. The movable drum in the miniature laun-
dering apparatus had 3 nine ;nch diameter and a nine inch depth,
The swatches were then mechanically agitated at room temperature
for ten minutes by rotating the movable drum. The swatches
30 were then rinsed in one liter of tap water for ~wo ~inutes and
then dried in a convsntional automatic dryer. This procedure
was repeated three times. The ~HWUF was calculated.
The above procedure was repeated with increased quantities
of wash liquor, but constant wash liquor concentration~ How-
35 ever, with weight ratios of wash liquor to swatches of S and 7,the movabie drum was rotated gently during the ten minute
~2~ 7
-- 44. --
mechanical agitation period so as to prevent oversutising. The
results were as follows:
Weight ~atis of Wash
Llquor to Dry Swatches ~HWUF Eireakout*
Artiflcial sebum
polyester 2 15 . 51 B C
3 14.24
16.93 A B
7 17.47
Artifi~iai sebum
polycotton 2 12 . 42 B
. . . 3 12.97 B
- 5 - 16.22
7 18.07 A
CRISCO polyester 2 8.53
3 6.52 A
8.01 A
7 9.48 A
::RISCO polycotton 2 10.70 B
3 1~.36 3
13.94 A
7 15.57 A
Triolein poiyester 2 12.41 B
3 13.G8
1 S .58 A
7 14.34 A B
Triolein poiycotton 2 13 . 02 B
3 13.24 B
16.48 A
7 1B.30 A
Beef tallow polyester 2 10.84 B
3 10.99 B
14.12 A
7 . 15.02 A
. . .
-- 45 --
Beef tallow polycotton 2 9.~
9 . 77 E3
s 13099 A
7 15.31 A
S Soiled polyester 2 24.43 B
3 25 . 40 B
S 28.51 A
7 29. 99 A
Soiled polycotton 2 29.83 B
3 32.25 A B
5 35 . 97 A
7 35 0 4B A
Polyester redepositisn 2 -1.2~ B
3 -1 . 35 E3
.49 A
7 ~92 P~
Polycotton redeposi~ion 2 -1 . 99 E3
3 -1 . 97 E~
S - .~3
7 -1 . 09 A B
*The Breakout was determined by an analy~is of variance
with the letters A, B and C representing a significant difference
at a 95% conridence level. For exampie, with the artificial sebum
polyest~r swatches there was a significant difference between the
weight ratios of 2 and 7, 3 and 5, 3 and 7, b~Jt no signiflcant
difference between weight ratios of 2 and 3, 2 and 5 and 5 and
7.
These data indicate that as the weight ratis is increased
from 5 to 7 there is no signi~icant increase in soil removal, albeit
40% more ~etergent composition is applied to the swatches. Also~
th~re appears to be not much increase in soil removal as the
weight ratio is increased from 2 to 3 and, then, to 5 in view of
the quantity of the increase of detergent composition applied to
the textlles,
YJhile particular embodime~ts of the present invention have
been illustrated and described, it will be obvious to those skilled
9~7
-- 46 --
in the art that various modifications can be made without depar~-
ing from the spirit and scope of the inven~ion. For example, the
wash liquor can be applied to the t~xtiles by a brush, rollers, a
wash liquor permeable structure mounted on the inner surface of
5 the movable drum to allow contact of the textiles with the wash
liquor that passes through the permeable structure, a sravity
feed system which allows the wash liquor to drop onto the moving
t~xtîles, or any other means ~Nhich applies the required amount of
wash liquor evenly and completely ~o the textiles; other detergent
10 compositions can be substltuted for the specific det~rgent com-
positions ~escribed herein, rtc.
Another aspect of this invention is that the concentrated
laundering process permits the effective use of detergent composi-
tions comprisin~ bleaches and enzymes at levels in such detergent
15 compositions that would provide essentially no benefit when such
deter~ent compositions are utilized at normal usage levels in
eonventional automatic wash processes. "Normal usage levels in
conventional automatic processes" are generally (a) the use of 96
grams of detergent composition in 64 liters of water at 40C for
20 the United States of America; (b) the use of 146 grams of deter-
gent composition in 20 liters of water at 75C for Europe: and (c)
the use of 40 grams of detergent composition in 30 liters of water
at 25C for Japan.
