Note: Descriptions are shown in the official language in which they were submitted.
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UNIFORM DELIVERY OF COMPOSITIONS
FIELD OF THE INVENTION
The present invention relates to the uniform delivery of treatment materials
in fabric
article drying appliances such as tumble dryers.
BACKGROUND OF THE INVENTION
Traditionally when applying treatment materials to fabrics in a fabric article
drying
appliance such as a tumble dryer, it has been difficult to achieve a uniform
distribution of the
treatment material onto the fabric. If the distribution of the treatment
material is not uniform, this
results in areas of the fabric being left untreated. This uneven distribution
further results in
undesirable fabric attributes which can interfere with such things as the
look, touch, smell, and
longevity of the fabric. Additionally, in many instances, it has also been
observed that rather than
being desirably deposited onto the fabric, the treatment material ends up
elsewhere such as being
lost through the fabric article drying appliance vent. Hence, not only is
uniform distribution of
the treatment material on the fabric important, but also providing efficient
delivery of the
treatment material to the fabric such that the treatment material ends up on
the fabric and not
elsewhere.
Accordingly, there is a need to provide a convenient and effective way of
uniformly and
efficiently delivering treatment materials to fabrics in a fabric article
drying appliance. The
present invention addresses this need.
SUMMARY OF THE INVENTION
In one aspect, the present invention relates to a system for spraying fabric
in a fabric
article drying appliance. The system comprises:
a) a tumble dryer; and
b) a spray for spraying a treatment composition onto fabric in the tumble
dryer wherein
the spray has:
i) a mean droplet size of the treatment composition of about 100 to about 1000
microns;
ii) a spray cone angle in the tumble dryer of about 35 to about 150 ;
iii) a flowrate at the point the spray enters the tumble dryer of about 0.5
ml/min to
about 100 ml/min; and
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iv) a linear velocity at the point the spray enters the tumble dryer of about
0.5 m/second
to about 20 m/second.
In one particular embodiment there is provided a system for spraying fabric in
a fabric
article drying appliance, the system comprising: a) a tumble dryer having a
rotating drum; b) a
treatment composition; c) a controller; and d) a pump, the pump comprising: i)
a conduit
wherein the conduit includes an inlet and a discharge for transferring the
treatment composition
from the inlet of the conduit to the discharge of the conduit; and ii) a
nozzle having at least
one orifice wherein the size of the orifice nozzle is between 200 microns to
600 microns
wherein the nozzle is connected to the discharge of the conduit; whereby the
controller controls
the spraying of the treatment composition through the nozzle so as to spray
onto fabric in the
tumble dryer while the tumble dryer drum is rotating, the spray being
characterized by a cone
angle and having: i) a mean droplet size of the treatment composition of 100
microns to 1000
microns; ii) a cone angle formed by the spray in the tumble dryer between 35
to 150 ; iii) a
flowrate at the point the spray enters the tumble dryer of 0.5 mUmin to 100
mUmin; iv) a linear
velocity at the point the spray enters the tumble dryer of 0.5 m/second to 20
m/second; and
wherein the nozzle is positioned into the tumble dryer such that it is either
in quadrant one,
quadrant two, quadrant three, or quadrant four, and wherein the nozzle when
present in
quadrant one has a tilt angle ranging from 80 to the left to 45 to the right
and from 45 up to
35 down; when present in quadrant two the nozzle has a tilt angle ranging
from 80 to the
right to 45 to the left and from 45 up to 15 down; when present in quadrant
three the nozzle
has a tilt angle ranging from 80 to the right to 45 to the left and from 45
up to 15 down; and
when present in quadrant four the nozzle has a tilt angle ranging from 80 to
the left to 15 to
the right and from 45 up to 15 down.
In another aspect, the present invention may comprise a device for depositing
benefit
composition in a fabric article drying appliance. The device comprises a pump
wherein the
pump comprises a conduit having an inlet and a discharge and a nozzle having
one or more
orifices connected to the discharge of the conduit. The inlet of the conduit
is in communication
with a source of a benefit composition so as to dispense the benefit
composition through the
conduit to the nozzle whereby the benefit composition has a mean droplet size
of from about
100 microns to about 1000 microns and wherein the cone angle formed by the
benefit
composition that is discharged from the nozzle is between about 35 and about
150 .
