Note: Descriptions are shown in the official language in which they were submitted.
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ARTICLE FOR CLEANING SURFACES
FIELD OF THE INVENTION
The present invention relates to cleaning cloths for dry wipe cleaning of
household
surfaces such as carpets, upholstery and clothing. The cloths can also be used
to clean
environmental surfaces such as furniture, floors, and the like, in an improved
dusting
operation.
CROSS REFERENCE
This application claims priority under Title 3 5, United States Code I 19(e)
from
Provisional Application Serial No. 60/011,447, filed February 9, 1996.
BACKGROUND OF THE INVENTION
Household cleaning tasks are conducted using articles and compositions which
are
designed to remove dirt and residues from a wide variety of surfaces. For
example, items
such as simple dust cloths and mops are conventionally used to remove
particulate matter
from hard surfaces such as furniture. Such items are often supplemented by
spray-o~n
waxy or oily compositions which are designed to enhance the uptake of dirt
particles.
Fabric surfaces are conventionally cleaned using various surfactants and
surfactant pastes.
For example carpet and fixrniture fabrics are typically scrubbed and/or
cleaned by means of
surfactants andlor solvents which are designed to loosen oily dirt from the
fabrics, and the
resulting residues are sometimes absorbed into a material such as clay or
kieselguhr, which
is then discarded. Garments and other fabrics such as draperies, tablecloths,
and the like,
are often cleaned by immersion processes involving various organic solvents
and/or by
conventional wet processes involving detersive surfactants and water, either
in an
immersion or spray-on operation.
In many instances, surface cleaning operations involve the application of
small
quantities of "pre-spotting" agents to discrete, highly stained areas of the
article being
cleaned. While effective for their intended use, such localized spot removal
treatment
compositions are generally expensive on a per-use basis and would not be
suitable for
large scale cleaning operations.
Accordingly, there is a continuing search for simple, effective cleaning
processes
and compositions for use by the consumer. Moreover, there is a continuing
search for
approved cleaning compositions which are cost effective.
The present invention provides a cleaning cloth for what can be termed "dry-
wipE:"
cleaning of household surfaces such as carpets, upholstery, clothing, and the
like. The
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dry-wipe cleaning articles herein can be passed across such surfaces, and
oils, particulates
and gummy residues are transferred onto the wipe fabric. The practice of the
invention '
provides an unexpectedly high level of cleaning, approaching wet detergent
cleaning in
some cases, but without the mess, prospective damage and recoiling potential
occasioned '
by the presence of unremoved wet detergent residues. In another mode, the
articles and
processes herein can be used in a conventional "dusting" operation on hard,
non-fabric
surfaces. In yet another mode, the articles herein can be used to clean living
beings, e.g.,
the hair on domestic pets, farm animals, as well as to clean human hair and
skin.
SITMMARY OF THE INVENTION
The present invention encompasses an article, typically a fibrous article, for
cleaning surfaces, comprising:
(a) a substrate, said substrate being characterized by its oleophilic nature
and
its ability to acquire a strong electrostatically positive charge when passed
across the surface being cleaned; and
{b) said substrate releasably containing an auxiliary cleaning composition,
preferably a monohydric alcohol which is a member selected from the
group consisting of ethanol, isopropanol, and mixtures thereof.
A preferred article herein is wherein the substrate comprises polyester
fibers. An
especially preferred article is wherein the substrate is SOMMERS STYLES 235
and 265.
In one embodiment, the auxiliary cleaning composition can comprise a member
selected from the group consisting of methoxy-, ethoxy-, propoxy- and butoxy-
propoxypropanol. In another embodiment, the auxiliary cleaning composition
comprises
1,2-octanediol. In yet another embodiment, the auxiliary cleaning composition
can
comprise a nonionic surfactant. The auxiliary cleaning composition can
comprise mixed
ingredients, such as a mixture of butoxy-propoxypropanol and 1,2-octanediol,
and a
nuxture of butoxy-propoxypropanol, 1,2-octanediol and an ethoxylated alcohol
or alkyl
phenol.
In an optional mode, the article herein is designed for use in a hot air
clothes dryer.
Under such circumstances, the article can comprise an aqueous
cleaning/refreshment
composition. Such compositions will typically comprise water {up to about
99.95%, by
weight) and from about 0.05% to about 2.5%, by weight, of a nonionic
surfactant,
especially an ethoxylated C 12-C 1 g alcohol.
The invention also encompasses a process for cleaning fabrics in a
conventional
automatic clothes dryer, comprising the steps of placing soiled fabrics
together with the
substrates herein, especially in sheet form, or with an article according to
any of the
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foregoing embodiments, in the drum of the clothes dryer, and operating the
dryer under
conventional usage conditions involving rotation of the dryer drum and the
introduction of
hot air into the drum.
All percentages, ratios and proportions herein are by weight, unless otherwise
specified. All documents cited are, in relevant part, incorporated herein by
reference.
)BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a sheet of the present type (1) for placement in the containment
bag
which is used in the in-dryer mode of the present process.
Figure 2 is a perspective of the sheet loosely resting on a notched, vapor-
venting
containment bag which is in a pre-folded condition.
Figure 3 is a perspective of the sheet within the bag which is ready to be
treated i.n
a hot air clothes dryer.
Figure 4 is a partial view of the notched wall of the bag and its disposition
relative
to the closure flap.
Figure S is a perspective of an un-notched vapor-venting bag containing a
sheet
which is ready for use in the present process.
DETAILED DESCRIPTION OF THE INVENTION
Substrates - The substrates herein are characterized by their oleophilic
nature and
by their ability to acquire a strong electrostatically positive charge when
passed across or
rubbed on the surface being cleaned. Such substrate materials had been
available as the
9000 series KRYONTM Non-Wovens of J. P. Stevens Company, especially KRYON
9003.
