Note: Descriptions are shown in the official language in which they were submitted.
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CLEANING COMPOSITIONS THAT REDUCE SHRINKAGE OF FABRICS
TECHNICAL FIELD
The present invention relates to compositions and articles containing these
compositions
that are designed to clean and refresh fabrics in a non-immersion cleaning
process while
minimizing shrinkage of the fabrics.
BACKGROUND OF THE INVENTION
Certain delicate fabrics are not suitable for conventional in-home immersion
cleaning
processes. Home washing machines, which provide excellent cleaning results for
the majority of
fabrics used in today's society, can, under certain conditions, shrink or
otherwise damage silk,
Linen, wool and other delicate fabrics. Consumers typically have their
delicate fabric items "dry-
cleaned". Unfortunately, dry-cleaning usually involves immersing the fabrics
in various
hydrocarbon and halocarbon solvents that require special handling and must be
reclaimed,
making the process unsuitable for in-home use. Hence, dry-cleaning has
traditionally been
restricted to commercial establishments making it less convenient and more
costly than in-home
laundering processes. But, excluding cost and convenience, dry-cleaning
processes remain
generally superior to in-home, immersion laundering processes for minimizing
fabric shrinkage.
Attempts have been made to provide in-home dry-cleaning systems that combine
the
fabric cleaning and refreshing of in-home, immersion laundering processes with
the fabric care
benefits of dry-cleaning processes. One such in-home system for cleaning and
refreshing
garments comprises a substrate sheet containing various liquid or gelled
cleaning agents, and a
plastic bag. The garments are placed in the bag together with the sheet, and
then tumbled in a
conventional clothes dryer. In a current commercial embodiment, multiple
single-use flat sheets
comprising a cleaning/refreshing agent and a single multi-use plastic bag are
provided in a
package. Unfortunately, such in-home processes are sub-optimal with respect to
fabric
shrinkage. To be clear, these in-home, non-immersion processes are
substantially superior to in-
home, immersion processes with respect to minimizing fabric shrinkage. And
these in-home,
non-immersion processes are similar to commercial dry-cleaning processes with
respect to
minimizing fabric shrinkage, but some minor amount of shrinkage can occur as a
result of either
process. Thus, there is a continuing need to find improved in-home, non-
immersion cleaning
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and refreshing processes, and cleaning and refreshing compositions for use
therein, which
provide acceptable cleaning while minimizing fabric shrinkage.
It has now also been unexpectedly discovered that certain organic compounds
when used
with a cleaning/refreshment composition within defined ratios, can reduce the
amount of
shrinkage that occurs during an in-home, non-immersion cleaninglrefreshment
process. The
present invention provides such a composition, and when used in the processes
of this invention,
and with the kits of this invention, fabrics can be cleaned and refreshed with
substantially less
shrinkage than conventional in-home immersion laundering processes. When using
the
composition, processes and kits of this invention the fabric shrinkage levels
are comparable to,
and in some cases substantially better than, commercial dry-cleaning with a
solvent immersion
process.
SUMMARY OF THE INVENTION
In one aspect of the present invention there is provided a composition for
treating
fabrics that comprises:
a) a fabric shrinkage reducing composition selected from the group consisting
of
ethylene glycol, all isomers of propanediol, butanediol, pentanediol,
hexanediol and
mixtures thereof, and more preferably selected from the group consisting of
neopentyl glycol, polyethylene glycol, 1,2-propanediol, 1,3-butanediol, 1-
octanol
and mixtures thereof; and
b) a liquid cleaning/refreshment composition.
The fabric shrinkage reducing composition and the liquid cleaning/refreshment
composition are
preferably releasably absorbed in a substrate in a weight ratio of from about
1:2 to about 1:5,
preferably from about 1:2 to about 1:4, more preferably from about 1:3 to
about 1:4, and most
preferably about 1:3.6. The cleaning/refreshment composition preferably
comprises water and a
member selected from the group consisting of surfactants, perfumes,
preservatives, bleaches,
auxiliary cleaning agents, organic solvents and mixtures thereof. The
preferred organic solvents
are glycol ethers, specifically, methoxy propoxy propanol, ethoxy propoxy
propanol, propoxy
propoxy propanol, butoxy propoxy propanol, butoxy propanol and mixtures
thereof. The
surfactant is preferably a nonionic surfactant, such as an ethoxylated alcohol
or ethoxylated
alkyl phenol and is present at up to about 2%, by weight of the
cleaning/refreshment
composition.
