Note: Descriptions are shown in the official language in which they were submitted.
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1
FABRIC SANITIZATION PROCESS
FIELD OF THE INVENTION
This invention relates to sanitization processes for use on fabrics or other
solid objects.
BACKGROUND OF THE INVENTION
The sanitization of small solid objects such as eating utensils, infant toys
and
paraphernalia, personal grooming; items such as combs and hair brushes, and
the like, against
bacteria can be effected by applying various antiseptic chemicals thereto.
However, such
chemicals may not be useful against fungi. In any event, the sanitization of
larger objects such
as garments by the direct application of antiseptic chemicals is expensive and
inconvenient. The
present invention provides an effective sanitization process which can be used
in the home and is
especially useful for treating fabrics in a non-immersion process.
Specifically, a treatment
process for sanitizing fabrics at home is disclosed.
Together with the soil and stain removal aspects of a typical dry fabric
treatment
process, there is also a consumer need for what can be termed fabric
sanitization and
"refreshment". Thus, garments which have lint, hair or other solid debris
clinging to their
surfaces, which may have adsorbed malodors, or which have become wrinkled or
otherwise lost
their fresh appearance, are often subjected to conventional commercial dry
cleaning processes
mainly to reestablish their freshness aspect. Such processes can also help
sanitize the garments
by removing or destroying microorganisms.
Attempts have been made to provide in-home dry cleaning systems. One type of
non-
immersion, in-home system for cleaning and refreshing garments comprises
multiple single-use
carrier sheets containing various liquid or gelled cleaning agents and a re-
usable plastic
containment bag. The garments are placed in the bag together with a sheet, and
then tumbled
with heating in a conventional clothes dryer. After the garments are cleaned
and refreshed, the
bag, which may retain traces of moisture, can then be stored for later re-use
when the process is
repeated.
It has now been discovered that, when properly constructed and operated, the
process
herein can kill or otherwise hinder the growth of bacteria and other
microbials which may be
present on solid articles such as soiled garments. Unexpectedly, when
conducted in the vapor-
venting manner of this invention, fungi are also killed or their growth
inhibited. As an added
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2
advantage, the interior surfaces of the containment bag are also sanitized.
Hence, when the bag
is stored between uses the growth of "mildew" or bacteria in the bag is
minimized.
BACKGROUND ART
The use of H202 in sterilization processes is described in U.S. 4,230,663, to
Forstrom, et
al., issued October 28, 1980 and IU.S. 4,169,124, to Forstrom, et al., issued
September 25, 1979
and U.S. 4,169,153 to Moore, et al., issued September 25, 1979. WO 97/00993A1,
published
January 9, 1997 to Weller, et al.; 'WO 97/00990A2, published January 9, 1997
to Tyerech, et al.;
GB 2,302,553A, published January 22, 1997 to Telesca, et al.; GB 2,302,878A,
published
February 5, 1997 to Weller, et al.; and GB 2,302,879A, published February 5,
1997 to Sidoti, et
al. all relate to in-dryer fabric clE:aning. U.S. 4,532,722, issued to S. H.
Sax, August 6, 1985,
relates to a fabric conditioning device for use in a laundry dryer. A peracid-
containing dry
cleaning composition is described in U.S. 4,013,575, issued to H. Castrantas,
et al., March 22,
1977. Dry cleaning processes are disclosed in: U.S. 5,591,236, issued January
7, 1997 to
Roetker; U.S. 5,547,476, issued August 20, 1996, to Siklosi and Roetker; 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, 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 3,591,510; 3,737,387;
3,764,544;
3,882,038; 3,907,496; 4,097,39'7; 4,102,824; 4,336,024; 4,594,362; 4,606,842;
4,758,641;
4,797,310; 4,802,997; 4,943,39:2; 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 91109104; WO
91/13145; WO
93/25654 and Hunt, D.G. and N.H. Morris, "PnB and DPnB Glycol Ethers", HAPPI,
April 1989,
pp. 78-82.
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3
SUMMARY OF THE INVENTION
The present invention encompasses, a process for sanitizing a fabric article
which is
contaminated with one or more microbials. The process comprising the steps o~
a) placing the fabric article in a vapor venting bag together with a cleaning
composition comprising water;
b) subjecting the vapor venting bag to a heat source which supplies sufficient
heat to
vaporize the water, thereby exposing the microbials to the resulting water
vapor; and
whereby at least about 50% of the; microbials are killed.
The cleaning/refreshing composition of the present invention preferably
comprises from
about 0.05% to about 3%, preferably from about 0.1% to about 2%, and more
preferably from
about 0.1 % to about 1 %, by weight of an antimicrobial agent selected from
the group consisting
of 5-chloro-2-(2,4-dichiorophenoxy)phenol, trichlorocarbanalide, hydrogen
peroxide, other
oxygen bleaches, 4-chloro-3,5-dimethylphenol, iodineliodophors, chlorhexidine,
phenols,
phospholipids, thymol, eugeniol, geraniol, oil of lemon grass, limonene and
mixtures thereof.
The cleaning/refreshing composition preferably further comprises a second
antimicrobial agent
selected from the group consisting of alkyl alkoxy sulfates, linear alkyl
benzene sulfonates,
amine oxides, polyhydroxy fatty acid amides, ethoxylated alcohols, diamines,
amides, alkyl
polyglucosides, betaines, and miixtures thereof. Fully-formulated compositions
will typically
comprise water, nonionic surfactant, perfume and one or more antimicrobial
agents.
In a preferred mode, said composition is releasably absorbed in a carrier,
especially a
carrier which is in sheet form. Most preferably, said carrier comprises a
fibrous, hydroentangled
web.
The process according to this invention preferably additionally comprises
subjecting
said container to a tumbling action concurrently with the heating and vapor
venting. In a
convenient mode, the source of the heat and of the tumbling action is an
integral appliance such
as a conventional hot air clothes dryer.
The container used in the process is preferably a flexible bag. This bag is
designed to be
re-usable and, most preferably, is heat-resistant. As disclosed more fully
hereinafter, the
preferred container is a vapor-venting containment bag which has a Vapor
Venting Equilibrium
(VVE) rating of at least about 40, preferably at least about 60, more
preferably no greater than
about 90, and most preferably no greater than about 80.
In a preferred aspect of the process of this invention a pre-treating step is
employed.
The pre-treating step comprises .applying a pre-treating composition to at
least a portion of the
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4
fabric article, wherein the pre-treating composition preferably comprises
comprises from about
0.05% to about 3%, preferably from about 0.1% to about 2%, and more preferably
from about
0.1% to about 1%, by weight of an antimicrobial agent selected from the group
consisting of 5-
chloro-2-(2,4-dichlorophenoxy)phenol, trichlorcarbanilide, hexachlorophene,
chlorhexadine, o-
phenylphenol, benzylquaternium salts and mixtures thereof. Most preferably the
pre-treating
composition comprises 5-chloro-2-(2,4-dichlorophenoxy)phenol. The pre-treating
step is
especially effective in combating; the malodorous compounds that are commonly
associated with
human body odor.
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 an exploded view of a sheet-form article ( 1 ) useful in the
present invention in
a pre-assembled state.