Such substrates are now available from Sommers Inc., 1410 Spruce Street,
Stroudsburl;,
PA 18360, especially the chemically bonded non-wovens, available as Styles 235
and 265.
SOMMERS Style 235 is a dry-layed, polyester fabric chemically bonded with an
acrylic
latex. The product weight (oz. per yd2) is 0.9 ~ 10% (0.003 g/cm2). Style 235
its
available in a thickness of 0.009 ~ 0.001 inch (0.23 ~ 0.02 mm). SOMNN1ERS
Style 265 is
likewise a dry-Iaid, polyester fabric chemically bonded with acrylic latex. It
has a product
weight {oz. per yd2) of 1.5 ~ 10% {0.005 g/cm2) and a thickness of 0.013 ~
0.001 inch
(0.33 t 0.2 mm). Such sheet-formed materials can be used herein as received
from the
manufacturer, or can be folded into mufti-layer pads.
Apart from the commercially available SOMMERS (or counterpart KRYOT~
materials used herein, substrates useful herein can be made by adhering
various
commercial Latex or acrylic latex suspensions on non-woven fabrics such as non-
woven
polyester available from Reemay. Whatever method is used to obtain the
substrate, a
simple test can be conducted to select substrates for use herein. One such
test involves the
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use of a Faraday cage to measure the friction-induced build-up of electrical
charge on the
substrate. In this test (conducted at 74°F (23°C)/12% relative
humidity) a 5 in. x 6 in. '
(12.7 x 15.2 cm) sample of substrate is affixed to a wooden block (insulator)
and hand-
rubbed 20 strokes across DACRONTM, nylon and HerculonTM carpeting. (The
operator '
should wear rubber gloves to prevent charge bleed-of~) The substrate is
promptly placed
in the Faraday cage, and the charge is measured. Illustrative results are as
follows.
SUBSTRATE NYLON DACRONTM HERCULONTM
SOMMERS 265 +1,15 +0,70 +1.25
SOMMERS 235 +1.08 +1.25 +1.13
KRYON 9003 +1.09 +0.66 +1.28
REEMAY (control)* -0.08 +0.07 -0.60
* 100% polyester; no binders or finishes.
Substrates useful in the present invention typically acquire a charge of at
least .
about +0.5 volts on at least one, preferably ail three, of the carpet samples
in the above
test. Preferably, the substrate acquires a charge of at least about 1.0 volts.
If the substrate
is desiccated, e.g., using heat, vacuum, water absorbents such as silica gel,
etc., the
acquired change can be increased by +0.5 to +I.0 volts. If the substrate is
affixed to a
heated block or carrier, the acquired charge can be as high as +3 volts.
Different from the
dryer-added sheets known in the art for fabric softening and anti-static
benefits (e.g.,
BOLJi~TCE'~'M sheets), the substrates herein do not contain cationic fabric
softeners, since
such softeners would tend to diminish the acquired positive charge.
Gleaning Method - A combination of two observed mechanisms would appear to
be operating in this cleaning development. The first is an oleophilic
attraction of the
substrate herein for oils and gums on the surface being cleaned. Synthetic,
non-woven
fabrics made from polyester polyolefins {especially polypropylene) and nylon
are
sufficiently oleophilic to achieve this portion of the cleaning mechanism
proposed herein.
Polyester is preferred. The second is that the substrate herein can acquire a
strong
electrostatically positive charge when rubbed across the surface being
cleaned. This
strong positive charge relative to the cleaned surface causes particulate soil
to be drawn to
the substrate. As an overall proposition, and while not intending to be
limited by theory, it ,
is believed that the fiber used as the substrate should be a good electrical
insulator and that
the charge is picked up by the discontinuous treatment on the surface of the
substrate, ,
either in the binder or in finishing agents.
It is further to be noted that special packaging and operational methods can
enhance the electrostatic effect of the substrates used herein. Desiccation
during
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packaging and/or heating during use both can advantageously reduce humidity
a;nd
moisture. It has been noted that high humidity and/or moisture can
disadvantageously
drain the charge build-up on the surface of the substrate. Thus, the surface
being cleaned
is preferably not wet. It is to be appreciated, however, that under usual
conditions where
5 humidity and moisture are dissipated, e.g., in a hot air clothes dryer, the
substrates herein
can be employed to advantage. When rendered sufficiently dry that they again
can pick up
the electrostatic charge, e.g., near the end of the drying cycle in an
automatic clothes
dryer, the substrates then regain their ability to function as a cleaning aid
in the manner
described herein.
IO Moreover, taking due consideration of the humidity/moisture limitations
noted
above, it has been determined that use of a suitable light solvent on the
substrate can help
soften gummy material present on the surface being cleaned, thereby further
enhancing the
cleaning effect. Materials such as monohydric alcohols and other non-aqueous
solvents
can be employed for this purpose. After evaporation of the light solvent, the
electrostatic
charge build-up attracts the Loosened soils to the substrate.
The cleaning process herein is carried out simply, yet effectively, by rubbing
the
substrate across the surface to be cleaned. In one mode, this can be
accomplished by
simple hand-rubbing. Such a procedure is convenient for use when cleaning
upholstered
furniture, environmental surfaces such as furniture, tabletops, ornamental
ware, and the
tike. This method can also be used for cleaning and removing detritus from
hair and fiir,
such as on domestic and farm animals, and even human hair. This latter use is
particularly
helpful under circumstances where it is unhandy or difficult to employ
conventional water-
based shampoos, e.g., in a hospital environment, when traveling, and the'
like. In another
mode, the substrate herein can be affixed to an apparatus, such as a mop,
broom, vacuum
sweeper, and the like, and rubbed across areas of floor carpeting, or the
like.