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In another aspect of the present invention there is provided an overall non-
immersion
cleaning/refreshment process for treating a fabric comprising the overall
steps of:
(a) placing the fabric together with a substrate in a containment bag;
(b) placing the bag in a hot air clothes dryer, or the like apparatus, and
operating the
apparatus with heat and tumbling; and
(c) removing the fabric from the bag.
In the process described above, releasably absorbed in the substrate is
preferably:
(i) a fabric shrinkage reducing composition selected from the group consisting
of
ethylene glycol, all isomers of propanediol, butanediol, pentanediol,
hexanediol and mixtures
thereof, and more preferably selected from the group consisting of neopentyl
glycol,
polyethylene glycol, 1,2-propanediol, 1,3-butanediol, 1-octanol and mixtures
thereof; and
(ii) a liquid cleaning/refreshment composition.
Further, the fabric shrinkage reducing composition and the liquid
cleaning/refreshment
composition are preferably present in a weight ratio of from about 1:2 to
about 1:5, preferably
from about 1:2 to about 1:4, more preferably from about 1:3 to about 1:4, and
most preferably
about 1:3.6. Preferably, vapors are vented from the bag during step (b). Even
more preferably,
in the above process the fabric has a first side and a second side and the
process further
comprises the steps of:
(a) applying a spot cleaning composition from a dispenser to a discrete
stained area
of the first side of the fabric;
(b) concurrently or consecutively with Step (a), contacting the first side of
the
fabric adjacent the stained area with a treatment member; and
(c) contacting the second side of the fabric adjacent the stained area with an
absorbent stain receiving article.
In yet another aspect of this invention there is provided a kit, comprising:
(a) multiple substrates with the fabric shrinkage reducing composition and the
liquid
cleaning/refreshment composition defined above releasably absorbed therein;
(b) a re-usable containment bag;
(c) optionally, a treatment member;
(d) optionally, a separate portion of a spot cleaning composition;
(e) optionally, one or more absorbent stain receiver articles.
In the kits of this invention, the separate portion of the spot cleaning
composition is preferably
provided in a container, and the treatment member is the distal tip of the
container.
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In another aspect of this invention there is provided a sheet which is
specifically adapted
to clean and/or refresh fabrics in a hot air clothes dryer, comprising:
(a) a substrate;
(b) from about 10 grams to about 30 grams of a liquid cleaninglrefreshment
composition comprising at least about 80%, preferably at least about 90% and
most preferably at least about 95%, by weight, of water releasably absorbed in
the substrate;
(c) from about 2 grams to about 20 grams of a fabric shrinkage reducing
composition selected from the group consisting of ethylene glycol, all isomers
of
propanediol, butanediol, pentanediol, hexanediol and mixtures thereof, and
more
preferably selected from the group consisting of neopentyl glycol,
polyethylene
glycol, 1,2-propanediol, 1,3-butanediol, I-octanol and mixtures thereof
releasably absorbed in the substrate.
The sheet of this invention preferably further comprises a vapor permeable
fibrous coversheet
that encases the outer surfaces of the substrate, and that is permeable to the
cleaning/refreshment
composition and the fabric shrinkage reducing composition. The coversheet
preferably has a
minimum thickness of at least about 8 mils, and is bonded to the substrate in
discrete areas.
BRIEF DESCRIPTION OF THE DRAWINGS
While this specification concludes with claims that distinctly define the
present
invention, it is believed that these claims can be better understood by
reference to the Detailed
Description Of The Invention and the drawings, wherein:
Figure 1 is a schematic representation of a fabric garment showing the
measurements
used to calculate the amount of shrinkage after each cycle of a fabric
treatment process.
DETAILED DESCRIPTION OF THE INVENTION
In one aspect, the present invention comprises a composition that is a mixture
of a fabric
shrinkage reducing composition and a liquid cleaninglrefreshment composition.