Figure 2 is a perspective of the assembled cleaning/refreshing article ( 1 ).
Figure 3 is a perspective of the article loosely resting on a notched, vapor-
venting
containment bag which is in a pre-folded condition.
Figure 4 is a perspective of the article within the bag which is ready to
receive fabrics or
other articles to be treated in a hot air clothes dryer, or similar apparatus.
Figure 5 is a partial view of the notched wall of the bag and its disposition
relative to the
closure flap.
Figure 6 is a perspective of an un-notched vapor-venting bag containing a
loose sheet-
form article used in the manner of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The principles of sterili~;ation and disinfection under various conditions are
well-known
and standard textbooks can lbe referred to for typical methods. Examples of
various
microorganisms, which are hereinafter collectively referred to as
"microbials", include: germs,
bacteria, viruses, parasites, fung:i/spores and mixtures thereof. Microbials
are known to be killed
or rendered inactive by various agents. Often, dead microbials are classified
as "cidal", while
inactive microbials are classified as "static". This distinction is not
important in the present
context, since dead and inactivE; microbials are collectively referred to
herein as "killed", and
any agents that "kill" microbials are collectively referred to herein as
"antimicrobials" or
"antimicrobial agents". Microbial activity can be effected by additional
factors including, but
not limited to, concentration, pHf, time of exposure to the antimicrobial
agent, and the like.
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WO 99/55390 PCT/IB99/00688
By "bacterium" or "bacteria" herein is meant any of the procaryotic
microorganisms
having round, rodlike, spiral or filamentous single-celled or noncellular
bodies.
By "fungus", "fungi", "fungi/spores" herein is meant any of the eucaryotic
(Eumcophyta) microorganisms comprising saprophytic and parasitic lower plants
that lack
chlorophyll, and including molds, mildews, rusts, smuts, yeasts and the like.
By "mildew" and "mold" herein are meant the commonplace terms for any
undesired
fungal growth often from the families Erysiphaceae and Peronosporaceae, but
not limited
thereto. Mildew is a term which is often used pejoratively to collectively
designate unwanted
fungal growth on solid objects, including garments.
By "sanitizing" herein is meant that a substantial number of microbials on the
fabric
articles being treated are killed. By a "substantial number" it is meant that
at least about 50%,
preferably at least about 90%, more preferably at least about 95%, most
preferably at least about
99%, of the microbials present on the fabric articles being treated are
killed.
The present invention includes a process for killing microbials that uses a
vapor venting
bag and a cleaning/refreshing composition comprising water. But anitmicrobial
agents can be
included in the present cleaning/re;freshing compositions for antimicrobial
action if they do not
adversely interfere with the surfacaants used herein. Examples of
anitmicrobial agents include
5-chloro-2-(2,4-dichlorophenoxy)phenol, trichlorocarbanalide, hydrogen
peroxide, other oxygen
bleaches, 4-chloro-3,5-dimethylphenol, iodine/iodophors, selected alcohols,
chlorhexidine,
phenols, phospholipids, thymol, eugeniol, geraniol, oil of lemon grass,
limonene and mixtures
thereof. Certain quaternary surfactants may also show antimicrobial action and
may be included
as a secondary antimicrobial agent.
Certain surfactants also demonstrate antimicrobial action. Examples of
surfactants which
are useful antimicrobial agents for use herein include anionic, cationic,
nonionic, and
amphoteric surfactants. Preferred examples are: alkyl alkoxy sulfates,
including alkyl ethoxy
sulfates, linear alkyl benzene :~ulfonates, amine oxides, polyhydroxy fatty
acid amides,
ethoxylated alcohols, diamines, amides, alkyl polyglucosides, betaines, and
mixtures thereof.
When the antimicrobial agent is a cationic surfactant it is preferred that the
cationic surfactant is
not a quaternary ammonium surfactant.
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WO 99/55390 PCT/IB99100688
b
Cleanin efreshin~ Articles
The cleaning/refreshing compositions of the present invention are preferably
carried into
the vapor venting bag via an absorbent carrier, which is preferably in the
form of a sheet and is
more preferably enrobed with a coversheet. The individual materials employed
to assemble the
absorbent carriers of the present iinvention are commercially available. The
terms used herein to
describe such materials have their conventional meanings. For purposes of
clarity, certain terms
used herein are defined in the text. The following description relates
primarily to the use of the
invention herein to clean, refresh and sanitize fabrics such as garments.
However, it is to be
appreciated that the same techniques can be used to sanitize other types of
solid objects.
An absorbent carrier of 'the type used herein can comprise a simple absorbent
sheet,
preferably constructed from a hydroentangled mat of fibers as described more
fully hereinafter.
As shown in Figure 1, a preferred article (1) of the present type can be
assembled as a laminate
comprising a topmost fibrous sheet ( 1 a), an absorbent carrier sheet as the
core ( 1 b) and a
bottommost fibrous sheet (lc). The combination of topsheet and bottomsheet
comprises a
"coversheet" which helps prevent water spotting of fabrics which come in
contact with the
article during the process of the invention.
The assembled laminate article (1) is shown in Figure 2. Figure 2 also shows
the bond
( 1 f) which extends around the periphery of the article. The purpose of this
bond is to ensure that
the absorbent carrier core maintains its original configuration relative to
the coversheet when the
article is being used in the manner of this invention. Stated simply, it has
been discovered that if
the absorbent sheet which comprises the core is not bonded to the "envelope"
provided by the
coversheet in-use, the carrier sheet tends to crumple and bunch-up inside the
coversheet. This
can interfere with the delivery of the cleaning/refreshment composition to the
items being
treated.
Moreover, it has also been discovered that it is not preferred to tightly bond
the
coversheet to the carrier, sheet across the entire face of the carrier sheet.
Tightly bonding the
coversheet closely to the carrier sheet can allow some liquid transfer to
occur through the
coversheet. Accordingly, the carrier sheet is preferably bonded to the
coversheet only in
discrete areas. In one embodiment as shown in Figure 2, this bonding is only
around the
periphery of the article. In another embodiment, spot-bonding at discrete
areas across the face
of the article can be employed. Various other bond patterns can be used.
Preferably, the
bonding is done at no more than about 50% of the area of the article, more
preferably no more
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7
than about 10% of the area of the article, most preferably no more than about
1% of the area of
the article.
Coversheet - The coversheets employed herein are distinguished from the
carrier
substrate sheets, inasmuch as the coversheets are relatively non-absorbent to
the liquid
cleaning/refreshment compositions as compared with the carrier sheets. The
coversheets are
constructed from hydrophobic fibers which tend not to absorb, "wick" or
otherwise promote the
transfer of fluids. While fluids can pass through the void spaces between the
fibers of the
coversheet, this occurs mainly when excessive pressure is applied to the
article. Thus, under
typical usage conditions the coversheet provides a physical barrier which
keeps the absorbent
carrier, which is damp from its load of aqueous cleaning/refreshment
composition, from coming
into direct contact with the fabrics being treated. Yet, the coversheet does
allow vapor transfer
of the cleaning/refreshment composition from the carrier through the
coversheet and into the
containment bag, and thence onto the fabrics being treated.