In one variation, the substrate can be affixed to heated appliance (e.g.,
electrical
heat] to soften gummy soils and to reduce the humidity of the substrate,
thereby increasing
the static charge. In still another mode, the articles are brought into
intimate rubbing
contact with garments which are tumbled together with the substrate in a
conventional hot
air clothes dryer. In yet another embodiment, the articles are affixed to a
non-conductor,
i.e., an electrically insulating implement, e.g., made of wood or plastic.
In still another embodiment, the articles herein can comprise the substrate in
a
sheet form which substantially encloses any hard, soft or semi-soft non-
conductor material.
For example, a Latex block, sponge or the like can provide a semi-soft non-
conductive
"core°' element whose outer surfaces are encased or otherwise enrobed
in the sheet
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substrate. Alternatively, the core can comprise a soft material such as
polyester or
polypropylene or other fibrous batting. The core element provides additional
bulk to such
articles, thereby providing convenient gripping means for the user. In yet
another mode,
the sheet substrate can be fashioned into a pocket or pouch which removably
encloses the
non-conductor core. After use, the outer sheet with its layer of dirt and
detritus can be
removed from the core and discarded. The core can be re-used by placing it
within a fresh
pocket or pouch comprising the substrate sheet. In various other modes, the
substrate can
be fashioned into mitts, gloves, pads and the like to provide ease-of use. In
one
embodiment, a mitt can be lined with a non-conductive material such as a
polyethylene
film which prevents the charge from bleeding off due to contact with moisture
on the
user's hand. The substrate can be provided in the form of rolls in the manner
of disposable
paper toweling, as individual sheets, and the like. These illustrations are
given by way of
explanation and not limitation of methods for using the substrates herein in a
cleaning
function. Whatever method or article is employed, the objective is to bring
the substrate
into close contact with the surface to be cleaned, said contact to be
accompanied by a
rubbing or other motion which causes the electrostatic charge to be developed
on the
surface of the substrate.
The size and shape of the substrate employed herein for cleaning purposes is
dictated generally by matters of convenience in use and, of course, by the
size of the article
being cleaned and the degree of soiling. Conveniently sized substrates for use
in cleaning
hair, furniture, ornamental ware, tabletops, and the like, is about 12 inches
x 12 inches
(30.5 cm x 30.5 cm). The size of the substrate for use in an automatic clothes
dryer can
range from about 100 in2 (645 cm2) to about 500 in2 (3226 cm2).
The following examples illustrate various cleaning processes according to the
present invention.
EXAMPLE I
A 15 cm X 15 cm sheet of SOMMERS Style 235 is rubbed vigorously across a
garment which is soiled with body soil and lint particles. The garment is
satisfactorily
cleaned.
EXAMPLE II
A 10 in. x 10 in. {25.4 cm x 25.4 cm) sheet of SOMMERS Style 265 is folded
over
twice to provide a pad weighing about 2.8g. 1.0 Gram of substantially water-
free (i.e.,
Less than about 2%, by weight, of water) isopropanol is uniformly absorbed in
the pad.
The pad is packaged in a sealed foil pouch. In use, the pad is removed from
the pouch and
rubbed across the soiled surfaces of garments, upholstery, and the like to
remove oily soil
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and detritus. In an optional mode, a light, substantially water-free perfume
is added to tlhe
pad for aesthetic purposes.
EXAMPLE III
A sheet of SOMMERS Style 26S is rubbed on the fur of a domestic animal to
remove soil. In an alternate mode, the sheet is lightly moistened (ca. 1 gram)
with
substantially water-free ethyl alcohol. The ethyl alcohol provides improved
release of oiily
soils from the fur without interfering with the electrostatic attraction of
the sheet for
particulate soil.
EXAMPLE IV
A sheet (S00 cm2) of SOMMERS Style 23S or SOMMERS Style 26S fabric is
placed together with damp fabrics in a conventional hot air clothes dryer. The
dryer is
operated in standard fashion whereby the tumbling action afforded to the
fabrics and sheet
causes them to come into close, rubbing contact. The dryer is operated until
substantially
all the moisture is removed from the fabric and the sheet, and tumbling is
thereafl:er
1S continued for an additional 1-10 minutes. The sheet helps remove
particulate and oily soil
present on the fabric surfaces.
In an alternate mode, hair, lint and other particulate detritus is removed
from
fabrics by placing dry fabrics in a conventional hot air clothes dryer and
tumbling said
fabrics with a sheet of SOMMERS Style 23S or SOMMERS Style 26S substrate for a
period of about 1 minute to about 1 S minutes.
EXAMPLE V
Electronic equipment, including phonograph records, compact discs, cathode ray
tubes (e.g., TV screens and computer monitors) and the like can be cleaned by
rubbing
their surfaces with a sheet or pad of SOMMERS Style 23S or 26S substrate. In
an
2S alternate mode, the substrate can contain a small amount of volatile
solvent such as
ethanol or isopropanol to assist in the removal of oily material present on
the surface of
the electronic components.
Fabric Cleaning/Refreshment - While the foregoing examples illustrate the use
of
substrates herein in environments which, mainly, are substantially water-free,
the following
further illustrates the use of the compositions and processes embodied in the
present
invention in a home dry cleaning operation using fully formulated cleaning
compositions
which can contain water. In these processes, the sheet substrate is employed
in
combination with a cleaning composition and, preferably, a vented containment
bag. In
apse, the moisture present in the cleaning composition first serves to assist
in cleaning l.he
3 S fabrics and provides a dewrinkling and general fabric "refreshment"
function, and is then
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vented from the bag by the heat of the laundry dryer. Once the moisture is
removed, the
sheet substrate herein can assume its electrostatic charge and attract and
remove
particulate soils. The following gives further details regarding the dry
cleaning
compositions which are suitable for use in such processes, as well as the
vented cleaning
bags which can be employed therein.