The fabric
shrinkage reducing composition and the liquid cleaning/refreshment composition
are releasably
absorbed in a substrate, which is preferably in the form of a sheet, and even
more preferably, the
substrate is encased in coversheet. A non-immersion cleaning/refreshment
process for treating a
fabric is also defined herein. This process comprises the steps of:
(a) placing the fabric together with a substrate in a containment bag;
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(b) placing the bag in a hot air clothes dryer, or the like apparatus, and
operating the
apparatus with heat and tumbling; and
(c) removing the fabric from the bag.
The fabric can be spot treated at anytime in conjunction with the cleaning and
refreshing process
of this invention, preferably the spot treatment occurs before the cleaning
and refreshing step.
The spot treatment process typically comprises the steps of:
(a) applying a spot cleaning composition from a dispenser to a discrete
stained area
on the first side of the fabric;
(b) concurrently or consecutively with Step (a), contacting the first side of
the
fabric adjacent the stained area with a treatment member; and
(c) contacting the second side of the fabric with an absorbent stain receiving
article.
Each of the elements of this invention are described in turn below.
By "cleaning" herein is meant the removal of soils and stains from fabrics.
"Spot
cleaning" is the localized cleaning on stained areas before or after the
cleaning/refreshment step
which is conducted in the bag. By "refreshment" herein is meant the removal of
malodors and/or
wrinkles from the overall fabrics, or the improvement of their overall
appearance, other than
primarily removing soils and stains, although some soil and stain removal can
occur concurrently
with refreshment.
"Shrinkage" is defined herein as the reduction in one or more of four
different
measurements on a test garment as shown in Figure 1. Specifically, wool,
wool/acrylic blends,
cotton, ramie/cotton blends, and rayon/acrylic blend garments, such as
sweaters were selected as
test garments to determine the shrinkage resulting from various cleaning
processes using various
cleaning compositions. The test garments are referred to herein collectively
as "long sleeve
garments". While different garments can be used to test shrinkage, long sleeve
garments have
numerous dimensions that can shrink independently of each other. Thus, long
sleeve garments
were selected as test garments for experimental reasons only because they
provide numerous
data points. It is understood that fabric shrinkage generally occurs
irrespective of the specific
garment form.
As shown in Figure 1, four specific dimensions are measured before and after
each
treatment cycle. All of the measurements are taken on the front of the long
sleeve garment, after
it has been placed on a hard, flat surface and smoothed by hand. That is, the
long sleeve
garments are not ironed before the measurements are taken. Permanent marker,
colored
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stitching, or other methods can be used to mark the exact location of each
measurement, so that
after each treatment cycle the measurements are taken at the same location.
With these
guidelines, it can be seen from Figure I that the "overall length" is the
distance from the bottom
hem of the long sleeve garment to the shoulder hem, the "arm length" is the
distance between
the hem on the bottom of one sleeve to the approximate mid-point of the hem
joining the sleeve
to the shirt, "width 1" is the distance between the side hems near the bottom
of the shirt, and
"width 2" is the distance between the two side hems near the arm pits of the
shirt.
Shrinkage Reducing Composition
The shrinkage reducing composition of this invention is preferably selected
from the
group consisting of ethylene glycol, all isomers of propanediol, butanediol,
pentanediol,
hexanediol and mixtures thereof, and more preferably selected from the group
consisting of
neopentyl glycol, polyethylene glycol, 1,2-propanediol, 1,3-butanediol, 1-
octanol and mixtures
thereof. The shrinkage reducing composition is preferably neopentyl glycol or
1,2-propanediol,
and is more preferably 1,2-propanediol. The ratio of shrinkage reducing
composition to
cleaning/refreshment composition is preferably from about 1:2 to about I:S,
preferably from
about 1:2 to about 1:4, more preferably from about I :3 to about 1:4, and most
preferably about
1:3.6.
It has been shown that the mixture of a shrinkage reducing composition with a
water
based cleaning/refreshment composition as defined below, when used in the non-
immersion
fabric treatment processes defined herein, substantially reduces shrinkage of
the treated
garments when compared to substantially identical garments treated in an
identical process
using only the cleaning/refreshment composition. Moreover, it has been shown
that using the
shrinkage reducing compositions on one substrate and the cleaning/refreshment
composition on
a second substrate in the non-immersion processes of this invention, does not
provide the
substantial shrinkage reduction observed when the two compositions are
releasably absorbed
onto the same substrate.