One type of coversheet herein comprises a fibrous, permeable nonwoven or woven
fabric. Such nonwoven or woven fibrous coversheets offer advantages over
formed-film type
coversheets known in the catamenials art. For example, formed-film coversheets
(as described
hereinafter) are often manufactured by hydroforming processes which are
particularly suitable
with polymer films such as polyethylene. While polyethylene can be used
herein, there is some
prospect that, due to its lower melting point, high dryer temperatures can
cause its softening
and/or melting in-use. This is particularly true if the article herein were to
be released from the
containment bag and fall into the hot dryer drum. While it is possible to
prepare formed-film
topsheets using nylon, polyester or other heat resistant polymeric sheets,
such manufacture
becomes somewhat more difficult and, hence, more expensive.
It has now also been determined that the coversheet herein should be of a
thickness
which effectively provides the physical barrier function. Even though made
from hydrophobic
fibers, if the coversheet is too thin, fluid passage can occur under the
intended usage conditions.
Accordingly, it has now been determined that the thickness of the fibrous
coversheet should
preferably be at least about 7 mils (0.18 mm), preferably tiom about 8 mils
(0.2 mm) to about 24
mils (0.6 mm). It has also been determined that the fibers used in the
coversheet are preferably
hydrophobic and preferably have a melting point above about 240°C.
Fibrous coversheets for use herein can readily be made from non-heat resistant
fibers
such as polyethylene. However, it has now been determined that preferred
fibrous coversheets
can be prepared using nylon (especially nylon-6), polyester, and the like,
heat-resistant fibers
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8
which can withstand even inadvertent misuse in the present process. The
flexible, cloth-like,
permeable topsheets made therefrom are conventional materials in the art of
nonwoven and
woven fabric making, and their manufacture forms no part of the instant
invention. Nonwoven
fabrics for use as coversheets are available commercially from companies such
as Reemay, Inc.,
Hickory, TN. Such coversheets also pick up solid dust particles, vagrant lint
and other fibers
from the fabrics being treated in the present process, thereby enhancing the
overall
clean/refreshed appearance of the fabrics following the treatment herein.
Such nonwoven or woven fibrous sheet materials can be used in a flat single
layer or as
multiple layers as the coversheet for the absorbent carrier core herein. In
another embodiment,
the absorbent core carrying the cleaning/refreshment composition is enrobed in
a polyester or
polyamide fibrous coversheet which has been ring rolled or otherwise crimped
to provide three
dimensional bulk. Optionally, this coversheet may be further covered by a
second coversheet in
an uncrimped configuration.
Such fibrous, preferably heat resistant and, most preferably, hydrophobic,
coversheets
thus provide various embodiments of the article herein. Suitable combinations
can be
employed, according to the desires of the manufacturer, without departing from
the spirit and
scope of the invention. If desired, the coversheet can be provided with
macroscopic
fenestrations through which the lint, fibers or particulate soils can pass,
thereby further helping
to entrap such foreign matter inside the article, itself.
A typical spun-bonded fibrous coversheet herein is commercially available from
Reemay and has the following characteristics.
(a) Fabric Type - Non-woven, semi-dull, whitened homopolymer 100% virgin, spun-
bonded polyester.
(b) Fiber Type - 6.0 Denier .straight, tri-lobal continuous fiber, copolymer
polyester.
Web Properties Ta_ rQet R
a) Basis weight, roll average oz~yd2 0.54 0.52 to 0.59
b) Thickness 8 mil 7-8 mil
c) Fuzz level
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As measured by Reemay sled/drag method based on 0-5 scale. S being no fuzz
level.
Belt side 2.5 5.0 1.8
Jet side 3.4 5.0 2.6
As noted above, another type of coversheet which can be used with the articles
herein
comprises the apertured "formed film" coversheets known in the art and from
commercial use
on catamenials. Apertured formed films are pervious to the liquid cleaning
and/or refreshment
compositions and vapors thereof, and yet non-absorbent. Thus, the surface of
the formed film
which is in contact with the fabrics remains relatively dry, thereby reducing
water spotting and
dye transfer. As with the fibrous coversheets, the apertured formed films
capture and retain lint,
fibrous matter such as pet hair, and the like, from the fabric being treated,
thereby enhancing the
cleaning/refreshment benefits afforded by the present articles. Suitable
formed films are
described in U.S. Pat. No. 3,929,135, entitled "Absorptive Structure Having
Tapered
Capillaries", issued to Thompson on December 30, 1975; U.S. Pat. No.
4,324,246, entitled
"Disposable Absorbent Article Having A Stain Resistant Coversheet", issued to
Mullane and
Smith on April 13, 1982; U.S. P'at. No. 4,342,314, entitled "Resilient Plastic
Web Exhibiting
Fiber-Like Properties", issued to Radel and Thompson on August 3, 1982; and
U.S. Pat. No.
4,463,045, entitled "Macroscopically Expanded Three-Dimensional Plastic Web
Exhibiting
Non-Glossy Visible Surface and Cloth-Like Tactile Impression", issued to Ahr,
Louis, Mullane
and Ouellete on July 3 i, 1984; U.S. Pat. No. 4,637,819 issued to Ouellette,
Alcombright &
Curro on January 20, 1987; U.S. Pat. No. 4,609,518 issued to Curro, Baird,
Gerth, Vernon &
Linman on September 2, 1986; IJ.S. Pat. No. 4,629,642 issued to Kernstock on
December 16,
1986; and EPO Pat. No. 0,165,807 of Osborn published 8/30/89; all of which are
incorporated
herein by reference. The apertures in such coversheets may be of uniform size
or can vary in
size, as disclosed in the foregoing published documents, which can be referred
to for technical
details, manufacturing methods, and the like. Such apertures may also vary in
diameter in the
manner of so-called "tapered capillaries". Such formed-film cover-sheets with
tapered capillary
apertures preferably are situated over the carrier sheet such that the smaller
end of the capillary
faces the carrier sheet and the larger end of the capillary faces outward.
This helps prevent bulk
liquid transfer, thereby minimizing water spotting on the fabrics being
treated. In the main,
apertures in the formed film coversheets used herein can have diameters in the
range of from
about 0.1 mm to about 1 mm, or as disclosed in the aforesaid patent
references.
Carrier - When used in the in-dryer step of the present process, the
cleaning/refreshment
and sanitizing compositions axe used in combination with an absorbent carrier.
The carrier
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WO 99/55390 PCT/IB99100688
releasably contains the compositions. By "releasably contains" means that the
compositions are
effectively released from the carrier onto the soiled fabrics as part of the
sanitizing non-
immersion cleaning and/or fabric refreshment processes herein. This release
occurs mainly by
volatilization of the composition from the carrier substrate through the vapor-
permeable
coversheet, or by a combination of vapor and liquid transfer, although when
treating fabrics bulk
liquid transfer is desirably minimized by means of the coversheet, as
disclosed hereinabove. It is
to be understood, however, that when water spotting is of no particular
concern to the user, the
coversheet need not be employed with the absorbent carrier substrate.
The carrier can be in any desired form, such as powders, flakes, shreds, and
the like.
