Note: Descriptions are shown in the official language in which they were submitted.
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1
FABRIC STAIN REMOVAL METHOD
TECHNICAL FIELD
Fabrics are spot-cleaned with no or minimal visible damage by means of a
protective sheet which overlays the stained area during the process.
BACKGROUND OF THE INVENTION
Fabrics are often "spot treated" in localized areas to eliminate stains which
are judged to be particularly persistent and difficult to remove. Such stain
removal
processes typically employ various liquids, gel or semi-solid spot remover
compositions. In general, the process involves applying the spot remover to
the
stained area and vigorously rubbing, brushing, or blotting the area until the
stain is
judged to be satisfactorily removed. The ease-of removal for any stain can
depend
on its chemical composition, the amount of the stain and the type of fabric.
Cotton,
in particular, holds onto stains very tenaciously. Cotton is composed of
loosely
bound fiber bundles which are extremely porous in nature and prone to swelling
and
stretching of the weave. Cotton also exhibits a "fuzzy" fabric surface where a
multitude of individual fibrils are loosely splayed just above the fabric
surface. As
the number of loose fibrils is increased, e.g., by mechanical abrasion, so
does the
level of light scattering across the fabric surface, thereby creating the
illusion of
excessive garment wear and/or fading.
While occasional, random spot cleaning of garments is not likely to cause
much fabric fibrillation, repeated applications in the area of the underarms
(to assist
malodor removal) or collar/cuff area (to remove body soils) can cause
cumulative
negative effects. The process of the present invention comprises the
overlayment of
the stained area with a protective, preferably porous, material during such
treatment
The process herein is thus particularly effective for protecting the fabric
against
abrasion during such spot treatments, especially during multiple cleaning
episodes
on a particular site. This technique is effective with essentially all garment
types,
including fine silks, rayon, wool, linen, cotton, polyester, and blends
thereof.
BACKGROUND ART
Dry cleaning processes are disclosed in: U.S. 5,547,476 issued 8/20/96 to
Siklosi & Roetker; U.S. 5,591,236 issued 1/7/97 to Roetker; U.S. 5,630,847
issued
5/20/97 to Roetker; U.S. 5,630,848 issued 5/20/97 to Young, et al.; U.S.
5,632,780
issued 5/27/97 to Siklosi; EP 429,172A1, published 29.05.91, Leigh, et al.;
and in
U.S. 5,238,587, issued 8/24/93, Smith, et al. Other references relating to dry
cleaning compositions and processes, as well as wrinkle treatments for
fabrics,
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include: GB 1,598,911; and U.S. Patents 4,126,563, 3,949,137, 3,593,544,
3,647,354; 3,432,253 and 1,747,324; and German applications 2,021,561 and
2,460,239, 0,208,989 and 4,007,362. Cleaning/pre-spotting compositions and
methods are also disclosed, for example, in U.S. Patents 5,102,573; 5,041,230;
4,909,962; 4,115,061; 4,886,615; 4,139,475; 4,849,257; 5,112,358; 4,659,496;
4,806,254; 5,213,624; 4,130,392; and 4,395,261. Sheet substrates for use in a
laundry dryer are disclosed in Canadian 1,005,204. U.S. 3,956,556 and
4,007,300
relate to perforated sheets for fabric conditioning in a clothes dryer. U.S.
4,692,277
discloses the use of 1,2-octanediol in liquid cleaners. See also U.S. Patents
3,591,SI0; 3,737,387; 3,764,544; 3,882,038; 3,907,496; 4,097,397; 4,102,824;
4,336,024; 4,606,842; 4,758,641; 4,797,310; 4,802,997; 4,943,392; 4,966,724;
4,983,317; 5,004,557; 5,062,973; 5,080,822; 5,173,200; EP 0 213 500; EPO 261
718;
G.B. 1,397,475; WO 91/09104; WO 91/13145; WO 93/25654 and Hunt, D.G. and
N.H. Moms, "PnB and DPnB Glycol Ethers", HAPPI, April 1989, pp. 78-82.
SUMMARY OF THE INVENTION
The present invention encompasses, in a process for removing stains from a
localized area of a fabric, comprising the steps of applying a cleaning
composition to
said stain and, concurrently or consecutively therewith, applying mechanical
action
to said stain by means of a cleaning device, the improvement which comprises
covering the stain with a sheet of protective covering material which
minimizes
abrasion of the fabric caused by the mechanical action of the cleaning device.
Fibrillation of the fabric, which creates a worn appearance, is thereby
minimized.
In a preferred mode, the cleaning composition is a liquid, especially liquids
comprising water and surfactant or water, surfactant and organic cleaning
solvent. A
typical composition comprises water, butoxy propoxy propanol, MgAES surfactant
and amine oxide surfactant.
In a highly preferred mode, the mechanical action is provided by the
dispenser tip of a bottle which contains multiple portions of the cleaning
compositions.
A particularly advantageous feature of the present invention is that a more
aggressive tip execution for the dispenser bottle can be employed with
significant
reduction of fabric damage/fibrillation. This is an important point since
control of
the tip quality during manufacture is sometimes difficult. Some tips may have
sharp
edges due to processing limitations at the point where the tip is formed in a
mold.
These sharp edges can increase the risk of fabric damage, and cannot easily be
removed without essentially 100% visual inspection via microscopy. The
_____._._ r.
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overlayment technique of this invention minimizes the need for such
inspection,
thereby making the process more "forgiving" with respect to fabric damage.
w A highly preferred process for removing stain from a localized stained area
on a fabric thus comprises:
(a) placing the stained area of the fabric over and in contact with an
absorbent
material, preferably the fibrous Absorbent Stain Receiver Article or FAM-
foam as disclosed hereinafter;
(b) applying a liquid cleaning composition to said stain from a container
having
a dispenser spout; and
(c) concurrently or consecutively with step (b), rubbing or pressing said
cleaning
composition into said stain using the distal tip of said spout, whereby said
stain is transferred into the fluid absorbent material, with the improvement
which comprises covering the stain with a sheet of protective covering
material which minimizes abrasion of the fabric caused by the mechanical
1~5 action of the spout tip, thereby minimizing fibrillation of the fabric
being
treated.
The protective covering material used herein in contact with the stained area
of the fabric being cleaned can be any woven or non-woven cloth or cloth-like
sheet
which, itself, has sufficient strength and integrity to withstand the
mechanical forces
of the stain removal process herein. The tip of the dispenser spout can be
concave,
convex, or flat. The cleaning composition can be as noted above. In a less
preferred
mode, the absorbent material can be any conventional material which absorbs
the
liquid cleaning composition such as cloth, non-woven fabric, disposable paper
toweling, and the like.