While not wanting to be bound by any one theory, it is believed that the
shrinkage
reducing compositions of this invention help maintain the fibers of the
treated fabrics in a
relaxed state while the water based cleaning/refreshment composition treats
the fabrics. The
relaxed fibers are less prone to shrinkage. As mentioned above, the reduced
shrinkage is
measured against a non-immersion process using only a cleaninglrefreshment
composition. It
bears noting that a non-immersion process using only a cleaning/refreshment
composition
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causes substantially less shrinkage than a conventional immersion laundering
process. Thus,
the compositions and processes taught herein are not only an improvement over
known non-
immersion processes, they are also a substantial improvement over conventional
immersion
laundering processes.
CleaninglRefreshment Composition
The cleaning/refreshment composition preferably comprises water and a member
selected from the group consisting of surfactants, perfumes, preservatives,
bleaches, auxiliary
cleaning agents, organic solvents and mixtures thereof. The preferred organic
solvents are
glycol ethers, specifically, methoxy propoxy propanol, ethoxy propoxy
propanol, propoxy
propoxy propanol, butoxy propoxy propanol, butoxy propanol and mixtures
thereof. The
surfactant is preferably a nonionic surfactant, such as an ethoxylated alcohol
or ethoxylated
alkyl phenol, and is present at up to about 2%, by weight of the
cleaning/refreshment
composition. Typical fabric cleaning refreshment/compositions herein can
comprise at least
about 80%, by weight, water, preferably at least about 90%, and more
preferably at least about
95% water.
The Examples below give specific ranges for the individual components of
preferred
cleaning/refreshment compositions for use herein. A more detailed description
of the individual
components of the cleaning/refreshment compositions, that is, the organic
solvents, surfactants,
perfumes, preservatives, bleaches and auxiliary cleaning agents can be found
in U.S. Patent No.
5,789,368, which issued on August 4, 1998 to You et al. The entire disclosure
of the You et al.
patent is incorporated herein by reference. Additionally, cleaning/refreshment
compositions are
described in co-pending U.S. Patent Application No. 08/789,171, which was
filed on January 24,
1997, in the name of Trinh et al. The entire disclosure of the Trinh et al.
Application is
incorporated herein by reference.
Substrate
When used in the in-dryer step of the present process, the shrinkage reducing
composition and the cleaning/refreshment composition are releasably absorbed
used in
combination with an absorbent substrate, herein after referred to as a
"substrate". The substrate
releasably contains the compositions. By "releasably contains" means that the
compositions are
effectively released from the substrate onto the soiled fabrics as part of the
non-immersion
cleaning and fabric refreshment processes herein. This release occurs mainly
by volatilization of
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the composition from the substrate through the vapor-permeable coversheet, or
by a combination
of,vapor and liquid transfer, although bulk liquid transfer is desirably
minimized by means of the
coversheet herein.
The substrate can be in any desired form, such as powders, flakes, shreds, and
the like.
However, it is highly preferred that the substrate be in the form of an
integral pad or "sheet" that
substantially maintains its structural integrity throughout the process. The
substrates and sheets
of this invention are sometimes referred to in the literature as "carriers" or
"absorbent carrier
sheets"; it is understood that all of these labels refer to liquid absorbing
materials that can be
used to conveniently transport liquids. Such substrates are described in
detail in U.S. Patent No.
5,789,368, to You et al. which was incorporated herein by reference above. The
manufacture of
these sheets 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, which are incorporated herein by reference.
The substrate is intended to contain a sufficient amount of the shrinkage
reducing
composition and cleaning/refreshment compositions to be effective for their
intended purpose.
The capacity of the substrate for such compositions will vary according to the
intended usage.
The size of the substrate should not be so large as to be unhandy for the
user. Typically, the
dimensions of the substrate will be sufficient to provide a macroscopic
surface area (both sides
of the substrate) of at least about 360 cm2, preferably in the range from
about 360 cm2 to about
3000 cm2. For example, a generally rectangular substrate 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.
Coversheet
The coversheets employed herein are distinguished from the substrate, inasmuch
as the
coversheets are relatively non-absorbent to the shrinkage reducing
compositions and
cleaning/refreshment compositions as compared with the substrate. 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
substrate, which is damp from its load of shrinkage reducing composition and
cleaning/refreshment composition, from coming into direct contact with the
fabrics being
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treated. Yet, the coversheet does allow vapor transfer of the shrinkage
reducing composition
and cleaning/refreshment composition from the substrate through the coversheet
and into the
containment bag, and thus onto the fabrics being treated. 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.