However, it is highly preferred that the carrier be in the form of an integral
pad or sheet which
substantially maintains its structural integrity throughout the process. Such
pads or sheets can be
prepared, for example, using well-known methods for manufacturing non-woven
sheets, paper
towels, fibrous batts, cores for bandages, diapers and catamenials, and the
like, using materials
such as wood pulp, cotton, rayon, polyester fibers, and mixtures thereof.
Woven cloth pads may
also be used, but are not preferred over non-woven pads due to cost
considerations. Integral
carrier pads or sheets may also be prepared from natural or synthetic sponges,
foams, and the
like.
The carriers are designed to be safe and effective under the intended
operating
conditions of the present process. The carriers must not be flammable during
the process, nor
should they deleteriously interact with the cleaning or refreshment
composition or with the
fabrics being cleaned. In general, non-woven polyester-based pads or sheets
are quite suitable
for use as the carrier herein.
The carrier used herein is most preferably non-tinting. By "non-tinting"
herein is meant
a carrier which resists the shedding of visible fibers or microfibers onto the
fabrics being
cleaned, i.e., the deposition of what is known in common parlance as "lint". A
carrier can easily
and adequately be judged for its acceptability with respect to its non-tinting
qualities by rubbing
it on a piece of dark blue woolen cloth and visually inspecting the cloth for
lint residues.
The non-Tinting qualities of sheet or pad carriers used herein can be achieved
by several
means, including but not limited to: preparing the carrier from a single
strand of fiber;
employing known bonding techniques commonly used with nonwoven materials,
e.g., point
bonding, print bonding, adhesive/resin saturation bonding, adhesive/resin
spray bonding, stitch
bonding and bonding with binder fibers.
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WO 99/55390 PCT/IB99/00688
I1
The size of the carrier should not be so large as to be unhandy for the user.
Typically,
the dimensions of the carrier willl be sufficient to provide a macroscopic
surface area (both sides
of the carrier) of at least about :360 cm2, preferably in the range from about
360 cm2 to about
3000 cm2. For example, a generally rectangular carrier may have the dimensions
(X-direction)
of from about 10 cm to about 35 cm, and (Y-direction) of from about 18 cm to
about 45 cm.
The carrier is intended to contain a sufficient amount of the
cleaning/refreshment
compositions to be effective for their intended purpose. The capacity of the
carrier for such
compositions will vary according; to the intended usage. For example, pads or
sheets which are
intended for a single use in cleaninglrefreshing/sanitizing fabrics will
require less capacity than
such pads or sheets which are intended for multiple uses. For a given type of
carrier the capacity
for the cleaning or refreshment composition will vary mainly with the
thickness or "caliper" (Z-
direction; dry basis) of the sheet or pad. For purposes of illustration,
typical single-use polyester
sheets used herein will have a thickness in the range from about 0.1 mm to
about 0.7 mm and a
basis weight in the range from ;about 30 g/m2 to about 100 g/m2. Typical mufti-
use polyester
pads herein will have a thickness in the range from about 0.2 mm to about 1.0
mm and a basis
weight in the range from about 40 g/m2 to about 150 g/m2. Open-cell sponge
sheets will range
in thickness from about 0.1 rnm~ to about 1.0 mm. Of course, the foregoing
dimensions may
vary, as long as the desired quantity of the cleaning or refreshment
composition is effectively
provided by means of the carrier.
A preferred carrier herein comprises a binderless (or optional low binder),
hydroentangled absorbent material, especially a material which is formulated
from a blend of
cellulosic, rayon, polyester and optional bicomponent fibers. Such materials
are available from
Dexter, Non-Wovens Division, 'The Dexter Corporation as HYDRASPUN~, especially
Grades
10244 and 10444. The manufacture of such materials forms no part of this
invention and is
already disclosed in the literature. See, for example, U.S. Patents 5,009,747,
Viazmensky, et al.,
April 23, 1991 and 5,292,581, Viazmensky, et al., March 8, 1994, incorporated
herein by
reference. Preferred materials for use herein have the following physical
properties.
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WO 99/55390 PCT/IB99/00688
12
Dexter Sheet Grade 10244
Units Targets Ranges
Basis Weight grn/m2 55 35-75
Thickness microns 355 100-1500
Density gm/cc 0.155 0.1-0.25
Dry Tensile grn/25 mm
MD 1700 400-2500
CD 650 100-500
Wet Tensile gm/25 mm
MD* 700 200-1250
CD* 300 100-500
Brightness % 80 60-90
Absorption Capacity % 735 400-900 (H20)
Dry Mullen gm/cm2 1050 700-1200
*MD - machine direction; CD - cross direction
As disclosed in U.S. 5,009,747 and 5,292,281, the hydroentangling process
provides a
nonwoven material which comprises cellulosic fibers, and preferably at least
about 5% by weight
of synthetic fibers, and requires less than 2% wet strength agent to achieve
improved wet
strength and wet toughness.
It has been discovered that this hydroentangled carrier material provides an
additional,
unexpected benefit due to its resiliency. In-use, the articles herein are
designed to function in a
substantially open configuration. However, the articles may be packaged and
sold to the
consumer as sheets which are in a folded configuration. It has been discovered
that the carrier
sheets made from conventional materials tend to undesirably revert to their
folded configuration
in-use. Indeed, this tendency to r<;-fold along the original fold lines seems
to be exacerbated by
the coversheet materials used herein. While the hydroentangled materials used
to form the
carrier sheet herein have less tendency to re-fold during use than do other
carrier materials, it has
been determined experimentally that up to 60% refold does seem to occur under
intended usage
conditions when the fibrous coversheet is present. In some instances, and
especially with certain
types of fabrics, this can be problc;matic, inasmuch as wet strikes can occur
along the sharp fold
lines, presumably due to pressure forcing the liquid composition through the
fibrous coversheet.
However, it has now beeci determined that by providing holes or otherwise
fenestrating
the carrier sheet, this tendency to re-fold is substantially lessened even
when the coversheet is
CA 02329335 2000-10-19
WO 99/55390 PCT/IB99/00688
13
used in the non-immersion cleaning/refreshment/sanitization process of the
present invention.
Thus, in a preferred mode of practicing the present invention a plurality of
holes, slits, or other
fenestrations are placed in the carrier sheet to help minimize re-fold when
the article is used.
The number and placement of l:he holes or other fenestrations can be
determined by routine
experimentation. Example I hereinafter gives the size and number of circular
holes which are
useful for an article of the size and with the load of cleaning/refreshment
composition described
therein.
Cleanin efreshing-Compositions - The user of the present process can be
provided
with various cleaning/refreshing compositions to use in the practice the
invention. Une problem
associated with known fabric treatment 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 used herein should., most preferably, be substantially free of
various gelling agents,
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. Water used in the compositions should preferably be
distilled, deionized or
otherwise rendered free of residue-forming materials. Stated otherwise the
compositions herein
should preferably be formulated so as to leave substantially no visible
residue on fabrics or other
solid surfaces being treated according to the practice of this invention.
Accordingly, in a preferred aspect of this invention there are provided
cleaning/refreshment and sanitizing compositions which are substantially free
of quantities of
materials which are sufficient to leave visible residues on the treated
fabrics.