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In another particular embodiment there is provided a device for depositing a
benefit
composition, the device comprising: a) a fabric article drying appliance
comprising a tumble
dryer having a rotating drum; b) a benefit composition; c) a pump, the pump
comprising; i) a
conduit wherein the conduit includes an inlet and a discharge; and ii) a
nozzle having at least
one orifice wherein the size of the orifice nozzle is between 200 microns to
600 microns
wherein the nozzle is connected to the discharge of the conduit; and iii) a
controller; wherein
the inlet of the conduit is in communication with a reservoir which is the
source of the benefit
composition wherein the controller controls the flow of benefit composition so
as to dispense
the benefit composition through the conduit from reservoir to the nozzle
whereby the benefit
composition is dispensed from the nozzle into the drum of the tumble dryer as
a spray, the
spray having a cone angle, during rotation of the drum whereby the spray of
benefit
composition has a mean droplet size of from 100 microns to 1000 microns and
wherein the
cone angle formed by the spray of benefit composition that is discharged from
the nozzle is
between 35 and 150 ; and wherein the nozzle is positioned into the drum of
the tumble dryer
such that it is either in quadrant one, quadrant two, quadrant three, or
quadrant four, and
wherein the nozzle when present in quadrant one has a tilt angle ranging from
80 to the left to
45 to the right and from 45 up to 35 down; when present in quadrant two the
nozzle has a tilt
angle ranging from 80 to the right to 45 to the left and from 45 up to 15
down; when
present in quadrant three the nozzle has a tilt angle ranging from 80 to the
right to 45 to the
left and from 45 up to 15 down; and when present in quadrant four the nozzle
has a tilt angle
ranging from 80 to the left to 15 to the right and from 45 up to 15 down.
In a further aspect, the present invention relates to a device which provides
uniform
distribution of a treatment composition on fabric in a fabric article drying
appliance. The device
comprises a fabric article treating device wherein the fabric article treating
device is associated
with the drum of a tumble dryer in a manner such that a benefit composition is
dispensed from
the fabric article treating device in the form of a spray into the drum
wherein the spray contacts
the fabric in the drum so as to provide a uniformity of about 75% or more
distribution of the
benefit composition on fabric present in the drum.
In yet another aspect, the present invention relates to a method for
depositing benefit
composition in the drum of a tumble dryer. The method comprises providing a
pump
comprising a conduit wherein the conduit includes an inlet and discharge and a
nozzle
connected to the discharge of the conduit. The inlet of the conduit is placed
in communication
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2b
with the source of benefit composition wherein the inlet of the conduit is in
communication
with the source of benefit composition. The benefit composition is dispensed
through the
conduit from the source of benefit composition to the nozzle and into the drum
of a tumble
dryer whereby the benefit composition has a mean droplet size of from about
100 microns to
about 1000 microns, a linear velocity through the nozzle of between about 0.5
m/second to
about 2 m/second. The nozzle may be positioned in the dryer drum in quadrant
one, quadrant
two, quadrant three, quadrant four, or a combination thereof. The nozzle has a
tilt angle
wherein the tilt angle in quadrant one ranges from about 80 to the left to
about 45 to the right
and from about 45 up to about 35 down; the tilt angle in quadrant two ranges
from about 80
to the right to about 45 to the left and from about 45 up to about 15 down;
the tilt angle in
quadrant three ranges from about 801 to the right to about 45 to the left and
about 45 up to
about 15 down; the tilt angle in quadrant four ranges from about 80 to the
left to about 15 to
the right and about 45 up to about 15 down; and combinations thereof.
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In a further aspect, the present invention relates to a method for providing
efficient
deposition of a benefit agent used to treat fabric. The method comprises
providing a fabric article
treating device and a benefit composition. The benefit composition is
associated with the fabric
article treating device such that the benefit composition is discharged into
the drum of a tumble
dryer either before the tumble dryer is rotated, during rotation of the tumble
dryer, or after
rotation of the tumble dryer, or a combination thereof. The cone angle formed
by the benefit
composition that is discharged into the tumble dryer is between about 35 to
about 150 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a dryer drum.