All percentages, ratios and proportions herein are by weight, unless otherwise
specified. All documents cited are, in relevant part, incorporated herein by
reference.
DETAILED DESCRIPTION OF THE INVENTION
Protective Covering Material - A wide variety of mesh, porous or non-porous
materials can be used as the protective covering material. However, a balance
between cleaning effectiveness and fabric protection must be taken into
consideration. Of course, an extremely thick layer of the protective covering
material would provide 100% protection, but would so interfere with the
mechanical
action on the stain that stain removal would be minimal. In general, thinner
is better
than thicker. Fibrous protective materials (e.g., woven or nonwoven cloth) are
preferred, but porous or nonporous fabrics or sheet films can also be used.
The fiber
composition of the protective material can also be varied, though best results
are
with materials that are reasonably translucent or have sufficient pore size
that the
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4
user is able to observe the underlying stain and the progress being made for
its
removal during the cleaning process.
Of course, the protective material should be sufficiently strong that it can
withstand the mechanical force being applied (typically about 400-1000 g
force).
S The protective material must be sufficiently supple that it can transmit the
force to
the underlying fabric/stain. Accordingly, the protective material must be
neither so
unyielding that the force is not transmitted, nor so compressible that the
force is
dissipated, or that the tip of the cleaning implement finds itself in a "well"
formed in
the material.
It is to be understood that the process herein can be conducted in either of
two fashions. In the first, the stain is treated with the cleaning
composition, then
overlaid with the protective material, followed by application of mechanical
force to
the protective material which transmits it to the stain. In the second, the
stain is
overlaid with the protective material, the cleaning composition is applied to
the
protective material and allowed to pass therethrough, and mechanical force is
applied. Of course, in the second option the protective covering material must
be
porous and permeable to the cleaning composition. The pores in the protective
material should preferably not be so large that the tip of the cleaning
implement can
pass through and come into direct contact with the fabric being treated. In
general,
for fibrous protective materials the diameter of the fibers should be at least
as large
as the microscope irregularities on the dispenser tip and should remain so
even under
m-use compression.
Moreover, the protective covering material should not be so absorbent with
respect to the cleaning composition that it deleteriously competes with the
fabric
being treated for absorption of the composition.
Having due regard for the foregoing considerations, convenient,
commercially available protective covering materials herein can comprise a
wide
variety of woven and non-woven fabrics. Non-limiting examples include organza,
which is preferred herein. Chiffon can also be used, but cleaning results are
somewhat diminished. Physical parameters for these materials are as follows.
.~ .
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Chiffon Organza*
Basis Weight (gsm) 49.15 26.33
a Caliper at .l psi (mm) 1.52 1.02
Caliper at 2 psi (mm) 1.27 0.76
Opacity (%) 65.5** 54.1**
*Microscopically, the organza has an average of 24 vertical and 25 horizontal
polyester threads per quarter inch.
**Higher is more opaque.
Other protective coverings include nylon stocking material, polyvinylidine
chloride or polyethylene sheeting such as Glad WrapTM (a commercial food
wrap),
polyester fabric, spun-bonded nonwovens, and the like.
The protective material is laid down over the stain. The liquid cleaning
solution is applied, preferably from a container with a dispensing spout. The
stained
area of the garment or fabric swatch is optionally, but preferably, in close
contact
with any convenient absorbent material as noted above. In a preferred mode, an
Absorbent Stain Receiver Article (ASRA; described below) or FAM foam is
employed.
Absorbent Material - The absorbent material used herein will be preferably
non-Tinting and capable of absorbing the amount of cleaning composition used
to
treat the stain. As noted above, various materials can be used for this
purpose. The
following illustrates two preferred absorbents for use herein, but is not
intended to
be limiting thereof.
Absorbent Stain Receiver Article "ASRA") - The ASRA herein can
comprise any of a number of absorbent structures which provide a capillary
pressure
difference through their thickness (Z-direction). When designing the ASRA for
use
in the spot removal process herein, the following matters are taken into
consideration. First, the cleaning solution only removes the soil from the
fibers of
the fabric even with agitation. If the cleaning solution which carnes the soil
is
allowed to remain in the fabric, the soil will be redeposited on the fabric as
the
cleaning solution dries. The more complete the removal of cleaning solution
from
w the fabric, the more complete will be the removal of soil.
Second, the fabric being treated is, itself, basically a fibrous absorbent
structure which holds liquid (i.e., the cleaning solution) in capillaries
between the
fibers. While some liquid may be absorbed into the fibers, most of the liquid
will be
held in interfiber capillaries (this includes capillaries between filaments
twisted into
a thread). Liquid held in the fabric may be removed by contacting it with
another
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6
absorbent structure such as the ASRA, herein. In this process, liquid is
transferred
from the capillaries of the fabric to the capillaries of the ASRA.
Third, liquid is held in capillaries by capillary pressure. Capillary pressure
(Pc) is generally described by the following equation:
Pc = (2XGXCosA)/R where
G = the surface tension of the liquid
A = the contact angle between the liquid and the capillary wall
R = the radius of the capillary
Accordingly, capillary pressure is highest in capillaries which have a low
contact
angle and a small radius. Liquid is held most tightly by high capillary
pressure and
will move from areas of low capillary pressure to areas of high capillary
pressure.
Hence, in the subject ASRA which provides a capillary pressure difference
through
its thickness, liquid will move from low capillary pressure areas to high
capillary
pressure areas. Capillary pressure can be measured using a variety of
techniques,
1 S but will employ the liquid cleaning composition as the test liquid.
In reality, most absorbent materials are complex structures comprised of a
range of capillary sizes and contact angles. For this discussion, the
capillary
pressure of a material or capillary pressure zone within a material is defined
as the
volumetric weighted average of the range of pressures found within that
material or
zone.
For purposes of illustration, in circumstances wherein a soiled fabric
saturated with cleaning solution is in liquid communication contact with two
stacked, identical layers of homogeneous absorbent material, such as a paper
towel,
solution and soil would readily transfer from the fabric to the towel until
the
capillary pressure is approximately equal in the two materials. At equilibrium
a
certain amount of solution and soil will remain in the fabric. The exact
amount will
depend on the basis weight and capillary pressure characteristics of the
fabric and
towel. A reduced amount of residual solution and soil in the fabric, and
therefore
better cleaning, would result from replacing the bottom layer (layer not in
direct
contact with the fabric) of towel with an absorbent layer of capillary
pressure higher
than that of the towel. By virtue of its higher capillary pressure this
absorbent layer
will cause more solution to transfer from the low capillary pressure top towel
layer
to the high capillary pressure absorbent layer which in turn causes more
solution to
transfer from the fabric to the top towel layer. The result is better cleaning
due to
less residual solution and soil remaining in the fabric.