The dry cleaning process using a vapor-venting containment bag is conducted in
a
tumbling apparatus in the presence of heat. In a convenient mode a perforated
or
otherwise vapor-venting container bag with the article herein which comprises
the
carner/cleaning composition and enveloping the soiled fabric is closed and
placed in the
drum of an automatic hot air clothes dryer. The drum is allowed to revolve,
which imparts
a tumbling action to the bag and agitation of its contents concurrently with
the tumbling.
By virtue of this agitation, the fabrics come in contact with the carrier
containing the
cleaning composition. The tumbling and heating are carried out for a period of
at least
about 10 minutes, typically from about 20 minutes to about 30 minutes. During
this time,
I S water and other vapors are vented from the bag. The process can be
conducted for longer
or shorter periods, depending on such factors as the degree and type of
soiling of the
fabrics, the nature of the soils, the nature of the fabrics, the fabric toad,
the amount of heat
applied, and the like, according to the needs of the user.
The chemical compositions which are used to provide the cleaning function in
the
present in-dryer process comprise ingredients which are safe and effective for
their
intended use. Since the in-dryer cleaning/refreshment process herein does not
involve an
aqueous rinse step, the compositions employ ingredients which do not leave
undesirable
residues on fabrics when employed in the manner disciosed herein. While
conventional
laundry detergents are typically formulated to provide good cleaning on cotton
and
cotton/polyester blend fabrics, the cleaning compositions herein must be
formulated to also
safely and effectively clean and refresh fabrics such as wool, silk, rayon,
rayon acetate, and
the like.
In addition, the cleaning/refreshment compositions herein comprise ingredients
which are specialty selected and formulated to minimize dye removal from the
fabrics being
cleaned. In this regard, it is recognized that the solvents typically used in
immersion dry
cleaning processes can remove some portion of certain types of dyes from
certain types of
fabrics. However, such removal is tolerable in immersion processes since the
dye is
removed relatively uniformly across the surface of the fabric. In contrast, it
has now been
determined that high concentrations of certain types of cleaning ingredients
at specific sites
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on fabric surfaces can result in unacceptable localized dye removal. The
preferred cleaning
' compositions herein are formulated to minimize or avoid this problem.
The dye removal attributes of the present cleaning compositions can be
compared
' with art-disclosed cleaners using photographic or photometric measurements,
or by means
of a simple, but effective, visual grading test. Numerical score units can be
assigned to
assist in visual grading and to allow for statistical treatment of the data,
if desired. Thus, in
one such test, a colored garment (typically, silk, which tends to be more
susceptible to d.ye
loss than most woolen or rayon fabrics) is treated by padding-on cleaner using
an
absorbent, white paper hand towel. Hand pressure is applied, and the amount of
dye which
is transferred onto the white towel is assessed visually.
In addition to the foregoing considerations, the clearung/refreshment
compositions
used herein are preferably formulated such that they are not so adhesive in
nature that they
render the device unhandy or difficult to use. However, and while not
intending to be
limiting of the present invention, the preferred compositions disclosed herein
afford a spot-
cleaning process which is both effective and aesthetically pleasing when used
with a deviice
according to this invention.
Having due regard to the foregoing considerations, the following illustrates
t:he
ingredients used in the cleaning compositions herein, but is not intended to
be limiting
thereof.
(a) Solvent - The compositions may optionally comprise from about 2% to
about 4%, typically from about 5% to about 25%, by weight, of organic
cleaning solvent. If solvent is used, the objective is to provide at least
about
0.4 g, preferably from about 0.5 g to about 2.5 g, of solvent per kg of
fabrics being cleaned.
(b) Emulsifier - The compositions may optionally comprise sufficient
emulsifier
to provide a stable, homogeneous composition comprising components (a),
(b) and (d). For the preferred emulsifiers disclosed hereinafter, levels as
low as 0.05%, preferably 0.07% to about 0.20%, by weight, are quite
satisfactory. If less efficient emulsifiers are used, levels up to about 2%,
by
weight, can be used, but may leave some noticeable residues on the fabrics.
(c) Water -The compositions may comprise about 60%, and can comprise from
about 80% to about 95%, or even as high as about 99.75%, by weight, of
water. For the in-dryer fabric process, the objective is to provide at least
about 6 g of water per kg of fabrics being cleaned and refreshed.
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(d) Optionals - The compositions herein may comprise various optional
ingredients, including perfumes, conventional surfactants, and the like. If '
used, such optional ingredients will typically comprise from about 0.1% to
about 10%, by weight, of the compositions, having due regard for residues '
5 on the cleaned fabrics.
It has now been determined that 1,2-octanediol ("OD") affords special
advantages
in the formulation of the cleaning compositions herein. From the standpoint of
aesthetics,
OD is a relatively innocuous and low odor rnateniaI. Moreover, OD appears to
volatilize
from fabric surfaces without leaving visible residues. This is especially
important in a dry
10 cleaning process of the present type which is conducted without a rinse
step. From the
performance standpoint, OD appears to function both as a solvent for
greasy/oily stains
and as what might be termed a "pseudo-surfactant" for particulate soils and
water-soluble
stains. Whatever the physical-chemical reason, OD has now been found to be a
superior
wetting agent with respect to both cleaning and ease-of use in the present
context of
home-use cleaning compositions and processes. If used, OD will comprise at
Least about
0.05%, typically from about 0.1% to about 1.5%, by weight of the cleaning
compositions
herein.