FIG. 2 is a perspective view of an embodiment of a stand-alone fabric article
treating
apparatus made according to the principles of the present invention.
FIG. 3 is a perspective view from the opposite angle of the fabric article
treating
apparatus of FIG. 2.
FIG. 4 is an elevational view from one end in partial cross-section of the
fabric article
treating apparatus of FIG. 2, illustrating the internal housing and external
housing, as joined
together by a flat cable.
FIG. 5 is an elevational view from one side in partial cross-section of the
internal housing
portion of the fabric article treating apparatus of FIG. 2.
FIG. 6 is a block diagram of some of the electrical and mechanical components
utilized in
the fabric article treating apparatus of FIG. 2.
FIG. 7 is a diagrammatic view in partial cross-section of the fabric article
treating
apparatus of FIG. 2, as it is mounted to the door of a clothes dryer
apparatus.
FIG. 8 is a perspective view of a fabric article drying appliance that has a
nozzle which
sprays a benefit composition into the drum portion of the dryer, as
constructed according to the
principles of the present invention.
FIG. 9 is a diagrammatic view of some of the components utilized by an
alternative
embodiment stand-alone fabric article treating apparatus that is constructed
according to the
principles of the present invention, in which the entire treating apparatus is
contained within a
single housing or enclosure.
FIG. 10 is a perspective view of another embodiment of a stand-alone unit for
dispensing
a benefit composition constructed according to the principles of the present
invention.
FIG. I 1 is a perspective view from an opposite angle of the unit of Fig. 10.
FIG. 12 is an exploded view of the unit illustrated in FIGS. 10 and 11.
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FIG. 13 is an exploded view of the fluid container, the first and second
fitments and the
first and second mounting shelves.
FIG. 14 is a block diagram of at least a portion of the electrical and
mechanical
components utilized in the unit of FIGS. 11 - 13.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to the uniform distribution of treatment
material onto fabrics
in fabric article drying appliances such as tumble dryers. In another aspect,
the invention relates to
efficiently depositing the treatment materials on the fabric so that the
materials are deposited on
the fabric and not elsewhere.
Definitions
As used herein, "fabric article" means an article that comprises a fabric.
Such articles
include, but are not limited to, clothing, shoes, curtains, towels, linens,
upholstery coverings and
cleaning implements.
As used herein, "during a dryer cycle" means while the dryer is operating.
As used herein, "treatment material" means a material or combination of
materials that
can deliver benefits to a fabric article. Examples of such benefits include
but are not limited to;
softening, crispness, water and/or stain repellency, refreshing, antistatic,
anti-shrinkage, anti-
microbial, durable press, wrinkle resistance, odor resistance, abrasion
resistance, anti-felting, anti-
pilling, dimensional stability, appearance enhancement such as color and
whiteness enhancement,
anti-soil redeposition, fragrance, enhanced absorbency, and mixtures thereof.
As used herein, "fabric treatment composition" means a composition that
comprises one
or more treatment materials. Suitable forms of fabric treatment compositions
include, but are not
limited to, fluidic substances, such as liquids or gases, and solid compounds,
such particles or
powders.
As used herein, the terms "treatment material", "treatment composition",
"fabric
treatment composition" and "benefit composition" are used interchangeably.
As used herein, the articles "a", "an", and "the" when used in a claim, are
understood to
mean one or more of the material that is claimed or described.
Unless otherwise noted, all component or composition levels are in reference
to the active
level of that component or composition, and are exclusive of impurities, for
example, residual
solvents or by-products, which may be present in commercially available
sources.
Unless otherwise indicated, all percentages and ratios are calculated based on
weight of
the total composition.
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Unless otherwise indicated, all measurements herein were performed at a
standard
atmospheric pressure of about 1 bar.