Aqueous Compositions For Cleaning./Refreshin~ or Pre-Treatin~Com,positions
(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) Antimicrobial agents - antimicrobial agents can be selected from the group
consisting of 5-chloro-2-(2,4-dichlorophenoxy)phenol, trichlorocarbanalide,
hydrogen peroxide, other oxygen bleaches, 4-chloro-3,5-dimethylphenol,
iodine/iodophors, chlorhexidine, phenols, phospholipids, thymol, eugeniol,
geraniol,
oil of lemon grass, limonene and mixtures thereof. A second antimicrobial
agent can
be selected from the. group consisting of alkyl alkoxy sulfates, linear alkyl
benzene
sulfonates, amine oxides, polyhydroxy fatty acid amides, ethoxylated alcohols,
diamines, amides, alkyl polyglucosides, betaines, and mixtures thereof.
CA 02329335 2000-10-19
WO 99155390 PCT/IB99/00688
14
(c) Surfactant - The corr~positions herein may optionally comprise, in
addition to the
antimicrobial agents listed above, 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.
(d) Optionals - The compositions herein may comprise minor amounts of various
optional ingredients, including bleach stabilizers, perfumes, 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) Chelator -Compositions which contain hydrogen peroxide or other oxygen
bleaches
will also typically contain a chelating agent. The chelating agent is selected
from
those which, themselves, are stable in aqueous hydrogen peroxide and which
stabilize the hydrogen peroxide by chelating vagrant metal ions. Such
chelating
agents are 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 hydrogen peroxide. 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 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 to
about 7.
Surfactants - Nonioni<;s 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 and random C 10-
C20 alkyl
sulfates, and C 10-C 1 g secondary (2,3) alkyl sulfates of the formula
CH3(CH2~(CHOS03 M+)
CH3 and CH3 (CH2)y(CHOSO3 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 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 C10-C16
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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 C 12-C 16 alkyl dimethyl amine oxide surfactants can
also be used.
A preferred mixture comprises lVlgAEIS/C12 dimethyl amine oxide at a weight
ratio of about
10:1. Other surfactants which improve phase stability and which optionally can
be used herein
include the polyhydroxy fatty acid amides, e.g., C12-C1~ N-methyl glucamide.
AS stabilized
compositions preferably comprise; 0.1 %-0.5%, by weight, 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 llevels.
Having due regard to the foregoing considerations, the following illustrates
the various
other ingredients which can be used in the liquid compositions herein, but is
not intended to be
limiting thereof.
Other Optionals - In addition to the water and the surfactants disclosed
above, liquid
compositions used herein 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.
Ingredient % (wt.) Formula Ranee
Antimicrobial Agent 0-3
Surfactant 0-2
Perfume 0-1.5
Water Balance
pH range from about 6 to about
8.
Preferred compositions for use
in the in-dryer cleaning/refreshmentJsanitization
process
herein are as follows.
In redient % wt. Ran~~e (% wt.)
Water 98.5 95.1-99.9
Antimicrobial Agent 0.1 0.05-3
Perfume 0.5 0-1.5
Surfactant* 0.5 0.05-2.0
Ethanol or Isopropanol 0 Optional to 4%
*Especially ethoxylated alcohols,
as disclosed herein. The fabric
refreshment
compositions may also contain Such anionic surfactants
anionic surfactants. are well-known in
CA 02329335 2000-10-19
WO 99/55390 PCT/IB99/00688
16
the detergency arts. Commercial surfactants available as TWEEN~, SPAN~,
AEROSOL OT~
and various sulfosuccinic esters are especially useful herein.
Perfume - It has been determined that higher molecular weight, high boiling
point,
malodorous chemicals tend to be retained on the fabrics, at least to some
degree. These
malodors can be overcome, or "masked", by perfumes. Accordingly, it will be
appreciated that
the perfumer should select at least some perfume chemicals which are
sufficiently high boiling
that they are not entirely lost during the process. A wide variety of
aldehydes, ketones, esters,
acetals, and the like, perfumery chemicals which have boiling points above
about 50°C,
preferably above about 85°C, are known. Such ingredients can be
delivered to the fabrics being
treated by means of the carrier substrate herein during the processes herein,
thereby helping to
reduce the user's perception of malodors. Non-limiting examples of perfume
materials with
relatively high boiling components include various essential oils, resinoids,
and resins from a
variety of sources including but not limited to orange oil, lemon oil,
patchouli, Peru balsam,
Olibanum resinoid, styrax, labdanum resin, nutmeg, cassia oil, benzoin resin,
coriander, lavandin
and lavender. Still other perfume chemicals include phenyl ethyl alcohol,
terpineol and mixed
pine oil terpenes, linalool, linalyl acetate, geraniol, nerol, 2-(1,1-
dimethylethyl)-cyclohexanol
acetate, orange terpenes and eugenol. Of course, lower boiling materials can
be included, with
the understanding that some loss will occur due to venting.
Vapor Venting Bay - The compositions are loaded on the carrier substrate which
is
preferably encased in the coversheet and the finished article is placed in a
bag environment for
use in a heated operating clothes dryer, or the like, to sanitize the fabrics
and to remove
malodors from the fabrics as a dry cleaning alternative or "fabric
refreshment" process. The
warm, humid environment created inside this bag volatilizes the aqueous
cleaning/refreshing
composition resulting in a sterilization of the fabric articles within and
removal of malodor
components in the manner of a "'steam distillation" process, and moistens
fabrics and the soils
thereon.
In addition to the desired sanitization effect, the moistening of fabrics with
the
volatilized cleaning/refreshing composition can loosen pre-set wrinkles. But
it has been
discovered that overly wet fabrics can experience setting of new wrinkles
during the drying
stage toward the end of the dryer cycle. Proper selection of the amount of
water used in the
process and, importantly, proper venting of the bag in the present manner can
minimize
wrinkling. Moreover, if the bag; is not vented, the volatilized malodorous
materials removed
from the fabrics can undesirably be re-deposited thereon.
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WO 99/55390 PCT/IB99/00688
17
In a highly preferred mode, the process of the present invention employs a
vapor-
venting containment bag. The bag is preferably designed for multiple uses and
reuses, and is
especially adapted for use by the consumer in any conventional hot air clothes
dryer apparatus,
such as those found in the home or in commercial laundry/cleaning
establishments. The bag is
designed to vent water and other vapors (including malodorous materials) which
emanate from
within the bag when used in the manner described herein. The vapors released
from the bag are
then exhausted through the air vent of the dryer apparatus.
The design of the venting ability of the bag achieves a proper balance of the
above
effects. A tightly-sealed, vapor impermeable "closed" bag will not release a
sufficient amount
of vapor which will overly moisten the fabrics, resulting in a reduction in
the killing of
microbials. An overly "open" bag design will not sufficiently moisten the
fabrics or soils to kill
the microbials. Further, the bag must be "closed" enough to billow and create
a void volume
under water vapor pressure, wherein the fabrics can tumble freely within the
bag and be exposed
to the vapors
The bag is designed with sufficient venting to trap a portion of water vapors
(especially
early in the dryer cycle) but to allow most of the water to escape by the end
of the cycle. Said
another way, the rate of vapor release is, preferably, optimized to secure a
balance of vapor
venting and vapor trapping. A preferred bag design employs a water vapor
impermeable film
such as nylon, with a the closure flap (preferably with a hook-and-loop VELCRO-
type
fastener) like that of a large envelope. The degree of slack in the fold-over
portion of the
closure flap can be varied to provide a vapor-venting air gap or partial
opening which controls
the rate of vapor venting from of the bag. In another mode, a notch is cut
along the edge of the
side wall opposite the flap to further adjust the venting. The fastener
devices shown in the
Figures run only partly along the closure, thereby allowing venting to also
occur at the lateral
edges of the closure.