Such fibrous, preferably heat resistant and, most preferably, hydrophobic,
coversheets
are described in detail in U.S. Patent No. 5,789,368, to You et al. which was
incorporated herein
by reference above. Additionally, co-pending U.S. provisional application
60/077,556, which
was filed on March 11, 1998, in the name of Wise et al., describes certain
improvements to the
coversheets of this invention. The entire disclosure of the Wise et al.
application is incorporated
herein by reference. Suitable combinations of the coversheets described in You
et al. with the
improvements described in Wise et al. can be employed, according to the
desires of the
manufacturer, without departing from the spirit and scope of the invention.
One potential problem with the sheets of this invention, that is the substrate
or the
combination of a substrate and a coversheet, is that they may be overused by
the consumer. The
sheets are typically provided with enough shrinkage reducing composition and
cleaning/refreshment composition for one use. If after the first use the sheet
looks clean, the
consumer may be inclined to reuse it. Reusing a sheet that contains an
insufficient amount of
shrinkage reducing composition and cleaning/refreshment composition will
generally be
ineffective. Thus, an indicator, such as a dye that changes color, can be
added to either of the
substrate or the coversheet. The indicator will alert the consumer that the
sheet has been used
and should be discarded. Preferably, the indicator changes the sheet color to
yellow, brown or
l~Y~
In the Wise et al. reference incorporated herein above, a different, yet
equally effective
solution to this problem is proposed. Specifically, a tackiness agent is
applied to the sheet. The
tackiness agent attracts and collects loose fibers, hair, lint and other stray
matter from the fabrics
being treated. This not only serves to remove these undesirable items from the
fabrics, it serves
as an indicator as well. At the end of the treatment process the stray
material that becomes
affixed to the sheet gives the sheet a "dirty" appearance, signaling the
consumer to throw the
sheet away.
Containment Bag
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The present invention provides a non-immersion cleaning and refreshing process
that is
carried out in a containment bag. The process herein can be conducted in a
sealed bag, but 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 most conventional hot air clothes dryer
apparatus, such as
those found in the home. 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 purge
malodors and will
overly moisten the fabrics, resulting in wrinkling. An overly "open" bag
design will not
sufficiently moisten the fabrics or soils to mobilize heavier malodors or to
remove pre-existing
fabric wrinkles. 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 preferred venting bags, and methods of using the bags in a non-immersion
cleaning
and refreshing process, are described in U.S. Patent No. 5,789,368, to You et
al. which was
incorporated herein by reference above. Additional disclosure of the bags,
methods of using and
making the bags, and materials of construction for the bags that are preferred
for use in this
invention can be found in U.S. Patent No. 5,762,648, which issued on June 9,
1998, to Yeazell,
and in U.S. Patent No. 5,681,355, which issued on October 28, 1997, to Davis
et al. Both the
Yeazell patent and the Davis et al. patent are incorporated herein by
reference.
More specifically, the preferred vapor-venting containment bags for use in
this
invention are designed 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 moisture
introduced into the
bag before the operating cycle of the clothes dryer, or other hot air
apparatus, used in the
processes herein. The percentage of vapor-venting can be determined from the
Vapor-Venting
Evaluation Test (VVE) that is defined below, in Example IV. As noted above,
the preferred
containment bags are 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 WE),
even more
preferably no more than about 80% (80 VVE).
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Spot Cleaning Composition
The user of the present process can be provided with various spot cleaning
compositions
to use in the optional pre-spotting procedure of this invention. These
compositions are used to
remove localized stains from the fabrics being treated, either before or after
the cleaning and
refreshing process defined herein. Necessarily, the spot cleaning composition
must be
compatible with the fabric being treated. That is, no meaningful amount of dye
should be
removed from the fabric during the spot treatment and the spot cleaning
composition should
leave no visible stains on the fabric. Therefore, in a preferred aspect of
this invention there are
provided spot cleaning compositions which are substantially free of materials
that 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%, and surfactant at levels of about 0.1% to
about 0.7%. A
preferred spot cleaning composition will also contain a cleaning solvent such
as butoxy propoxy
propanol (BPP) at a low, but effective, level, typically about 1% to about 4%,
preferably about
2%.