A preferred solvent herein is butoxy propoxy propanol (BPP) which is available
in
commercial quantities as a mixture of isomers in about equal amounts. The
isomers, and
mixtures thereof, are useful herein. The isomer structures are as follows:
n-C 4Hg-O -C H2C H2C Hz-('? -C H2C H2C H2-O H
C H3
~-C4Hg-O -C H2-C -O -C H2C H2C H2-O H
H
CH3
~-C 4Hg-O -C H2C H2C Hz--~-O -C H2-C -O H
i
H
BPP is outstanding for cleaning, and is so effective that it allows the amount
of the
relatively expensive 1,2-octanediol to be minimized. Moreover, it allows for
the
formulation of effective clearing compositions herein without the use of
conventional
surfactants. Importantly, the odor of BPP is of a degree and character that it
can be
relatively easily masked by conventional perfume ingredients. While BPP is not
completely
miscible with water and, hence, could negatively impact processing of the
cleaning
compositions herein, that potential problem has been successfi.rlly overcome
by means of
the PEMLTLEN-type polyacrylate emulsifiers, as disclosed hereinafter.
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The BPP solvent used herein is preferably a mixture of the aforesaid isomers.
In a
preferred mode, the cleaning compositions comprise a mixture of the 1,2-
octanediol and
BPP, at a weight ratio of OD:BPP in the range of from about 1:250 to about
2:1,
preferably from about 1:200 to about 1:5.
A highly preferred emulsifier herein is commercially available under the
trademark
PEMULEN, The B. F. Goodrich Company, and is described in U.S. Patents
4,758,641 and
5,004,557, incorporated herein by reference. PEMULEN polymeric emulsifiers are
hil;h
molecular weight polyacrytic acid polymers. The structure of PEMULEN includes
a sm~ali
portion that is oil-loving (lipophilic) and a large water-loving (hydrophilic)
portion. The
structure allows PEMULEN to function as a primary oil-in-water emulsifier.
T;he
lipophilic portion adsorbs at the oil-water interface, and the hydrophilic
portion swells in
the water forming a network around the oil droplets to provide emulsion
stability. An
important advantage for the use of such polyacrylate emulsifiers herein is
that cleaning
compositions can be prepared which contain solvents or levels of solvents that
a~.re
otherwise not soluble or readily miscible with water. A further advantage is
that ei~ective
emulsification can be accomplished using PEMULEN-type emulsifier at extremely
law
usage levels (0.05-0.2%), thereby minimizing the level of any residue left on
fabrics
following product usage. For comparison, typically about 3-7% of conventional
anionic or
nonionic surfactants are required to stabilize oil-in-water emulsions, which
increases the
likelihood that a residue will be left on the fabrics. Another advantage is
that
emulsification (processing) can be accomplished e#~ectively at room
temperature.
While the cleaning compositions herein function quite well with only the 1,2-
'
octanediol, BPP, Pemulen and water, they may also optionally contain detersive
surfactants
to further enhance their cleaning performance. While a wide variety of
detersive
surfactants such as the C 12-C is alkyl sulfates and alkylbenzene sulfonates,
the C I2-C 16
ethoxylated (EO 0.5-10 avg.) alcohols, the C12-CI4 N-methyl glucamides, and
the tike
can be used herein, it is highly preferred to use surfactants which provide
high grease/oil
removal. Included among such preferred surfactants are the C 12-C 16 alkyl
ethoxy sulfates
(AES), especially in their magnesium salt form, and the C 12-C 16 dimethyl
amine oxides.
Especially preferred mixtures comprise MgAEl S/C 12 dimethyl amine oxide, at a
weight
ratio of about 10:1, and MgAE 1 S/C 12 dimethyl amine oxide at a 2: I weight
ratio. If used,
such surfactants will typically comprise from about 0.05% to about 2.5%, by
weight, of i:he
cleaning compositions herein.
In addition to the preferred solvents and emulsifiers disclosed above, the
cleaning
compositions herein may comprise various optional ingredients, such as
perfumes,
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WO 97!29178 PCT/LTS97!01661
12
preservatives, co-solvents, brighteners, salts for viscosity control, pH
adjusters or buffers,
anti-static agents such as VERSAFLEX 157 or VERSAFLEX 2004 from National
Starch
and Chemical Company, softeners, colorants, mothproofing agents, insect
repellents, and
the like. Enzymes such as proteases, amylases, lipases and mixtures thereof
can also be -
S used at levels from about 0.0001% to about 1% of the compositions. The
following
illustrates preferred ranges for cleaning compositions for use herein, but is
not intended to
be limiting thereof.
Ingredient °/ (wt.) Formula Rank
BPP* S-2S%
1,2-Octanediol 0.1-7%
PEMULEN* * 0.05-0.20%
Neodol 23-6.5*** 0. I-2.S%
Perfume 0.01-1.S%
Water Balance
pH range from about 6 to about 8.
*Other solvents or co-solvents which can be used herein include various glycol
ethers,
including materials marketed under trademarks such as Carbitol, methyl
Carbitol, butyl
Carbitol, propyl Carbitol, and hexyl Cellosolve, and especially methoxy
propoxy propanol
(MPP), ethoxy propoxy propanol (EPP), propoxy propoxy propanol (PPP), and all
isomers
and mixtures, respectively, of MPP, EPP, and PPP, and the like, and mixtures
thereof.
Indeed, although somewhat less preferred, the MPP, EPP and PPP, respectively,
can
replace the BPP solvent in the foregoing cleaning compositions. The Levels of
these
solvents, and their ratios with I,2-octanediol, are the same as with the
preferred BPP
solvent. If desired, and having due regard for safety and odor for in-home
use, various
conventional chlorinated and hydrocarbon dry cleaning solvents may also be
used.
Included among these are 1,2-dichloroethane, trichloroethylene, isoparaffins,
and mixtures
thereof.
**As disclosed in U.S. Patents 4,758,641 and 5,004,557, such polyacrylates
include
homopolymers which may be crossIinked to varying degrees, as well as non-
crosslinked.