This type of multi-layer system is also beneficial when Z-directional pressure
is applied to the wetted stained fabric and ASRA. This pressure compresses the
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7
various materials, thereby lowering their void volume and liquid absorption
capacity
(increasing the % saturation of the materials}. This can cause liquid to be
squeezed
out. The layered structure allows for free liquid to be absorbed by the lower
layer,
i.e., the one furthest away from the fabric. This lessens the reabsorption of
liquid by
the fabric. This is especially true if the bottom layer (layer of highest
capillary
pressure) is also relatively incompressible (retains a higher percentage of
its void
volume under pressure) compared to the top layer (layer of lower capillary
pressure}.
In this case it may be desirable for the top layer to be resiliently
compressible so as
to express liquid under pressure which can be absorbed by the bottom layer.
Thus the ASRA can comprise two or more relatively distinct layers which
differ in capillary pressure. As can be seen from the capillary pressure
equation, a
difference in capillary pressure can be achieved by varying the capillary size
or the
contact angle between the cleaning solution and the ASR.A. Both factors can be
controlled by the composition of the ASRA. The contact angle portion of the
equation can also be affected by chemical treatment of the ASRA with, for
example,
a surfactant to lower the contact angle or a water repellent material such as
silicone
to increase contact angle.
The effectiveness of an ASRA comprising multiple layers of differing
capillary pressure can be enhanced by locating most of the total absorbent
capacity
in the high capillary pressure portion. The top fabric facing layer need only
be thick
enough to insulate the fabric from the liquid held in the bottom layer.
The effectiveness of the layered ASRA can be further enhanced by selecting
the low capillary pressure portion to have a capillary pressure higher than
that of the
fabric being treated.
In an ASRA comprised of two or more layers differing in capillary pressure,
the pattern of capillary pressure change can be characterized as "stepped".
Through
the thickness of the ASRA there is a sharp change or step in capillary
pressure at the
layer interfaces. It will be appreciated that the ASRA herein need not
comprise
multiple distinct layers, but rather can comprise a single layer structure
with a
relatively continuous capillary size gradient through its thickness.
Fibers - The ASRA can be made from a variety of materials including
fibrous absorbents and foams. Useful fibrous absorbents include nonwoven
fabrics
(carded, hydroentangled, thermal bonded, latex bonded, meltblown, spun, etc.),
thermal bonded airlaid nonwovens ("TBAL"), latex bonded airlaid nonwovens
("LBAL"), mufti-bonded airlaid nonwovens ("MBAL" combined latex and thermal
bonded), wet laid paper, woven fabrics, knitted fabrics or combination of
materials
(i.e., top layer of a carded nonwoven, and a bottom layer of wet laid paper).
These
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fibrous absorbents can be manufactured using a wide variety of fibers
including both
natural and synthetic fibers. Useful fibers include wood pulp, rayon, cotton,
cotton
linters, polyester, polyethylene, polypropylene, acrylic, nylon, mufti-
component
binder fibers, etc. Multiple fiber types can be blended together to make
useful
materials. Useful foam materials include polyurethane foams and high internal
phase emulsion foams. The critical factor is to have a difference in capillary
pressure within the thickness of the ASRA. A broad range of fiber sizes can be
employed. A typical, but non-limiting range of diameters is from about
0.5 micrometers to about 60 micrometers. For meltblown, the preferred fibers
are
less than about 10 micrometers. Typical spun-bond and synthetic staple fibers
range
in diameter from about 14 to about 60 micrometers. In general, one selects
smaller
diameter fibers for the high capillary pressure layer and higher diameters for
low
capillary pressure. Fiber length can depend on the forming process that is
being
used and the desired capillary pressure. Spun-bonds comprise a substantially
continuous fiber. For air-laid fibers, 4-6 mm is typical. For carded fibers
the range
is typically 25-100 mm. In addition, it has now been found that enriching the
upper
layer in bicomponent fibers decreases Tinting during use. Cleaning can also be
enhanced by making the top layer rich in synthetic (e.g., bicomponent) fibers
due to
their lipophilic nature which aids in the removal of oily stains from the
fabric being
treated.
Absorbent gelling materials ("AGM") such as those sometimes referred to in
the diaper art as 'supersorbers' can be added to either or both layers of the
receiver or
as a discrete layer between the fiber layers or on the back of the bottom
Iayer of the
ASRA. Functionally, the AGM provides additional liquid absorption capacity and
serves to drain the capillaries in the ASRA structure which helps to maintain
the
capillary pressure gradient as liquid is absorbed.
In light of the foregoing considerations, the ASRA herein can be defined as
an absorbent structure which has a capillary pressure difference through its
thickness
(Z-direction). In a typical, but non-limiting mode, this can be achieved by
having
relatively larger capillaries (for example 50-100 micrometers radius) in the
upper,
liquid-receiving ;portion of the ASRA which is placed in contact with the
fabric
being treated. The lower, liquid-storage portion having relatively smaller
capillaries
(for example 5-30 micrometers radius). Irrespective of the size employed, it
is
desirable that the difference in average capillary pressure between the two
layers be
large enough that the overlap in capillary pressure range between the two
layers is
minimized.
__ _ _ .. . _._ _ _~a. __
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Basis Weight - The basis weight of the ASRA can vary depending on the
amount of cleaning solution which must be absorbed. A preferred 127 mm X
127 mm receiver absorbs about 10-50 grams of water. Since very little liquid
is used
in the typical stain removal process, much less capacity is actually required.
A
typical TBAL ASRA pad weighs about 4-6 grams. A useful range is therefore
about
1 gram to about 7 grams. A variety of sizes can be used, e.g., 90 mm x 140 mm.
Size - The preferred size of the ASR.A is about 127 mm X 127 mm, but other
sizes can be used, e.g., 90 mm x 140 mm. The shape can also be varied.
Thickness - The overall thickness of the preferred ASRA is about 3 mm
(120 mils) but can be varied widely. The low end may be limited by the desire
to
provide absorbency impression. A reasonable range is 25 mils to 200 mils.