Preferred spot cleaning compositions are exemplified below, and are described
in U.S.
Patent No. 5,789,368, to You et al. which was incorporated herein by reference
above.
Additionally, spot cleaning compositions are described in U.S. Patent No.
5,630,847, which
issued on May 20, 1997, to Roetker. The entire disclosure of the Roetker
patent is incorporated
herein by reference.
Treatment Member
In one embodiment, a treatment member is provided to assist in removing
localized
stains from fabrics. In a preferred aspect of this invention, the spot
cleaning composition is
provided in a dispenser, such as a bottle, and the dispenser has a distal tip
that can serve as the
treatment member. Additionally, the treatment member can comprise an absorbent
base material
which can be, for example, a natural or synthetic sponge, an absorbent
cellulosic sheet or pad, or
the like. In contact with and extending outward from this base material can be
multiple
protrusions. Specific examples of treatment members can be found in U.S.
Patent No.
5,789,368, to You et al. which was incorporated herein by reference above.
Absorbent Stain Receiving Article
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An absorbent stain receiving article, sometimes referred to herein as a stain
receiver, can
optionally be used in the optional pre-spotting operations herein. Such stain
receivers can be
any absorbent material which imbibes the liquid composition used in the pre-
spotting operation.
Disposable paper towels, cloth towels such as BOUNTYTM brand towels, clean
rags, etc., can be
used. However, in a preferred mode the stain receiver is designed specifically
to "wick" or
"draw" the liquid compositions away from the stained area. One preferred type
of stain receiver
consists of a nonwoven pad, such as a thermally bonded air laid fabric
("TBAL"). Another
highly preferred type of stain receiver for use herein comprises polymeric
foam, wherein the
polymeric foam comprises a polymerized water-in-oil emulsion, sometimes
referred to as "poly-
HIPE". The manufacture of polymeric foam is very extensively described in the
patent
literature; see, for example: U.S. Patent No. 5,260,345 to DesMarais, Stone,
Thompson, Young,
LaVon and Dyer, issued November 9, 1993; U.S. Patent No. 5,550,167 to
DesMarais, issued
August 27, 1996, and U.S. 5,650,222 to DesMarais et al., issued July 22, 1997,
all incorporated
herein by reference. Typical conditions for forming the polymeric foams of the
present
invention are described in co-pending U.S. Patent Application Serial No.
09/042,418, filed
March 13, 1998 by T. A. DesMarais, et al., titled "Absorbent Materials for
Distributing Aqueous
Liquids", the disclosure of which is incorporated herein by reference.
Additional disclosure of
conditions for forming the polymeric foams for use in the present invention
are described in co-
pending U.S. Provisional Patent Application Serial No. 60/077,955, filed March
13, 1998 by T.
A. DesMarais, et al., titled "Abrasion Resistant Polymeric Foam And Stain
Receivers Made
Therefrom", the disclosure of which is incorporated herein by reference.
The various stain receivers described herein, and described in the references
incorporated herein by reference, preferably comprise a liquid impermeable
backsheet. The
backsheet can be made of, for example, a thin layer of polypropylene,
polyethylene and the like.
The backsheet provides protection for the surface that the stain receiver
rests on from the spot
cleaning composition. For example, spot cleaning processes are typically
performed on a hard
surface, such as a table top. The stain receiver is placed on the table and
the fabric to be treated
in placed on the stain receiver. Spot cleaning composition is applied to the
stained area of the
fabric and then drawn into the stain receiver. But in the absence of a back
sheet, the spot
cleaning composition can leak onto the table top, possibly causing damage
thereto.
While the backsheet preferably covers only one side of the absorbent stain
receiver,
leaving the opposite side exposed to receive the spot cleaning solution, the
back sheet may
extend over the edges of the receiver to protect against leakage of the spot
cleaning solution
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from the edges of the stain receiver. But extending the backsheet over the
edges and onto the
absorbing side of the receiver minimizes the surface area available for
receiving the spot
cleaning solution. One solution to this paradox is to have a portion of the
back sheet extend
beyond one or more of the edges of the stain receiver in the form of "wings".