Preferred herein are homopolymers having a molecular weight in the range of
from about
100,000 to about 10,000,000, preferably 200,000 to 5,000,000.
***CI2_C13 alcohol average ethoxylate (EO) 6.5; trademark Shell.
removal from fabrics as disclosed above is as follows.
A dry cleaning composition with reduced tendency to cause dye "bleeding" or
3S removal from fabrics as disclosed above is as follows.
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WO 97/29178 PCT/LTS97/01661
13
INGREDIENT PERCENT i(wt.) RANGE
Butoxypropoxy propanol (BPP) 7.000 4.0 - 25.0%
NEODOL 23 - 6.5 * 0.750 0.05 - 2.5%
1,2-Octanediol 0.500 0.1 - 10.0%
Perfume 0.750 0.1 - 2.0%
Pemulen TR-1 0.125 0.05 - 0.2%
Potassium Hydroxide (KOH) 0.060 0.024 - 0.10
Potassium Chloride 0.075 0.02 - 020
Water (distilled or deionized) 90.740 60.0 - 95.0%
Target pH = 7.0
*Shell; C12-C13 alcohol, ethoxylated
with average EO of6.5.
Another in-dryer cleaning and fabric refreshmentosition useful
comp herein is as
follows.
EXAMPLE VI
High water content ("Sweet Water"), low residue cleaning/refreshment
compositions for use in the in-dryer fabric cleaning/refreshment processes
herein are as
follows. The compositions are used in the manner disclosed hereinabove to
clean and
refresh fabrics.
ComQonents Percent Range (%) Function
Water De-ionized 98.8997 97-99.9 Vapor Phase Cleaning
TWEEN 20 0.50 0.5-1.0 Wetting Agent
Perfume 0.50 0.1-1.50 Scent, Aesthetics
KATHON CG* 0.0003 0.0001-0.0030 Anti-bacterial
Sodium Benzoate* 0.10 0.05-1.0 Anti-fungal
*Optional preservative ingredients.
20-30 Grams, preferably about 23 grams, of the "Sweet Water" composition are
absorbed into a SOMMERS 235 or 265 (28 cm x 38 cm) carrier sheet (the sheet is
preferably not "dripping" wet) which is of a size which provides sufficient
surface area that
effective contact between the surface of the carrier sheet and the surface of
the fabrics
being cleaned and refreshed is achieved. The sheet is used in the manner
described
hereinafter to clean and refresh fabrics in a hot air clothes dryer.
Besides the optional nonionic surfactants in the cleaning compositions herein,
which are preferably Cg-C 1 g ethoxylated (E01-15) aicohols or the
corresponding
ethoxylated alkyl phenols, the compositions can contain enzymes to further
enhance
cleaning performance. Lipases, amylases and protease enzymes, or mixtures
thereof, can
CA 02246231 1998-08-10
WO 97/29178 PCT/US97/01661
14
be used. If used, such enzymes will typically comprise from about 0.001% to
about 5%,
preferably from about 0.01% to about 1%, by weight, of the composition.
Commercial
detersive enzymes such as LIPOLASE, ESPERASE, ALCALASE, SAVINASE and
TE~tI. (all ex. NOVO) and MAXATASE and RAPIDASE (ex. International Bio-
Synthesis, Inc.) can be used. The compositions herein can optionally be
stabilized for
storage using conventional preservatives such as KATHON~ at a level of 0.0001%-
1%,
by weight.
The garments or other fabrics to be cleaned/refreshed are loaded into a vapor
venting containment bag as shown in the Figures together with a sheet
according to this
Example VI. The bag is closed and tumbled in a conventional hot air clothes
dryer for 30
60 minutes at temperatures above about 50°C, typically 50-85°C
but ranging in some
dryers as high as 200°C, and above, depending on dryer design, dryer
vent design and like
factors. In general, the "high" heat setting of the dryer is used. As shown in
the Figures,
the preferred bag used in this step is provided with a vapor-venting closure
which provides
one or more gaps through which vapors are released from the bag, in-use.
Alternatively,
the bag can be provided with a series of holes or other fenestrations which
provide vapor
venting. However, such venting is not as ei~ective as the vapor-venting
closure shown in
the Figures.
In one embodiment, the vapor-venting containment bag comprises an open end, a
closed end and flexible side walls having inner and outer surfaces, the open
end of said bag
having a section of one side wall extending beyond said open end to provide a
flexible flap,
said flap having first fastening device axed thereto, said flap being foldable
to extend
over a portion of the outside surface of the opposing side wall, said flap
being ai~xable to
the outer surface of the opposing wall of the bag by engaging said first
fastening device on
the inside face of the flap with a second fastening device present on the
outside face of
said opposing side wall, said first and second fastening devices, when thus
engaged,
forming a fastener, thereby providing a closure for the open end of the bag.
Said first and
second fastening devices are disposed so as, when engaged, to provide vapor-
venting
along said closure, especially at the lateral edges of the closure. The bag
herein is most
preferably formed from film which is heat resistant up to at least about
204°C-260°C.
Nylon is a preferred film material for forming the bag. In another embodiment,
the edge of
one wall of the bag is notched along a substantial portion of its width to
facilitate and
optimize vapor venting.
In an alternate mode, the flap can be folded to provide the closure, tucked
inside
the opposing side wall, and secured there by a fastener. In this mode, vapors
are vented
CA 02246231 1998-08-10
WO 97129178 PCT/US97/01661
along the closure and especially at the lateral edges of the closure. In yet
another mode,
the side walls are of the same size and no flap is provided. Fastening devices
placed
intermittently along portions of the inner surfaces of the side walls are
engaged when the
lips of the side walls are pressed together to provide closure. One or more
vapor-venting
5 gaps are formed in those regions of the closure where no fastening device is
present.