As described more fully hereinafter, the preferred venting bag is provided
with a vapor-
venting closure which provides .one or more gaps through which vapors are
released from the
bag, in-use. In a preferred embodiment, the size of this gap is selected to
provide controlled
vapor release from the bag under the indicated operating conditions. While
other gap sizes and
operating conditions can be used, a preferred balance between vapor
containment within the bag
-to perform the sanitization of the fabrics along with the
cleaning/refreshment function and
vapor release from the bag- has now been determined using the principles
disclosed hereinafter.
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WO 99/55390 PCT/IB99/00688
18
Alternatively, the bag can be provided with a series of holes or other
fenestrations which
provide vapor venting. However, such venting is not as effective as the vapor-
venting closure.
In one mode, the present invention employs a vapor-venting containment bag
comprising 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 affixed
thereto, said flap being
foldable to extend over a portion of the outside surface of the opposing side
wall, said flap being
affixable 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-26U°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 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 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 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, comprise 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 wherein said first and second fastener
devices, together,
comprise an adhesive fastener; bags wherein said first and second fastening
devices, together,
CA 02329335 2000-10-19
WO 99/55390 PCT/IB99/00688
19
comprise a toggle-type fastener; bags wherein said first and second fastening
devices, together,
form a snap-type fastener; as welll 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 can 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 cllosure. In yet another embodiment, both ends
of the bag are
provided with a vapor venting closure.
Preferred bags of the foregoing type which are designed for use in a
conventional U.S.-
style automatic, in-home hot air clothes dryer will have a volume in the range
from about 10,000
cm3 to about 25,000 cm3.
The invention also employs a process for cleaning or refreshing fabrics by
contacting
said fabrics with a fabric cleaning/refreshing composition comprising water in
the aforesaid
vapor-venting containment bag. This process is conveniently carried out in a
hot air clothes
dryer, or the like. Those skilled in the art will recognize that hot air
clothes dryers operate at
temperatures sufficient to vapori~:e water, that is, from about 40°C to
about 250°C, preferably,
from about 40°C to about 150°C; whereby the fabrics and vapor
venting bag are sterilized, and
malodors present on the fabrics are vented from the bag by means of the vapor-
venting closure.
The following is intended to assist the formulator in the manufacture and use
of vapor-
venting bags in the manner of this invention, but is not intended to be
limiting thereof.
Bag Dimensions - Figure 4 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 the 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 5 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 cm)
wide. The distance
(9) from the lateral edge of the bag to the outermost edge of the fastening
device (3) located on
the inside of the flap (5) is about 2 inches (5 cm). In this 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 c.m) and whose total length is about 22 inches
(55.9 cm).
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WO 99/55390 PCT/IB99/00688
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 em) 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)
affixed to the
flap is about 3/8 inches (0.95 cm). The distance (17) between fold (11) and
the lowermost edge
of the notch is about 1/2 inch ( 1.27 cm). This distance also can be varied to
decrease or increase
vapor venting. A range of 0.25-l.-'i inches (0.64-3.81 cm) is typical. The
distance (18) between
the uppermost edge of the VELCR;O~-type strip (6) and the bottom edge of the
notch is about
3/4 inches (1.9 cm). The distance. (19) between the bottommost edge of the
VELCRO~-type
strip (3) and the fold (11 ) is about ll 1/4 inches (3.17 cm).
Figure 6 gives additional details of the dimensions of an un-notched envelope
bag of the
foregoing overall size comprising sidewalk (2a) and (2b). Again, each VELCRO-
type strip
(3) and (6) is about 3/4 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 finches (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 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
CA 02329335 2000-10-19
WO 99/55390 PCT/IB99/00688
21
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 4 and 6, in one embodiment, 1
to 3 mil (0.025-
0.076 mm) heat-resistant Nylon-i6 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
equipment 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 end-
use.
For example, a relatively smaller bag can be provided which is sufficient to
contain one or two
silk blouses. Alternatively, a larger bag suitable for handling a man's suit
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 sufficient 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 Japanese
dryers.
The bag herein is preferably flexible, yet is preferably durable enough to
withstand
multiple uses. The bag also preferably has sufficient stiffness 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 (1-3 mil) thickness polymer sheets. if more
rigidity in the
bag 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-e:xtruded nylon and/or polyester or nylon
and/or polyester outer
and/or inner layers surrounding a less 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 circumstances where
excessive heating is not of concern, the
bag can be made of polyester, polypropylene or any convenient polymer
material.
Vapor Venting Evaluation - In its broadest sense, the preferred vapor-venting
containment bag used herein is designed to be able to vent at least about 40%,
preferably at least
about 60%, up to about 90%, preferably no more than about 80%, by weight, of
the total
CA 02329335 2000-10-19
WO 99/55390 PCT/IB99/00688
22
moisture introduced into the bag within the operating cycle of the clothes
dryer or other hot air
apparatus used in the process herein. (Of course most, if not all, of organic
cleaning solvents, if
any, will also be vented during together with the water. However, since water
comprises by far
the major portion of the cleaning/refreshment compositions herein, it is more
convenient to
measure and report the venting as water vapor venting.)
It will be appreciated by those knowledgeable about the operation of hot air
clothes
dryers and similar apparatus that the rate of venting will usually not be
constant over the entire
operating cycle. All dryers have a warm-up period at the beginning of the
operating cycle, and
this can vary according to the specifications of the manufacturer. Most dryers
have a cool-down
period at the end of the operating cycle. Some venting from the containment
bag can occur
during these warm-up and cool-down periods, but its rate is generally less
than the venting rate
over the main period of the drying cycle. Moreover, even during the main
period of the cycle,
many modern dryers are constructed with thermostat settings which cause the
air temperature in
the dryer to be increased and decreased periodically, thereby preventing
overheating. Thus, an
average, rather than constant, dryer operating temperature in the target range
of from about 50°C
to about 85°C is typically achieved.
Moreover, the user of the: present containment bag may choose to stop the
operation of
the drying apparatus before the cycle has been completed. Some users may wish
to secure
fabrics which are still slightly damp so that they can be readily ironed, hung
up to dry, or
subjected to other finishing operations.
Apart from the time period employed, the Vapor-Venting Equilibrium ("VVE") for
any
given type of vapor-venting closure will depend mainly on the temperature
achieved within the
dryer - which, as noted above, is typically reported as an average "dryer air
temperature". In
point of fact, the temperature reached within the containment bag is more
significant in this
respect, but can be difficult to measure with accuracy. Since the heat
transmittal through the
walls of the bag is rather efficient due to the thinness of the walls and the
tumbling action
afforded by conventional clothes dryers, it is a reasonable approximation to
measure the VVE
with reference to the average dryer air temperature.