The wings
provide additional protection by insuring that the spot cleaning composition
is contained if it
leaks from the edges of the stain receiver, while simultaneously maximizing
the absorbent
surface area of the stain receiver.
Cleaning And Refreshing Processes
The shrinkage reducing composition and the cleaning/refreshment composition
are
loaded on the substrate which is preferably encased in a coversheet, and the
substrate is placed
in a bag with the fabrics to be treated. The bag is closed and placed in a
heated operating clothes
dryer, or the like, to remove malodors from the fabrics. The warm, humid
environment created
inside the bag volatilizes malodor components in the manner of a "steam
distillation" process,
and moistens fabrics and the soils thereon. This moistening of fabrics can
loosen pre-set
wrinkles, without setting of new wrinkles during the drying stage toward the
end of the dryer
cycle. Proper selection of the amount of shrinkage reducing composition and
the
cleaning/refreshment composition, and specifically the amount of water used in
the process and,
importantly, proper venting of the bag in the present manner can minimize
shrinkage of the
fabrics. Moreover, if the bag is not vented, the volatilized malodorous
materials removed from
the fabrics can undesirably be re-deposited thereon.
In more detail, the cleaning and refreshing process herein can be conducted in
the
following manner. Modifications of the process can be practiced without
departing from the
spirit and scope of the present invention.
(i) optionally, conducting a pre-spotting process according to the description
below,
on localized stained areas of the fabric;
(ii) placing the entire fabric together with the substrate that releasably
contains a
shrinkage reducing composition and a cleaning/refreshment composition in a
containment bag;
(iii) placing the bag in a device to provide agitation, e.g., such as in a hot
air clothes
dryer and operating the dryer with heat and tumbling to moisten the fabric;
and
(iv) removing the fabric from the bag.
(v) promptly hanging the fabrics to complete drying and/or to prevent re-
wrinkling.
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More specifically, the cleaning and refreshment process is conveniently
conducted in a
tumbling apparatus, preferably in the presence of heat. The substrate
containing the releasably
absorbed shrinkage reducing composition and cleaning/refreshment composition
is placed along
with the fabrics to be treated in a nylon or other heat-resistant, and
preferably vapor-venting bag.
The bag is closed and placed in the drum of an automatic hot air clothes dryer
at temperatures of
40°C-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. 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.
In more detail, a pre-spotting process can be conducted in the following
manner.
Modifications of the process can be practiced without departing from the
spirit and scope of the
present invention.
I . Place a stained area of the fabric over and in contact with the poly-HIPS
or TBAL
stain receiver described herein or, less preferably, an ordinary folded paper
towel
(e.g., preferably white or non-printed - to avoid dye transfer from the towel -
BOUNTY~ brand) on any suitable surface such as a table top, in a tray, etc.
2. Apply enough spot cleaning composition from a dispenser bottle with a
narrow
spout which directs the composition onto the stain (without unnecessarily
saturating the surrounding area of the fabric) to saturate the localized
stained area -
about 10 drops; more may be used for a larger stain.
3. Optionally, let the composition penetrate the stain for 3-S minutes.
4. Optionally, apply additional composition - about 10 drops; more may be used
for
larger stains.
S. Use the treatment member, such as the distal tip on the dispenser bottle to
work the
stain completely out. Contact can be maintained for a period of I-60 seconds
for
lighter stains and 1-5 minutes, or longer, for heavier or more persistent
stains.
6. Optionally, blot the fabric, e.g., between paper towels, to remove excess
composition. Or, the treated area can be blotted with a dampened sponge or
other
absorbent medium to flush the fibers and remove excess composition.
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The following Examples further illustrate the invention, but are not intended
to be
limiting thereof.
EXAMPLE I
Cleanine and Refreshine Compositions
Fabric cleaning/refreshment compositions according to the present invention,
for use in a
containment bag, are prepared as follows:
In-"gredient % wt.
Emulsifier (TWEEN 20)* 0.5
Perfume 0.5
KATHON~ 0.0003
Sodium Benzoate 0.1
Water Balance
*Polyoxyethylene (20) sorbitan monolaurate available from ICI Surfactants.
Additionally, preferred compositions for use in the in-dryer
cleaning/refreshment step of
the process herein are as follows.
In reg diem % wt. Range (% wt.)