Lint Control Binder Spray - The ASRA is preferably dust free. Some
materials are naturally dust free (synthetic nonwoven fabrics). Some,
generally
cellulose containing materials, can be dusty because not all the fibers are
bonded.
Dust can be reduced by bonding substantially all the fibers which reside on or
near
the surface of the ASRA which contacts the fabric being treated. This can be
accomplished by applying resins such as latex, starch, polyvinyl alcohol or
the like.
Cold or hot crimping, sonic bonding, heat bonding and/or stitching may also be
used
along all edges of the receiver to further reduce Tinting tendency.
Backin Sheet - The ASRA is generally sufficiently robust that it can be used
as-is. However, in order to prevent strike-through of the liquid onto the
table top or
other treatment surface selected by the user, it is preferred to affix a
liquid-
impermeable barrier sheet to the bottom-most surface of the lower layer. This
backing sheet also improves the integrity of the overall article. The bottom-
most
layer can be extrusion coated with an 0.5-2.0 mil, preferably 1.0 mil, layer
of
polyethylene or polypropylene film using conventional procedures. A film layer
could also be adhesively or thermally laminated to the bottom layer. The film
layer
is designed to be a pinhole-free barrier to prevent any undesired leakage of
the
cleaning composition beyond the receiver. This backing sheet can be printed
with
usage instruction, embossed and/or decorated, according to the desires of the
formulator. The ASRA is intended for use outside the dryer. However, since the
receiver may inadvertently be placed in the dryer and subjected to high
temperatures,
it is preferred that the backing sheet be made of a heat resistant f lm such
as
polypropylene or nylon.
Colors - White is the preferred color for the ASRA as it allows the user to
observe transfer of the stain from the fabric to the receiver. However, there
is no
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functional limit to the choice of color. The backing sheet can optionally be a
contrasting color.
Embossing - The ASRA can also be embossed with any desired pattern or
logo.
5 Manufacture - A typical, but non-limiting, embodiment of the ASRA herein
is a TBAL material which consists of an upper, low capillary pressure layer
which is
placed in liquid communication contact with the fabric being treated and a
bottom
high capillary pressure layer. The ASRA can be conveniently manufactured using
procedures known in the art for manufacturing TBAL materials; see U.S.
4,640,810.
10 As an overall proposition, TBAL manufacturing processes typically comprise
laying-down a web of absorbent fibers, such as relatively short (2-4 mm) wood
pulp
fibers, in which are commingled relatively long (4-6 mm) bi-component fibers.
The
sheath of the bicomponent fiber melts with the application of heat to achieve
thermal
bonding. The bi-component fibers intermingled throughout the wood pulp fibers
thereby act to 'glue' the entire mat together. Both layers in one embodiment
of the
ASRA herein can be a homogeneous blend of wood pulp fibers and bi-component
thermal bonding fibers. In a more preferred embodiment, the top layer is I00%
concentric bi-component fiber comprising 50:50 (wt.) polyethylene (PE) and
polypropylene (PP) comprising a PP core enrobed in an outer sheath of PE. The
gradient is achieved by providing a higher proportion of bicomponent bonding
fibers
in the top layer compared to the bottom layer. Using a TBAL process as
described
in U.S. 4,640,810, the top, low capillary pressure layer is formed by a first
forming
station from 100% bicomponent fiber (AL-Thermal-C, 1.7 dtex, 6 mm long
available from Danaklon a/s). Basis weight of this all-bicomponent top layer
is
approximately 30 gsm (grams/meter2). The bottom, high capillary pressure layer
is
formed upon the top layer by second and third forming stations from a fiber
blend
consisting of approximately 72% wood pulp (Flint River Fluff available from
Weyerhaeuser Co.) and approximately 28% bi-component binder fiber. Basis
weight of this bottom layer is approximately 270 gsm. Each of the second and
third
forming station deposits approximately half of the total weight of the bottom
layer.
The two layers are then calendered to provide a final combined thickness of
approximately 3 mm. Subsequently, a 1.0 mil coating of polypropylene is
extrusion
coated onto the exposed surface of the bottom layer. Individual receivers are
cut to
127 mm X 127 mm size. In one optional mode, since the material will be wound
into a roll before applying the back sheet, a binder (e.g., latex - Airflex
124 available
from Air Products) can be applied to the exposed surface of the lower layer
prior to
thermal bonding to prevent transfer of dust to the top all-bicomponent layer.
_~~_~._ _ . T.
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Alternatively, a non-Tinting sheet can be placed on the ASRA during roll-up to
prevent Tinting due to contact between the surfaces.
The composition and basis weights of the layers can be varied while still
providing an ASRA with the desired capillary pressure gradient and cleaning
S performance. Non-limiting examples are as follows.
Bottom High Capillarity Layer Composition Top Low Capillarity
Ratio PulplBicomponent Fiber Basis Weight 100% Bicomponent Basis Weight
270 gsm (wt./wt.) sm)
72/28 20
72/28 10
79/21 30
79/21 20
79/21 10
86/14 10
86/14 20
86/14 30
Another TBAL structure useful herein comprises a top (fluid receiving) layer
comprising about 50% bicomponent fiber and 50% wood pulp, with a basis weight
of about 50 gsm. The bottom layer is an 80/20 (wt.) blend of wood pulp and
bicomponent staple fiber with a basis weight of about 150 gsm.
It will be appreciated by those skilled in the art of absorbent materials that
the foregoing ASRA's will provide layers or zones of relatively higher and
lower
capillarity. The terms "high" and "low"/"higher" and "lower" are to be
understood
as being relative to the capillarities of the layers or zones in ASRA's herein
and not
to some external standard. Accordingly, as long as the capillarity of the
upper, fluid
receiving layer or zone is lower than that of the underlying layer or zone,
the
ASRA's will function in their intended manner. However, for comparison
purposes
and not by way of limitation, the capillarity of the "low" capillarity layer
will
typically be in the range from about 2 cm of water to about 15 cm of water,
and the
capillarity of the "high" capillarity layer will typically be in the range
from about 10
cm of water to about 50 cm of water. (Capillarity can be measured using the
cleaning composition of interest according to the procedure reported at Column
11,
U.S. Patent 4,610,678, Weisman, et al., issued September 6, 1986, with
reference to
the basic procedure and apparatus design as reported by Burgeni and Kapur,
"Capillary Sorption Equilibria in Fiber Masses", Textile Research Journal, 37
(1967)
362, which publications are incorporated herein by reference.)