While the fastening devices herein can comprise chemical adhesives, the bag is
preferably designed for multiple uses. Accordingly, reusable mechanical
fasteners are
preferred for use herein. Any reusable mechanical fastener or fastening means
can be
used, as long as the elements of the fastener can be arranged so that, when
the bag is
10 closed and the fastener is engaged, a vapor-venting closure is provided.
Non-limiting
examples include: bags wherein said first and second fastening devices,
together, compri se
a hook and loop (VELCRO~-type) fastener; hook fasteners such as described in
U.S.
Patent 5,058,247 to Thomas & Blaney issued October 22, 1991; bags wherein said
first
and second fastening devices, together, comprise a hook and string type
fastener; bags
15 wherein said first and second fastener devices, together, comprise an
adhesive fastener;
bags wherein said first and second fastening devices, together, comprise a
toggle-type
fastener; bags wherein said first and second fastening devices, together, form
a snap-type
fastener; as well as hook and eye fasteners, ZIP LOK~-style fasteners, zipper-
type
fasteners, and the like, so long as the fasteners are situated so that vapor
venting is
achieved. Other fasteners can be employed, so long as the vapor-venting is
maintained
when the bag is closed, and the fastener is sufficiently robust that the flap
does not open .as
the bag and its contents are being tumbled in the clothes dryer. The fastening
devices c;m
be situated that the multiple vapor-venting gaps are formed along the closure,
or at the
lateral edges, or so that the gap is offset to one end of the closure. In yet
another
embodiment, both ends of the bag are provided with a vapor venting closure.
Figure 3 shows the overall dimensions of a notched bag: i.e., length (7) to
fold line
27 5/8 inches (70.2 cm); width (8} of bag 26 inches {66 cm), with a flap to
the base of tlhe
fold line (11) of 2 3/8 inches (6 cm). In the Tests reported hereinafter, this
bag is referred
to by its open dimensions as "26 in. x 30 in." (66.04 cm x 76.20 cm).
Figure 4 gives additional details of the positioning of the various elements
of the
notched bag. In this embodiment, all dimensions are the same for both the left
hand and
right hand sides of the bag. The dimensions herein are for an opened bag which
is about
30 inches (76.2 cm) in overall length (including the flap) and about 26 inches
(66 crn)
wide. The distance (9) from the lateral edge of the bag to the outermost edge
of t:he
fastening device (3) located on the inside of the flap (5) is about 2 inches
(5 em}. In ttis
CA 02246231 1998-08-10
WO 97/29178 PCT/US97/01661
I6
embodiment, the fastening device (3) on the inside of wall (2a) comprises the
loop portion
of a VELCRO~-type strip whose width ( 13 ) is about 0.75 inches ( 1.9 cm) and
whose
total length is about 22 inches (55.9 cm). Fastening device (6} is similarly
situated on the
outside of wall 2(b) and comprises the hook portion of a 3/4 inch ( 1.9 cm)
VELCRO~-
type strip. Distance (9) can be decreased or increased to decrease or increase
venting at
the edges of the flap when the bag is closed and the fastener is engaged. The
distance (10)
between the uppermost edge of the flap and the base of the notch is about 2
7/8 inches
(7.3 cm). The distance (14) between the lateral edge of the bag and the
lateral edge of the
notch is about 0.25 inches (0.64 cm). The distance (15) between the uppermost
edge of
the flap and the fold ( 11 ) is about 2 3/8 inches (6 cm). The distance ( 16)
between the
uppermost edge of the flap and the leading edge of the VELCRO~-type strip (3)
.afl~'lxed
to the flap is about 3/8 inches (0.95 cm). The distance (17) between fold (I1)
and the
lowermost edge of the notch is about 1/2 inch (I.27 cm). This distance also
can be varied
to decrease or increase vapor venting. A range of 0.25-I.5 inches (0.64-3.8I
cm) is
typical. The distance (18) between the uppermost edge of the VELCRO~-type
strip (6)
and the bottom edge of the notch is about 3l4 inches ( I .9 cm). The distance
( I9) between
the bottommost edge of the VELCRO~-type strip (3) and the fold (I1) is about I
1/4
inches (3.17 cm).
Figure 5 gives additional details of the dimensions of an un-notched envelope
bag
of the foregoing overall size comprising sidewalls (2a) and (2b). Again, each
VELCRO~
type strip (3) and (6) is about 3l4 inches (1.9 cm) in width and about 22
inches (55.9 cm)
in length. Each strip is' positioned so as to be inboard from each of the
lateral edges of the
finished bag wall and flap by about 2 inches (5 cm). The distance (12) between
the leading
edge of the sidewall (2b) to the base edge of the fastener strip (3) on the
flap portion of
the bag is about 2 1/2 inches (6.35 cm). The distance {20) between the base
edge of the
fastener strip (6) to the leading edge of the sidewall (2b) is about 2.25
inches (5.7 cm).
The distance (21) between the leading edge of the fastener strip (6) to the
leading edge of
the sidewall is about 1 3/8 inches (3.5 cm). The distance (22) between fold
(11) and the
base edge of the fastener strip (3) is about 2 inches (5 cm). The distance
(23) between the
leading edge of fastener strip (3) and the uppermost edge of the flap which is
an extension
of sidewall (2a) is about 0.25 inches (0.64 cm). Distance (24) is about 3 5/8
inches
(9.2 cm). As in the foregoing notched bag, the positioning and length of the
fasteners can
be adjusted to decrease or increase venting.