Moreover, it will be appreciated that the vapor-venting from the containment
bag should
not be so rapid that the aqueous cleaning/refreshment composition does not
have the opportunity
to moisten the fabrics being treated and to mobilize and remove the
soils/malodors therefrom.
However, this is not of practical concern herein, inasmuch as the delivery of
the composition
from its carrier substrate onto the fabrics afforded by the tumbling action of
the apparatus occurs
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23
at such a rate that premature loss. of the composition by premature
vaporization and venting is
not a significant factor. Indeed, the preferred bag herein is designed to
prevent such premature
venting, thereby allowing the liquid and vapors of the cleaning/refreshment
composition to
remain within the bag for a period which is sufficiently long to perform its
intended functions on
the fabrics being treated.
The following Vapor-Venting Evaluation Test (VVET) illustrates the foregoing
points
in more detail. Larger or smaller containment bags can be used, depending on
the volume of the
dryer drum, the size of the fabric load, and the like. As noted above,
however, in each instance
the containment bag is designed to achieve a degree of venting, or VVE
"score", of at least about
40% (40 VVE), preferably at least about 60% (60 WE), up to about 90% (90 VVE).
VAPOR-VENTING EVALUAT10N TEST
Materials:
Envelope or "Standard", i.e., Control Containment Bag to be evaluated for WE.
Carrier Substrate (15"x11"; 38.1 cm x 27.9 cm) HYDRASPLJN~ carrier substrate
sheet from
Dexter with (10444) or without (10244) Binder
Wool Blouse: RN77390, Style 12288, Weight approx. 224 grams
Silk Blouse: RN40787, Style 0161, Weight approx. 81 grams
Rayon Swatch: 45"x17" (114.3 cm x 43.2 em), Weight approx. 60 grams
Pouch: 5"x6.375" (12.7 cm x 16.2 cm) to contain the Carrier Substrate and
water
De-ionized Water; Weight is variable to establish VVE.
Pretreatment of Fabrics:
1. The wool, silk, and rayon materials are placed in a Whirlpool dryer (Model
LEC7646DQ0) for 10 minutes at high heat setting, with the heating cycle
ranging from
about 140°F-165°F to remove moisture picked up at ambient
condition.
2. The fabrics are then removed from the dryer and placed in sealed nylon or
plastic bags
(minimum 3 mil. thickness) to minimize moisture pick up from the atmosphere.
Test Procedure:
1. Water of various measured weights from 0 to about 40 grams is applied to
the carrier
substrate a minimum of 30 minutes before running a vented bag test. The
substrate is
folded, placed in a pouch and sealed.
2. Each fabric is weighed separately and the dry weights are recorded. Weights
are also
recorded for the dry carrier substrate, the dry pouch containing the
substrate, and the dry
containment bag being evaluated.
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3. Each garment is placed in the bag being evaluated for vapor venting along
with the
water-containing substrate (removed from its pouch and unfolded).
4. The bag is closed without expressing the air and placed in the Whirlpool
Dryer for 30
minutes at the high heat setting, with tumbling per the standard mode of
operation of the
dryer.
5. At the end of 30 minutes the bag is removed from the dryer and each fabric,
the carrier
substrate, the bag and the pouch are weighed for water weight gain relative to
the dry
state. (A possible minor loss in weight for the containment bag due to dryer
heat is
ignored in the calculations.)
6. The weight gain of each garment is recorded as a percent of the total
moisture applied to
the carrier substrate.
7. The remaining unmeasured moisture divided by the total moisture is recorded
as percent
vented from the dryer bag.
8. When a series of total applied moisture levels are evaluated, it is seen
that above about
15-20 grams of water the % vented becomes essentially constant, and this is
the Vapor-
Venting Equilibrium value, or VVE, for the particular bag venting design.
It can be seen from examining a series of VVET results at various initial
moisture levels
that the water at lower initial levels is being disproportionately captured by
the garment load, the
headspace, and the nylon bag, such that venting of water and volatile malodors
begins in earnest
only after the VVE value is achieved. Since this occurs only when about I S-20
grams or more of
water is initially charged, it is seen that a WE of greater than about 40 is
needed to avoid
excessive wetting of garments, leading to unacceptable wet-setting of
wrinkles, as discussed
herein.
Pre-Treating Steu - The overall process herein optionally comprises a pre-
treating step
which can also serve as a spot removal step on isolated, heavily stained areas
of the fabric. This
pre-treating step can be effective: in neutralizing certain malodor causing
chemicals such as
isovalaric acid, short chain amines and short chain sulfur compounds. These
compounds are
known to be the by-products of bacterial "digestion" of human perspiration
components.
The pre-treating step preferably comprises the step of applying a pre-treating
composition to at least a portion of the fabric, wherein the pre-treating
composition comprises
an antimicrobial agent selected from the group consisting of 5-chloro-2-(2,4-
dichlorophenoxy)phenol, trichlorcarbanilide, hexachlorophene, chlorhexadine, o-
phenylphenol,
benzylquaternium salts and mixtures thereof. The pre-treating composition
preferably further
CA 02329335 2000-10-19
WO 99/55390 PCT/IB99/00688
comprises water, a minor amount of a solvent such as Butoxy Propoxy Propanol
(BPP), and
surfactants such as those discussE:d above. The pre-treating composition can
be rubbed into the
fabric using the tip of the bottle that contains the pre-treating composition
or with an implement.
The excess pre-treating composition can be absorbed by an absorbent stain
receiver that is
preferably placed on the side of the fabric opposite to the side that receives
the pre-treating
composition. The absorbent stain receiver can be a conventional paper towel, a
thermally
bonded air laid sheet, an absorbent polymeric foam or the like.
Following this localized pretreating step, the entire fabric can be
cleaned/refreshed in
the vapor-venting containment bag. This latter step provides a marked
improvement in the
overall appearance and refreshment of fabrics, especially with respect to the
near absence of
malodors and wrinkles, as compared with untreated fabrics.
PROCESS COMPONENTS
The use of the article with the vapor-venting bag, the compositions and the
processes of
this invention are described in more detail hereinafter. Such disclosure is by
way of illustration
and not limitation of the invention herein. The definitional terms used herein
have the following
meanings.
Figure 3 illustrates one form of a pre-formed, notched containment bag in an
open
configuration with the loose article ( I ), first side wall (2a), second side
wall (2b), first fastening
device (3), side seal (4) for the bag and flexible flap (5). In use, flexible
flap {5) is folded along
fold line ( 11 ) to provide the vapor-venting closure for the bag.
Figure 4 shows the "envelope-style" notched bag in a finished configuration
and
containing the loose article ( 1 ). In-use, the fabrics to be
cleaned/refreshed are placed in the bag
with the article (I) and flap (5) is folded along fold line (11) to engage
first fastening device (3)
with the opposing second fastening device (6) to fasten the flap, thereby
providing a vapor-
venting closure which is sufficiently stable to withstand tumbling in a hot
air clothes dryer or
similar device.
Figure 5 shows a cut-away view of the corner of the notched containment bag
illustrating the interior of the first side wall (2a) and second side wall
(2b), first fastening device
(3), second fastening device (6), flap (5), and fold line ( I 1 ). The
distance between the edge of
the bag (9) and the depth of the notch { 11 ) in second side wall (2b) are
dimensions which are set
forth hereinabove.