It should be understood that every maximum numerical limitation given
throughout this
specification includes every lower numerical limitation, as if such lower
numerical limitations
were expressly written herein. Every minimum numerical limitation given
throughout this
specification will include every higher numerical limitation, as if such
higher numerical
limitations were expressly written herein. Every numerical range given
throughout this
specification will include every narrower numerical range that falls within
such broader numerical
range, as if such narrower numerical ranges were all expressly written herein.
Delivery System
In one aspect of the present invention, the delivery system is comprised of a
spray for
delivering treatment materials to fabrics in a fabric article drying appliance
such as a tumble
dryer. The dryer drum is typically rotating during delivery of the treatment
materials but may
also be stationary during delivery. The spray comprises a treatment
composition. The treatment
composition comprising the spray of the present invention has a mean droplet
size of about 100
microns to about 1400 microns, about 200 microns to about 1300 microns, about
300 microns to
about 1200 microns, or about 500 microns to about 1100 microns. A suitable
instrument for
measuring droplet size is the Malvem particle sizer manufactured by Malvern
Instruments Ltd. of
Framingham, Massachusetts.
The viscosity of the treatment composition comprising the spray, as measured
at
approximately 24 C using a Model DV-lI Brookfield Viscometer with a LV I
spindle, is about
200 cps or less, about 100 cps or less, or about 50 cps or less. The
Brookfield Model DV-fI
viscometer is available from Brookfield of Middleboro, Massachusetts. The
static surface tension
of the treatment composition comprising the spray as measured between
approximately 20 C -
25 C is about 3 to about 100 dynes/cm, about 4 to about 70 dynes/cm, or about
5 to about 40
dynes/cm. A suitable instrument for measuring static surface tension is a
KrussTM Tensiometer,
Model K12 manufactured by Kruss of Matthews, North Carolina.
The treatment composition may be sprayed through a nozzle and into the drum of
a fabric
article drying appliance such as the drum of a tumble dryer. The nozzle
typically will have a
diameter of about 200 to about 600 microns or about 250 to about 400 microns.
A non-limiting
example of a nozzle suitable for this purpose is a pressure swirl atomizing
nozzle. Non-limiting
examples of suitable nozzles include the CosmosTM 13 NBU nozzle manufactured
by Precision
Valve Corporation of Marietta, Georgia, the WX12 and WD32 nozzles manufactured
by Saint-
Gobain Calmar USA, Inc. of City of Industry, California, and SeaquistTM Model
No. DU-3813
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manufactured by Seaquist Dispensing of Cary, Illinois. The nozzle may be in
association with a
spraying device. The nozzle may be permanently attached or releaseably
attached to a spraying
device. One non-limiting example of a releaseably attached nozzle is a nozzle
which is threaded
such that it can easily be removed from or placed in a spraying device. The
nozzle may be
disposable. The spraying device may be free standing or it may be associated
with the drying
appliance as discussed in further detail below.
It is desirable that the fabrics in the fabric article drying appliance not
come into direct
contact with the nozzle while the nozzle is operating as this may inhibit flow
from the nozzle.
Hence, it may be desirable for the nozzle to include a deflector which
deflects the fabric away
from the nozzle. The deflector may surround all or a portion of the nozzle
(for example the top
portion of the nozzle). The degree of extension of the deflector into the
fabric article drying
appliance is selected so as to insure that the deflector does not intercept
the cone angle of the
spray under normal use conditions. The deflector may be made from any suitable
material, non-
limiting examples of which include plastic, metal, Plexiglas, and the like.
The deflector may be of
any shape provided that the shape selected does not negatively impact fabric
integrity during
tumble drying process (i.e.; no sharp edges/corners or rough surfaces).
The placement of the nozzle and angle of the nozzle may be varied so as to
optimize
spray contact with the fabric in the tumble dryer. In order to facilitate the
determination of where
the nozzle should be positioned in relation to optimizing spray contact with
the fabric, the dryer
drum may be divided into four equal quadrants as shown in FIG. 1. The four
quadrants
(quadrant one 601, quadrant two 602, quadrant three 603, and quadrant four
604) are determined
by the intersection of the x-axis 630and y-axis 640 of the dryer drum 600. The
position of the
nozzle 610 may then be varied in relation to these quadrants. One non-limiting
example of
placement of the nozzle 610 within the quadrant may be along the quadrant
bisection line=612 as
shown for the second quadrant 602 in FIG. 1.