The construction of the preferred, heat-resistant vapor-venting bag used
herein to
contain the fabrics in a hot air laundry dryer or similar device preferably
employs thermal
CA 02246231 1998-08-10
WO 97/29178 PCTlUS97/01661
17
resistant films to provide the needed temperature resistance to internal self
sealing and
external surface deformation sometimes caused by overheated clothes dryers. In
addition,
the bags are resistant to the chemical agents used in the cleaning or
refreshment
compositions herein. By proper selection of bag material, unacceptable results
such as bag
melting, melted holes in bags, and sealing of bag wall-to-wall are avoided. In
a preferred
mode, the fastener is also constructed of a thermal resistant material. As
shown in Figures
3 and 5, in one embodiment, 1 to 3 mil (0.025-0.076 mm) heat-resistant Nvlon-6
film is
folded and sealed into a containment bag. Sealing can be done using standard
impulse
heating equipment. In an alternate mode, a sheet of nylon is simply folded in
half and
sealed along two of its edges. In yet another mode, bags can be made by air
blowing
operations. The method of assembling the bags can be varied, depending on the
equipmE;nt
available to the manufacturer and is not critical to the practice of the
invention.
The dimensions of the containment bag can vary, depending on the intended er~d-
use. For example, a relatively smaller bag can be provided which is sufficient
to contain
one or two blouses. Alternatively, a larger bag suitable for handling a man's
athletic
garment can be provided. Typically, the bags herein will have an internal
volume of from
about 10,000 cm3 to about 25,000 cm3. Bags in this size range are suf~rcient
to
accommodate a reasonable load of fabrics (e.g., 0.2-5 kg) without being so
large as to
block dryer vents in most U. S.-style home dryers. Somewhat smaller bags may
be used in
relatively smaller European and 3apanese dryers.
The bag herein is preferably flexible, yet is preferabl~,durable enough to
withstand
multiple uses. The bag also preferably has sufficient stif~tess that it can
billow, in-use,
thereby allowing its contents to tumble freely within the bag during use.'
Typically, such
bags are prepared from 0.025 mm to 0.076 mm (I-3 mil) thickness polymer
sheets. If
more rigidity in the hag is desired, somewhat thicker sheets can be used.
In addition to thermally stable "nylon-only" bags, the containment bags herein
can
also be prepared using sheets of co-extruded nylon and/or polyester or nylon
and/or
polyester outer and/or inner layers surrounding a Iess thermally suitable
inner core such as
polypropylene. In an alternate mode, a bag is constructed using a nonwoven
outer "shell"
comprising a heat-resistant material such as nylon or polyethylene
terephthalate and an
inner sheet of a polymer which provides a vapor barrier. The non-woven outer
shell
protects the bag from melting and provides an improved tactile impression to
the user.
Whatever the construction, the objective is to protect the bag's integrity
under conditions
of thermal stress at temperatures up to at least about 400-500°F
(204°C to 260°C). Under
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WO 97/29178 PCT/US97101661
18
circumstances where excessive heating is not of concern, the bag can be made
of polyester,
polypropylene or any convenient polymer material.
The dimensions of the containment bag can also vary, depending on the intended
end-use. For example, a bag can be provided which is sufficient to contain one
or two silk
blouses. Alternatively, a bag suitable for handling a man's suit can be
provided. As noted,
the bags herein will typically have an internal volume of from about 10,000
cm3 to about
25,000 cm3. Bags in this size range are sufficient to accommodate a reasonable
load of
fabrics (e.g., 0.5-5 kg) without being so large as to block dryer vents.
In a preferred embodiment, 0.025 mm to 0.075 mm nylon film is sealed into a 26
inch (66 cm} x 30 in. (76 cm) bag. Sealing is preferably done using standard
impulse
heating equipment. In an alternate mode, a sheet of nylon is simply folded in
half and
sealed along two of its edges. In yet another mode, bags can be made by air
blowing
operations.
As noted, in addition to bags with the vapor-venting closure, the walls of
bags
which are made from polymer sheet stock can be provided with slits, holes
(preferred) or
the like to provide means for the venting to occur. This can be simply, yet
ei~ectively,
achieved by punching holes in the walls of the bag using any convenient
instrument. in a
typical mode, 5-20 pairs of 1/4 inch (0.6 cm) - 1 inch (2.54 cm) holes are
uniformly
punched in the walls of a substantially rectangular bag having a total volume
of about
25,000 cm3. This provides adequate venting in the process herein. In another
mode, a
series of longitudinal s~;ts are cut in the walls of the bag.
EXAMPLE VII
The foregoing Examples illustrate the use of a commercially available
substrate
herein. This Example illustrates the preparation of a substrate sheet for use
herein. In this
process, the acrylic latex "bonding" or "coating" is applied by means of a
spray-on rather
than a dip coating, since it is preferred that the latex be present on the
sheet in discrete,
discontinuous spots rather than as a continuous Layer of coating. In one mode
of
manufacture, TEC brand acrylic latex emulsion #869 (TEC Incorporated, an H. B.
Fuller
company) is sprayed with a hand pump sprayer onto both sides of commercial
Reemay
polyester non-woven fabric of the type described above, typically, but not
limited to, fabric
having a weight (oz. per yd2) in the 0.8-1.6 (0.0026 g/cm2 - 0.0053 g/cm2)
range. After
drying overnight at ambient temperature, it is determined that about 9.0 wt.
%, based on _
the original fabric weight, is present as dried residual acrylic latex.
Samples prepared in
this manner test as +0.07 volts untreated (control) vs. +0.67 volts treated
with the acrylic
latex. As a range, acrylic latex-loaded samples prepared in this manner
typically comprise
CA 02246231 1998-08-10
WO 97/29178 PCT/US97/01661
19
about 4% to about 12% added acrylic latex, by weight. This results in about
0.5 to about
I.2 added positive volts in the electrostatic test described above.
Sheets of the foregoing type with the acrylic binder, preferably as a
discontinuous
coating, are used in the manner of any of the foregoing Examples by placing
them in
contact with and passing them across a soiled surface, thereby cleaning all
manner of
surfaces, including fabrics.