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Usage Conditions - The ASRA herein is intended to be made so
inexpensively that it can be discarded after a single use. However, the
structures are
sufficiently robust that multiple re-uses are possible. In any event, the user
should
preferably position the article such that "clean" areas are positioned under
the stained
areas of the fabric being treated in order to avoid release of old stains from
the
ASRA back onto the fabric.
Another type of absorbent useful herein comprises Functional Absorbent
Materials ("FAM's") which are in the form of water-absorbent foams having a
controlled capillary size. The physical structure and resulting high
capillarity of
FAM-type foams provide very effective water absorption, while at the same time
the
chemical composition of the FAM typically renders it highly lipophilic. Thus,
the
FAM can essentially provide both hydrophilicity and lipophilicity
simultaneously.
(FAM foams can be treated to render them hydrophilic. Both the hydrophobic or
hydrophilic FAM can be used herein.)
1 S The acquisition and absorbency of the FAM with respect to the liquid
cleaning compositions herein is superior to most other types of absorbent
materials.
For example, the FAM has a capacity of about b g (H20) per gram of foam at a
suction pressure of 100 cm of water. By contrast, cellulose wood fiber
structures
have substantially no capacity above about 80 cm of water. Since, in the
present
process the volume of liquid cleaning composition used is relatively low (a
few
milliliters is typical) the amount of FAM used can be small. This means that
the pad
of FAM which underlays the stained area of fabric can be quite thin and still
be
effective.
The manufacture of FAM-type foams for use as the ASRA herein forms no
part of the present invention. The manufacture of FAM foam is very extensively
described in the patent literature; see, for example: U.S. 5,260,345 to
DesMarais,
Stone, Thompson, Young, LaVon and Dyer, issued November 9, 1993; U.S.
5,268,224 to DesMarais, Stone, Thompson, Young, LaVon and Dyer, issued
December 7, 1993; U.S. 5,147,345 to Young, LaVon and Taylor, issued September
15, 1992 and companion patent U.S. 5,318,554 issued June 7, 1994; U.S.
5,149,720
to DesMarais, Dick and Shiveley, issued September 22, 1992 and companion
patents
U.S. 5,198,472, issued March 30, 1993 and U.S. 5,250,576 issued October 5,
1993;
U.S. 5,352,711 to DesMarais, issued October 4, 1994; PCT application 93/04115
published March 4, 1993, and U.S. 5,292,777 to DesMarais and Stone, issued
March
8, 1994; U.S. 5,387,207 to Dyer, DesMarais, LaVon, Stone, Taylor and Young,
issued February 7, 1995; U.S. 5,500,451 to Goldman and Scheibel, issued March
19,
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CA 02296359 2000-O1-18
WO 99/04082 PCTNS98/15003
13
1996; and U.S. 5,550,167 to DesMarais, issued August 27, 1996, all
incorporated
herein by reference.
Absorbents made of FAM foam can be used in either of two ways. In one
mode, the uncompressed foam is used. Uncompressed FAM pads having a thickness
in the range of about 0.3 mm to about 1 S mm are useful. In another mode, the
FAM
foam can be used in a compressed state which swells as liquid cleaner with its
load
of stain material is imbibed. Compressed FAM foams having thicknesses in the
range of about 0.02 inches (0.5 mm) to about 0.185 inches (4.7 mm) are
suitable
herein.
The preparation of FAM foam (also sometimes referred to in the literature as
"HIPE", i.e., high internal phase emulsion) is described in the patents cited
hereinabove. The following Example illustrates the preparation of a compressed
foam for use herein.
Preparation of Emulsion and FAM Foams Therefrom
A) Emulsion Preparation
Anhydrous calcium chloride (36.32 kg) and potassium persulfate (189 g) are
dissolved in 378 liters of water. This provides the water phase stream to be
used in a
continuous process for forming the emulsion.
To a monomer combination comprising distilled divinylbenzene (42.4%
divinylbenzene and 57.6% ethyl styrene) (1980 g), 2-ethylhexyl acrylate {3300
g),
and hexanedioldiacrylate (720 g) is added a diglycerol monooleate emulsifier
(360
g), ditallow dimethyl ammonium methyl sulfate (60g), and Tinuvin 765 (15g).
The
diglycerol monooleate emulsifier (Grindsted Products; Brabrand, Denmark)
comprises approximately 81% diglycerol monooleate, 1% other diglycerol
monoesters, 3% polyols, and 15% other polyglycerol esters, imparts a minimum
oil/water interfacial tension value of approximately 2.7 dyne/cm and has an
oil/water
critical aggregation concentration of approximately 2.8 wt. %. After mixing,
this
combination of materials is allowed to settle overnight. No visible residue is
formed
and all of the mixture is withdrawn and used as the oil phase in a continuous
process
for forming the emulsion.
Separate streams of the oil phase (25°C) and water phase (53°-
55°C) are fed
to a dynamic mixing apparatus. Thorough mixing of the combined streams in the
. dynamic mixing apparatus is achieved by means of a pin impeller. The pin
impeller
comprises a cylindrical shaft of about 36.8 cm in length with a diameter of
about 2.5
cm. The shaft holds 6 rows of pins, 3 rows having 33 pins and 3 rows having 32
pins, each having a diameter of 0.5 cm extending outwardly from the central
axis of
the shaft to a length of 2.5 cm. The pin impeller is mounted in a cylindrical
sleeve
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WO 99/04082 PCT/US98/15003
14
which forms the dynamic mixing apparatus, and the pins have a clearance of 1.5
mm
from the walls of the cylindrical sleeve.
A minor portion of the effluent exiting the dynamic mixing apparatus is
withdrawn and enters a recirculation zone; see PCT U.S. 96/00082 published 18
July
96 and EPO 96/905110.1 filed 11 January 96. The Waukesha pump in the
recirculation zone returns the minor portion to the entry point of the oil and
water
phase flow streams to the dynamic mixing zone.
The combined mixing and recirculation apparatus set-up is filled with oil
phase and water phase at a ratio of 4 parts water to 1 part oil. The dynamic
mixing
apparatus is vented to allow air to escape while filling the apparatus
completely.
The flow rates during filling are 7.6 g/sec oil phase and 30.3 cc/sec water
phase.
Once the apparatus set-up is filled the vent is closed. Agitation is then
begun
in the dynamic mixer, with the impeller turning at 1450 RPM and recirculation
is
begun at a rate of about 30 cc/sec. The flow rate of the water phase is then
steadily
increased to a rate of 151 cc/sec over a time period of about 1 min., and the
oii phase
flow rate is reduced to 3 g/sec over a time period of about 3 min. The
recirculation
rate is steadily increased to about 150 cc/sec during the latter time period.