Water 99.0 95.1-99.9
Perfume 0.5 0.05-1.5
Surfactant* 0.5 0.05-2.0
Ethanol or Isopropanol 0 Optional to 4%
Solvent (e.g. BPP) 0 Optional to 4%
pH range from about 6 to about 8.
Besides the other ingredients, the foregoing compositions can contain enzymes
to further
enhance cleaning performance, as described in the Trinh et al. patent
incorporated herein above.
EXAMPLE II
Preparation Of A Substrate Comprisin~A Shrinkase Reducing Composition
And A Cleanin /g_Refreshment Composition
A 10 1/4 in. x 14 1/4 in. (26 cm x 36 cm) substrate in the form. of a sheet is
prepared
from HYDRASPLJN~ material, manufactured by the Dexter Corp. The substrate
sheet is
covered on both sides with a topsheet and a bottomsheet of 8 mil (0.2 mm)
Reemay fabric
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coversheet material. The coversheet (i.e., both topsheet and bottomsheet) are
bonded to the
substrate sheet by a Vertrod~ or other standard heat sealer device, such as
conventional sonic
sealing devices, thereby bonding the laminate structure together around the
entire periphery of
the sheet. The edges of the 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 sheet 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 substrate/coversheet sheet is placed in the pouch. The folds can be
of any
type, for example., an accordion-style fold or rolled and then the roll is
folded in half. This size
is not critical but is convenient for placement in a pouch.
5 grams of the shrinkage reducing composition and I 8 grams of the
cleaning/refreshment
composition are poured onto the substrate sheet/coversheet in any order, more
preferably the
shrinkage reducing composition and the cleaning/refreshment composition are
mixed before
pouring onto the substrate. The compositions are allowed to absorb into the
substrate. The
pouch is sealed immediately after the liquid product is introduced into the
pouch and stored until
time-of use.
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EXAMPLE III
Snot Cleanine Compositions
A spot cleaning composition for use for use in the present invention,
preferably with a
dispenser as defined above, and with a TBAL or poly-HIPS foam stain receiver,
is prepared as
follows:
INGREDIENT % (Wt.Lonionic) Ranne % (Wt.)
Hydrogen peroxide 1.000 0-2
Amino tris(methylene phosphonic acid)* 0.040 0-0.06
Butoxypropoxypropanol {BPP) 2.000 1-6
Neodol 23 6.5 0.250 0-1
Kathon preservative 0.0003 Optional**
Water 96.710 Balance
pH target = 7; range = 6 - 8
* Stabilizer for hydrogen peroxide
**Sufficient to provide a preservative function.
Another example of a preferred, high water content, low residue spot cleaning
composition for use in the pre-spotting step herein is as follows.
INGREDIENT Anionic Composition (%)
Hydrogen peroxide 1.000
Amino tris(methylene phosphonic acid)* 0.0400
Butoxypropoxypropanol (BPP) 2.000
NH4 Coconut E 1 S 0.285
Dodecyldimethylamine oxide 0.031
Magnesium chloride 0.018
Magnesium sulfate 0.019
Hydrotrope, perfume, other minors, 0.101
Kathon preservative 0.0003
Water (deionized or distilled) 96.507
Target pH 6.0
* Stabilizer for hydrogen peroxide
Preferably, to minimize the potential for dye damage as disclosed hereinabove,
H202-
containing pre-spotting compositions comprise the anionic or nonionic
surfactant in an amount
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(by weight of composition) which is less than the amount of H202. Preferably,
the weight ratio
of surfactant:H202 is in the range of about 1:10 to about 1:1.5, most
preferably about 1:4 to
about 1:3.
EXAMPLE IV
Valor Ventine Evaluation Test (WEJ
Materials needed for the WE test:
-Envelope or "Standard", i.e., Control Containment Bag to be evaluated for WE.
-Carrier Substrate (15"x11"; 38.1 cm x 27.9 cm) HYDRASPUN~ 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 cm), Weight approx. 60 grams.
-Pouch: 5"x6.375" (12.7 cm x 16.2 cm) to contain the Substrate and water.
-De-ionized Water; Weight is variable to establish WE.
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 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 substrate, the dry pouch containing the substrate, and
the dry
containment bag being evaluated.
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.
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5. At the end of 30 minutes the bag is removed from the dryer and each fabric,
the
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 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.