Figure 6 depicts an un-notched venting bag with the article (1) loosely
contained therein.
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The Bag Dimensions given hereinabove are for containment bags which are
designed to
tumble freely within the drum of a conventional, U. S.-style in-home hot air
clothes dryer having
a drum volume of about 170-210 liters (home size). The bag of the stated
dimensions is
designed to treat up to about 5 k.g fabric load in a single use. The
dimensions can be adjusted
proportionately for larger or smaller bags to achieve the desired VVE and to
ensure effective use
in dryers with larger or smaller drums. For example, the total volume of a
containment bag
constructed for use in an average European home clothes dryer (or U.S.
"apartment" size; ca.
90 liter drum volume) would be about 60% of the volume for an average U.S.
dryer.
OVERALL PROCESS
The overall process is conveniently conducted in a tumbling apparatus,
preferably in the
presence of heat. The nylon or other heat-resistant vapor-venting bag with the
article herein plus
aqueous cleaning/refreshment composition and containing the fabric being
treated is closed and
placed in the drum of an automatic hot air clothes dryer at temperatures of
from about 40°C to
about 250°C, preferably, from about 40°C to about I50°C.
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
article containing the
composition. The tumbling and heating are carried out for a period of at least
about 10 minutes,
typically from about 20 minutes to about 60 minutes. This step 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 load, the amount of
heat applied, and the
like, according to the needs of the user. During the step, greater than about
40%, typically 40%
to about 80%, of the moisture is vented from the bag.
The following Examples further illustrate the invention, but are not intended
to be
limiting thereof.
EXAMPLE I
A low residue liquid fabric
cleaning/refreshment product
for use in a vented dryer
bag is
prepared, as follows.
Ingredient % wt.
Antimicrobia) Agent 0.5
Emulsifier (TWEEN 2U)* 0.5
Perfume 0.5
KATHON~ 0.0003
Sodium Benzoate 0.1
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Water Balance
*Polyoxyethylene (20) sorbitan monolaurate available from ICI Surfactants.
A 10 1/4 in. x 14 1/4 in. (26 cm x 36 cm) carrier sheet of HYDRASPLJN~ is
prepared.
The carrier sheet is covered on both sides with a topsheet and a bottomsheet
of 8 mil (0.2 mm)
Reemay fabric coversheet material of the type described hereinabove. The
coversheet (i.e., both
topsheet and bottomsheet) are bonded to the carrier sheet by a Vertrod~ or
other standard heat
sealer device, thereby bonding the laminate structure together around the
entire periphery of the
carrier sheet. The edges of the carrier sheet around its periphery are
intercalated between the
topsheet and bottomsheet by the bond. As noted above, the width of the bond is
kept to a
minimum and is about 0.25 in. (6.4 mm).
The bonded laminate structure thus prepared is folded and placed in a pouch.
Any
plastic pouch which does not leak would be suitable. For example, a foil
laminated pouch of the
type used in the food service industry can be employed. Such pouches are well-
known in the
industry and are made from materials which do not absorb food flavors. In like
manner, the
formulator herein may wish to avoid absorption of the perfume used in the
cleaning/refreshment
composition by the pouch. Various pouches are useful herein and are
commercially available
on a routine basis.
The folded carrier sheet/c;oversheet article is placed in the pouch. The folds
can be of
any type, e.g., an accordion-style fold, such that the final dimension of the
folded sheet is about
13.5 cm x 9.5 cm. This size is not critical but is convenient for placement in
a pouch. 23 Grams
of the liquid product are poured onto the carrier sheet/coversheet and allowed
to absorb into it
for a minimum of 30 minutes, preferably for about 4 hours. The pouch is sealed
immediately
after the liquid product is introduced into the pouch and stored until time-of
use.
1n an alternate mode, the article can be rolled somewhat loosely around a
cylindrical
void into a generally tubular shape of about 26 cm length and a diameter of
about 2-3 cm. The
rolled article is then folded to haliP its length at about its rnid-point by
means of a thrusting blade
which also serves to insert the article into a retaining pouch. It is observed
that, with such rolling
method, essentially no severely sharp creases are formed, and the final
doubling of the rolled
tube is under such stress that only in the very center of the bend are a few
sharper creases
formed. The result is that permanent refolding along crease lines is
essentially avoided, and
release of the cleaning/refreshment composition from the article in-use is
optimized.
Any plastic or flexible pouch which does not leak is suitable for use herein.
For
example, a foil laminated pouch of the type used in the food service industry
can be employed.
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Such pouches are well-known in the industry and are made from materials which
do not absorb
food flavors. In like manner, the formulator herein may wish to avoid
absorption of the perfume
used in the cleaning/refreshment composition by the pouch. Various pouches are
useful herein
and are commercially available on a routine basis. As a point of comparison,
the pouch
containing the rolled/folded article herein has overall dimensions of about
8.5 cm x 17.7 cm,
whereas a pouch for a similar planar-folded article is about 13 cm x 17.7 cm.
As an entirely optional matter, the carrier sheet can also have holes punched
therethrough in order to further maximize its ability to maintain an open
configuration in-use.
Indeed, the holes can be punched through the entire article, including the
coversheet, itself. For
an article having the overall dimensions of about 27 cm x 37 cm, 16 round
holes, each about 0.5
in. (1.27 cm) in diameter are evenly spaced across the HYDRASPL1N carrier
sheet. Slits or other
perforations may be used in like manner.
The fabric to be treated is placed into a 26 in. x 30 in. {66 x 76 cm) vapor-
venting nylon
bag as shown in the Figures together with the sheet (which is removed from its
storage pouch,
unfolded and/or unrolled) releasably containing the aforesaid
cleaning/refreshment product. The
mouth of the bag is closed to provide vapor-venting, and the bag and its
contents are placed in
the drum of a conventional hot air clothes dryer. The dryer is operated in
standard fashion for
20-60 minutes at a high heat setting (an air temperature range of about 140-
170°F; 60-70°C).
After the tumbling action of the dryer ceases, the cleaned and refreshed
fabric is removed from
the bag. The used sheet is discarded. The fabric (which is preferably still
slightly damp) is
preferably hung on a conventional hanger to complete the drying process
thereby further
avoiding wrinkles.
EXAMPLE II
Aspergillus niger is selected as a typical fungal microorganism, that is, as a
test
microbial. Fabrics inoculated therewith are treated in the manner of this
invention using the
vented bag. As a control, fabrics .are similarly inoculated with the test
microbials arid are left
unexposed to the dryer treatment. T'he results indicate that at least about
90% of the test
microbes initially present were killed by the test treatment. These results
would not be expected
by those skilled in the art.
EXAMPLE III
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Escherichia coli is selected as a typical bacterial microorganism, that is, as
a test
microbial. Fabrics inoculated therewith are treated in the manner of this
invention using the
vented bag. As a control, fabrics are similarly inoculated with the test
microbials and are left
unexposed to the dryer treatment. The results indicate that greater than
99.97% of the test
microbes initially present were killed by the test treatment. These results
would not be expected
by those skilled in the art.