The back
pressure created by the dynamic mixer and static mixing zone (TAH Industries
Model Number 101-212) at this point is about 14.7 PSI (101.4 kPa), which
represents the total back pressure of the system. The Waukesha pump speed is
then
steadily decreased to a yield a recirculation rate of about 75 cc/sec. The
impeller
speed in then steadily increased to 1 S50 RPM over a period of about 10
seconds.
The back pressure increases to about 16.3 PSI (112 kPa).
B) Polymerization of Emulsion
The emulsion flowing from the static mixer is collected in a round
polypropylene tub, 17 in. (43 cm) in diameter and 7.5 in (10 cm) high, with a
concentric insert made of Celcon plastic. The insert is 5 in (12.7 cm) in
diameter at
its base and 4.75 in (12 cm) in diameter at its top and is 6.75 in (17.1 cm)
high. The
emulsion-containing tubs are kept in a room maintained at 65 °C. for 18
hours to
bring about polymerization and form the foam.
C) Foam Washing and Dewatering
The cured FAM foam is removed from the curing tubs. The foam at this
point has residual water phase (containing dissolved emulsifiers, electrolyte,
initiator
residues, and initiator) about 45-55 times (45-55X) the weight of polymerized
monomers. The foam is sliced with a sharp reciprocating saw blade into sheets
which are 0.185 inches (0.47 cm) in thickness. These sheets are then subjected
to
compression in a series of 2 porous nip rolls equipped with vacuum which
gradually
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CA 02296359 2000-O1-18
WO 99/04082 PCT/US98/15003
reduce the residual water phase content of the foam to about 6 times (6X) the
weight
of the polymerized material. At this point, the sheets are then resaturated
with a
1.5% CaCl2 solution at 60°C., are squeezed in a series of 3 porous nip
rolls
equipped with vacuum to a water phase content of about 4X. The CaCl2 content
of
5 the foam is between 8 and 10 %.
The foam remains compressed after the final nip at a thickness of about
0.025 in. (0.063 cm). The foam is then dried in air for about 16 hours. Such
drying
reduces the moisture content to about 9-17 % by weight of polymerized
material.
At this point, the foam sheets are very drapeable. In this collapsed state,
the density
10 of the foam is about 0.14 g/cc. A fluid-impermeable backing sheet (e.g., 1
mil
polypropylene) can optionally be applied. If desired, the FAM sheet can be
encased
in a liquid permeable fabric (e.g., nylon stocking material or woven or non-
woven
fabric such as spunbonded polyester; Reemay; basis weight about 18 gsm) to
reinforce the FAM against flaking, in-use.
15 As noted above, for use as a stain receiver in the localized stain cleaning
operation herein, a sheet of the ASRA or the FAM is placed beneath and in
close
contact with the backside of the stained area of a fabric. The cleaning
composition
is mechanically manipulated into the stain, and, together with its load of
stain
material, is transferred through the fabric and into the underlying ASRA or
FAM
pad.
Comuositions - The user of the present process can be provided with various,
preferably liquid, compositions to use as spot cleaning compositions. One
problem
associated with known fabric cleaning compositions is their tendency to leave
visible
residues on fabric surfaces. Such residues are problematic and are preferably
to be
avoided herein since the present process does not involve conventional
immersion or
rinse steps. Accordingly, the compositions herein should, most preferably, be
substantially free of various polyacrylate-based emulsifiers, polymeric anti-
static
agents, inorganic builder salts and other residue-forming materials, except at
low
levels of about 0.1%-0.3%, and preferably 0%, of the final compositions.
Stated
otherwise the compositions herein should be formulated so as to leave
substantially
no visible residue on fabrics being treated according to the practice of this
invention.
Accordingly, in a preferred aspect of this invention there are provided liquid
cleaning (i.e., spot-cleaning) compositions which are substantially free of
materials
which leave visible residues on the treated fabrics. This necessarily means
that the
preferred compositions are formulated to contain the highest level of volatile
materials possible, preferably water, typically about 95%, preferably about
97.7%, a
cleaning solvent such as BPP at a low, but effective, level, typically about 1
% to
CA 02296359 2000-O1-18
WO 99/04082 PCTNS98/15003
16
about 4%, preferably about 2%, and surfactant at levels of about 0.1 to about
0.7%.
Advantageously, when thus formulated such compositions exist as aqueous
solutions
rather than as suspensions or emulsions. Thus, such compositions do not
require use
of additional emulsifiers, thickening agents, suspending agents, and the like,
all of
which can contribute to the formation of undesirable visible residues on the
fabric.
Indeed, as an overall proposition, any of the chemical compositions which are
used to provide the spot removal function herein comprise ingredients which
are safe
and effective for their intended use, and, as noted above, preferably do not
leave
unacceptable amounts of visible residues on the fabrics. While conventional
laundry
detergents are typically formulated to provide good cleaning on cotton and
cotton/polyester blend fabrics, the 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 compositions herein comprise
ingredients
which are specially selected and formulated to minimize dye removal or
migration
from the stain site of fugitive, unfixed dye 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 on fabric surfaces can result in unacceptable localized dye
removal.
The preferred compositions herein are formulated to minimize or avoid this
problem.
The dye removal attributes of the present 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 dye loss than most woolen or rayon fabrics} is treated by
padding-on
cleaner/refresher 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. Numerical units ranging from: (1) "I think I see a little dye on the
towel";
(2) "I know I see some dye on the towel"; (3) I see a lot of dye on the
towel"; through
(4) "I know I see quite a lot of dye on the towel" are assigned by panelists.
In addition to the foregoing considerations, the compositions used herein are
preferably formulated such that they are easily dispensed and not so adhesive
in
nature that they render dispensing from the container to be unhandy or
difficult.
However, and while not intending to be limiting of the present invention, the
_»..._-._ _v .__ _. ...~....__ _~ ._._ . T .
CA 02296359 2000-O1-18
WO 99/04082 PCT/US98/15003
17
preferred compositions disclosed herein afford a spot-cleaning process which
is both
effective and aesthetically pleasing when used in the manner disclosed herein.
CA 02296359 2000-O1-18
WO 99/04082 PCT/US98/15003
18
Aq-ueous Stain Cleaning Compositions
(a) Water -The preferred, low residue compositions herein may comprise
from about 90%, preferably from about 95.5% to about 99.9%, by
weight, of water.