The bleaches that can be utilized in the detergent somposi-
25 tions are peroxygen bleaching compounds capable of yieldinghydrogen peroxide in an aqueous 501ution. Thece compounds are
well known in the art and include hydrogen peroxide and the
a.kali metal peroxides, organir peroxide bleaching c:ompounds such
as urea peroxide, and inorganic persalt bleaching compounds,
30 such as the alkali metal perborates, percarbonates, perphos-
phates, and the like. Mixtures of two or more such bleaching
compounds can also b~ used, if desired. Pre~erred peroxygen
bleaching compounds include sodium perborate, commercially
available in the ~orm of mono- and tetrahydratesi sodium carbon-
35 ate peroxyhydrate, sodium pyrophosphate peroxyhydrate, ureaperoxyhydrate, and sodium peroxide. The level of such bleaches
~2~
-- 1~7 --
in the detergent compositions is from 0,01~ to about 0.5~ and
pre~erably from about û.l~ to about 0.5% ~f available oxygenO
Other blezches that can be utilized are activated bleaches
uch as peracids or peroxygen bleaching compounds capable of
5 yielding hydrogen peroxide in an aqu~ous solution plu5 a bleach
activator that can rPact to generate a peracid. Such peracids
and bleach activators are well known in the art. For exampie,
see U.S. Patents 4,126,573, Johnston (Nvvember 21, 1978) and
4,100,095, Hutchins et al tJune 11, 1978) which deal with per-
acids and U.S. Patents 4,248,928, Spadini et al ~February 3
1981) and 4,220,562, Spadini et al (Sep~emb~r 12, 19801, which
deal with bleach aetivators. The preferred peracid is
. m~gnesium monoperoxy ph~halate hexahydxa~e asdisclosed in published European Paten~ Application No.
0,027,693. The det~rgent compositions can contain from about
û.03~ to about 0.3% and preferably from ~bout 0.1% to about 0.2596
of available oxygen that can potentially be generated by peracid.
As another alternative, the detergent compositions can
contain a ehlorine bleach. Chlorine bleaches are w~ll known in
the art. The preferred chlorine bleach i5 sodium dichlorocyanur-
ate dihydrate. Other suitable chlorine bleaches are sodium and
potassium dichlorocyanurates, diehlorocyanuric acid; 1,3-dichloro-
5,5-dimethyl hydantoin; N,N'-dichlorobenzoylene urea; paratoluene
sul~ondichloroamide; trichloromelamine; N-chloroamnleline;
N-chlorosuccinimide; N, N'-dichloroazodicarbonamide; N-chloro-
acetyl urea; N,N'-dichlorobiuret; chlorinated dicyandiamide;
sodium hypochlorite; calcium hypochlorite; and lithium hypo-
chlorite. The detergent compositions contain from about 0 . 03% to
about 1.2% and preferably frorn about 0.196 to about 0.6~ of avail-
able chlorine.
The enzymes ~hat can be utilized in the detergen~ composi-
tions are protease, emylases and mixtures thereof. The level of
proteases present in the detergent composition is from about 0 . 01
Anson Units (A.U.) per 100 grams to about 0.27 A.U. per 100
grams and preferably from about 0.06 A.U.p~r 100 grams to about
0.25 A.U. per 100 grams. The level of amylase present in the
-- ~8 --
detergent composition is frQm about 150 Amylase Units per 100
grams of detergent composition to abau~ 24,000 Amylase Llnits per
100 grams of detergent composition and preferably from about
1200 Amylase lJnits per 100 grams of detergent composition to
about 6000 Amylase Units per 1û0 grams of detergent composi~ion.
Amylase Units are defined in U. K . Patent 1 ,275 ,3~1 Desforges
(published May 24, 1972)o
The concentrated laundering process also permits the effec-
tive use of novel detergent compositions comprising other desir-
able auxiliary ingredients at levels ~hat would provide essentially
no eonsumer noticeable benefit at normal usage levels in conven-
tional automatic wash processes. Such ingredients include o~?tioal
brighteners, soil release agents, antis~atic agents, ~yes, per-
fumes, pH adjusting agents, detergency builders, antibact2riai
agents, antifungal agents, antitarnish and anticorrosion agents,
etc. Preferably, tilese ingredients are used at levels in a deter-
g~nt composltion that provide no corlsumer noticeable benefit when
the detergent cornposition is used in conventional automatic home-
type washing machine processes at normal usage levels.
A "consumer noticeable benefit" is based upon a reprecenta-
tive number of consumers, the benefit bein~ such that it can be
recognized by a majority of the consumers at the 95% confidence
level. More preferably these ingredients are used at less than
3/4 of the level at which a consumer benefit is seen, mo5t pref-
erably at less than 1/2 of said level.
I$ Is intended to cover in the appended claims all such
modifications that are within the scope of this invention.