(b) Solvent - The compositions herein may comprise from about 0% to
about 10%, by weight, of butoxy propoxy propanol (BPP) solvent or
other solvents as disclosed herein. Preferred spot cleaners will
comprise 1-4% BPP.
(c) Surfactant - The compositions herein may optionally comprise from
about 0.05% to about 2%, by weight, of surfactants, such as MgAES
and NH4AES, amine oxides, ethoxylated alcohols or alkyl phenols,
alkyl sulfates, and mixtures thereof. The use of surfactants limited to
the lower end of the range is preferred for some dyes and fabric types.
Typically, the weight ratio of BPP solventaurfactant(s) is in the range
of from about 10:1 to about 1:1. One preferred composition
comprises 2% BPP/0.25% Neodol 23 6.5. Another preferred
composition comprises 4% BPP/0.4% AS. Most preferred is a
composition of 2% BBP/0.3% MgAEIS/0.03% dodecyl dimethyl
amine oxide.
(d) Optionals - The compositions herein may comprise minor amounts of
various optional ingredients, including bleach stabilizers, perfumes,
preservatives, and the like. If used, such optional ingredients will
typically comprise from about 0.05% to about 2%, by weight, of the
compositions, having due regard for residues on the cleaned fabrics.
(e) Bleach - The compositions herein may also optionally comprise from
about 0.25% to about 7%, by weight, of hydrogen peroxide. Preferred
spot cleaners will comprise 0.5 to about 3% hydrogen peroxide. It
will be appreciated that peroxide sources other than H202 can be used
herein. Thus, various per-acids, per-salts, per-bleaches and the like
known from the detergency art can be used. However, such materials
are expensive, difficult to formulate in liquid products, can leave
residues on fabrics and offer no special advantages over H202 when
used in the present manner.
(f) Chelator -Compositions which contain H202 will also typically
contain a chelating agent. The chelating agent is selected from those
which, themselves, are stable in aqueous H202 and which stabilize
the H202 by chelating vagrant metal ions. Such chelating agents are
__ ___._.__.__ _. __ _~.... _. ~_.
CA 02296359 2000-O1-18
WO 99/04082 PCT/US98/15003
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typically already present at low, peroxide-stabilizing amounts (0.01-
1%) in commercial sources of hydrogen peroxide. A variety of
_ phosphonate chelators are known in stabilizing H202. The amino
phosphonates are especially useful for this purpose. Various amino
phosphonates are available as under the DEQUEST~ trade name
from the Monsanto Company, St. Louis, Missouri. Representative,
but non-limiting, examples include ethylenediamine tetrakis
(methylene phosphonic) acid, diethylenetriamine penta(methylene
phosphonic) acid, and the water-soluble salts thereof. Amino
tris(methylene phosphonic) acid or its water-soluble salts (as
DEQUEST 2000~) is a preferred chelator.
The pH range of the cleaning compositions helps provide stability to the
hydrogen peroxide and is typically in the acid-slightly basic range from about
3 to
about 8, preferably about 6.
Organic Solvent - The preferred cleaning 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-C4H9-O-CHZCH2CH2-O-CH2CH2CH2-OH
CH3
n-C4H9-O-CH2-C-O-CH2CH2CH2-OH
H
~ H3
n-C4H9-O-CH2CH2CH2-O-CH2- i -OH
H
While the cleaning compositions herein function quite well with only the
BPP, water and surfactant, they may also optionally contain other ingredients
to
further enhance their stability. Hydrotropes such as sodium toluene sulfonate
and
sodium cumene sulfonate, short-chain alcohols such as ethanol and isopropanol,
and
the like, can be present in the compositions. If used, such ingredients will
typically
comprise from about 0.05% to about 5%, by weight, of the stabilized
compositions
herein.
Surfactants - Nonionics such as the ethoxylated C 10-C 16 alcohols, e.g.,
NEODOL 23-6.5, can be used in the compositions. The alkyl sulfate surfactants
which may be used herein as cleaners and to stabilize aqueous compositions are
the
Cg-C 1 g primary ("AS"; preferred C 10-C 14, sodium salts), as well as
branched-chain
CA 02296359 2000-O1-18
WO 99/04082 PCT/US98/15003
and random CIO-C2p alkyl sulfates, and C1p-Clg secondary (2,3) alkyl sulfates
of
the formula CH3(CH2)x(CHOS03 M+) CH3 and CH3 (CH2)y(CHOS03 M+)
CH2CH3 where x and (y + 1 ) are integers of at least about 7, preferably at
least
about 9, and M is a water-solubilizing cation, especially sodium, as well as
5 unsaturated sulfates such as oleyl sulfate. Alkyl ethoxy sulfate (AES)
surfactants
used herein are conventionally depicted as having the formula R(EO)xS03Z,
wherein R is C1p-C16 alkyl, EO is -CH2CH2-O-, x is 1-10 and can include
mixtures
which are conventionally reported as averages, e.g., (EO)2.5, (EO)6.5 and the
like,
and Z is a cation such as sodium ammonium or magnesium (MgAES). The C12-
I 0 C I 6 alkyl dimethyl amine oxide surfactants can also be used. A preferred
mixture
comprises MgAEl S/C 12 dimethyl amine oxide at a weight ratio of about 10: I .
Other surfactants which improve phase stability and which optionally can be
used
herein include the polyhydroxy fatty acid amides, e.g., C12-C14 N-methyl
glucamide. AS stabilized compositions preferably comprise 0.1%-0.5%, by
weight,
15 of the compositions herein. MgAES and amine oxides, if used, can comprise
0.01 %-2%, by weight, of the compositions. The other surfactants can be used
at
similar levels.
Other Optionals - In addition to the water, the preferred BPP solvent, the
optional H202 and the surfactants disclosed above, liquid compositions used
herein
20 may comprise various optional ingredients, such as perfumes, preservatives,
brighteners, salts for viscosity control, pH adjusters or buffers, and the
like. The
following illustrates preferred ranges for cleaning compositions for use
herein, but is
not intended to be limiting thereof.
In edient % (wt.) Formula Range
BPP (Solvent) 0.05-5
Surfactant 0-2
Perfume 0.01-1.5
Water Balance
pH range from about 6 to about 8.
Other solvents or co-solvents which can optionally 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 BPP, as well as butoxy propanol (BP), and the like, and mixtures thereof.
If
used, such solvents or co-solvents will typically comprise from about 0.5% to
about
......,..~.~_........ T....... . _......
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WO 99/04082 PCT/US98/15003
21
2.5%, by weight, of the aqueous compositions herein. Non-aqueous (less than
50%
water} compositions useful herein can comprise the same solvents.
Dispenser - In the preferred mode herein, the dispenser comprises a container
for the liquid cleaning composition, said container having a dispensing means
which
- 5 comprises a spout, preferably in the form of a hollow tube, which is
connected to
said container and is in communication with the interior of the container. In-
use, a
portion of the liquid composition within the interior of said container flows
from the
container through said spout, out the distal tip of said spout, and onto the
stain which
is being treated. The user manipulates the composition by daubing, smearing,
pressing, or the like, using the distal tip which impinges on the protective
covering
material to work the composition into the stain. A circular, rubbing motion is
typical. By this means, the composition can be focused on the stained area. As
the
stain is loosened by the combined use of the aforesaid mechanical manipulation
(the
force of which is transmitted through the protective material and onto the
fabric
being treated) and the cleaning composition, the stain residues and the
composition
are transferred away from the fabric and into the underlying stain receiver.
The
fabric is then preferably re-positioned so that a fresh area of stain receiver
underlies
other stained areas, and the process is repeated until the stain removal
operation is
completed. The fabrics can then be used, as desired, or otherwise laundered or
dry-
cleaned.
The following Examples illustrate the invention in more detail, but are not
intended to be limiting thereof.
EXAMPLE I
A process for removing stain from a localized area on a fabric is conducted
by:
(a) preferably, underlaying the area containing said stain with an absorbent
material, e.g., absorbent toweling, or, more preferably, a TBAL ASRA or a
FAM-foam absorbent;
(b) overlaying said area of stain with a sheet of organza fabric in direct
contact
with the stain as the protective material;
(c) applying a liquid cleaner (pre-spotter) composition of Example II to said
stain from a container having a dispenser spout; and
(d) rubbing or pressing the distal tip of the spout on the sheet of organza
overlaying the stain, thereby driving said cleaning composition into said
stain, whereby said stain is transferred into the absorbent material and the
fabric being treated is protected from abrasion.
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22
In this mode, the face of the distal tip of said spout can be concave, convex,
flat, or the like. A typical dispenser ("dispenser" being the container plus
spout for
the purposes of this Example) herein has the following dimensions, which are
not to
be considered limiting thereof. The volume of the container bottle used on the
dispenser is typically 2 oz. - 4 oz. (fluid ounces; 59 mls to 118 mls). The
larger size
container bottle can be high density polyethylene. Low density polyethylene is
preferably used for the smaller bottle since it is easier to squeeze. The
overall length
of the spout is about 0.747 inches (1.89 cm). The spout is of a generally
conical
shape, with a diameter at its proximal base (where it joins with the container
bottle)
of about 0.596 inches (1.51 cm) and at its distal of 0.182 inches (4.6 mm).
The
diameter of the channel within the spout through which the cleaning fluid
flows is
approximately 0.062 inches (1.57 mm). In this embodiment, the channel runs
from
the container bottle for a distance of about 0.474 inches (1.2 cm) and then
expands
slightly as it communicates with the concavity to form the exit orifice at the
distal
1 S end of the spout.
EXAMPLE II
Examples of preferred, high water content compositions for use in the stain
removal operation herein are as follows. The compositions are listed as
"nonionic"
or "anionic", depending on the type of surfactant used therein.
In egr diem Nonionic ~%1 Anionic I(%)
Butoxypropoxypropanol (BPP)2.00 2.00
NEODOL 23 6.5 0.250 ---
NH4Coconut E1S* --- 0.285
Dodecyldimethylamine oxide --- 0.031
MgCl2 --- 0.018
MgS04 --- 0.019
Hydrotrope, perfume,
other minors --- 0.1 O1
KATHON preservative 0.0003 0.0003
Water 97.750 97.547
*Ammonium salt of C12-C14 (coconut alkyl) ethoxy (EO-1) sulfate.
EXAMPLE iII
A liquid stain cleaning composition is formulated by admixing the following
ingredients.
Ingredient % wt.
Bpp 4.0
C 12-C 14 AS, Na salt 0.25
_.... _....,._., .............. . _._.T.......
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WO 99/04082 PCT/US98/15003
23
Water and minors* Balance
*Includes preservatives such as KATHON~ at levels of 0.00001%-1%, by weight.
The fabric to be treated is laid flat on an absorbent TBAL stain receiver
sheet
or any of the other ASRA's or FAM absorbent disclosed herein, and 0.5 ml-4 ml
of
- S the composition are dispensed onto the stain either directly or through
the porous
protective material which is used to cover the stain. The composition is
worked into
the stain by applying mechanical force to the protective material at the stain
site
using the tip of the dispenser. Other cleaning devices such as arcuate
brushes, solid
probes, rubber spatulas, and the like, can be used to provide the mechanical
force.
Other useful compositions which can be used in this step are as follows:
Ingredient Percent wt.) Range; wt~
BPP 4.0 0.1-4.0%
C12-C14 AS 0.4 0.1 - 0.5%
Nonionic Surfactant (optional)* 0.1 0 - 0.5%
Water (distilled or deionized) Balance 95-99.8%
Target pH = 7.0
*The optional nonionic surfactants in the compositions herein are preferably
C12-
C 14 N-methyl glucamides or ethoxylated C 12-C 16 alcohols (EO 1-10).
The foregoing illustrates cleaning compositions using an AS surfactant.
Improved cleaning performance can be achieved using MgAES and amine oxide
surfactants, although possibly with some reduction in phase stability. Thus,
aqueous
compositions with ca. 2-3% BPP can be stabilized using MgAES surfactants.
However, for compositions containing 4%, and higher, BPP, the formulator may
wish to include AS surfactant. The amount and blend of surfactants will depend
on
the degree of temperature-dependent phase stability desired by the formulator.
Amine oxide surfactants such as dimethyl dodecyl amine oxide can also be used
in
the compositions.
While the process and components thereof have been described herein both
broadly and in detail, modifications thereof which meet the foregoing
considerations
fall within the spirit and scope of the present invention. Kits according to
the
present invention conveniently contain from about 1 to about 6 of the sheet-
form
ASRA's or sheet-form FAM absorbent, bottled portions (typically about 10 ml to
about 100 ml) of the liquid cleaning composition, and 1 to about 10 sheets of
the
protective covering material. However, larger or smaller quantities of the
protective
sheets, receivers and/or the cleaning composition can be provided.