The nozzle 610 may also be angled in either the left to right direction and/or
the up to
down direction. This angling of the nozzle is referred to herein as "tilt
angle". The tilt angle may
vary from quadrant to quadrant. For instance, as viewed looking straight into
the dryer drum from
the door side of the dryer, in the first quadrant 601 the tilt angle may be
from about 80 to the left
to about 45 to the right and/or from about 45 up to about 35 down. In the
second quadrant 602
the tilt angle may vary from about 80 to the right to about 45 to the left
and/or from about 450
up to about 35 down. In the third quadrant 603 the tilt angle may vary from
about 80 to the
right to about 45 to the left and/or about 45 up and about 15 down. In the
fourth quadrant 604
the tilt angle may vary from about 80 to the left to about 15 to the right
and/or about 45 up and
about 15 down.
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The tilt angle is typically selected such that the nozzle is not directly
aimed at the dryer
vent/lint screen or at the top of the drum. Furthermore, it is generally
desirable that the nozzle be
angled such that the spray from the nozzle is delivered through the void
space/tunnel created by
the tumbling of the fabrics around the perimeter of the dryer drum so as to
contact the fabrics at
the bottom of the rotating circle of fabrics. Also it may be desirable that
the nozzle be angled
such that the spray intercepts the fabrics being tumbled in the dryer as the
fabrics drop from their
highest vertical point to their lowest vertical point during dryer drum
rotation.
It may be desirable in some instances to utilize more than one nozzle. Each
nozzle could
be designed to spray concurrently or at different times, flow rate, velocity,
etc. than the other
nozzle(s).
The flowrate of the spray in the drum of the fabric article drying appliance
such as a
tumble dryer is about 0.5 to about 100 ml/minute, about 1 to about 75
ml/minute, about 2 to about
50 ml/minute, or about 15 to about 25 ml/minute. One suitable method for
determining flow rate
is found in ASME/ANSI MFC-9M-1988, entitled "Measurement of Liquid Flow in
Closed
Conduits by Weighing Method".
The linear velocity of the spray in the drum of the tumble dryer is about 0.05
to about 2
m/second or about 0.1 to about I m/second. The length of the spray in the drum
of the tumble
dryer is from about 20% to about 95% of the length of the drum as measured
along the rotational
axis of the drum. One suitable method for determining linear velocity is by
utilizing Laser
Doppler Anemometry such as described in "Laser Doppler and Phase Doppler
Measurement
Techniques" part of the "Experimental Fluid Mechanics" series, written by
Albrecht, H.E.,
Damaschke, N., Borys, M., and Tropea, C., 2003, XIV, 738, page 382.
The cone angle of the spray refers to the angle the spray forms as it is
sprayed into the
drum of the tumble dryer. A method for determining cone angle is described
below. The cone
angle of the spray is about 35 to about 150 or about 40 to about 110 or
about 50 to about 90 .
Spraying Device
As previously indicated the present invention may include a spraying device
for
delivering the benefit composition into the tumble dryer. The spraying device
may be a stand-
alone device or it may be incorporated into the fabric article drying
appliance.. As used herein the
term "spraying device" is used interchangeably with the term "fabric article
treating apparatus".
Non-limiting examples of suitable spraying devices which may be used with the
present invention
are disclosed in the following commonly assigned co-pending applications: U.S.
Patent
Application Publication No. 2004/0259750, published on December 23, 2004 and
entitled
"Processes and Apparatuses for Applying a Benefit Composition to One or More
Fabric Articles
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During a Fabric Enhancement Operation"; WO 2004/12007, published on November
4, 2004 and
entitled "Volatile Material Delivery Method"; U.S. Patent Application
Publication No.
2004/0123490, published July 1, 2004 and entitled "Fabric Article Treating
Method and Device
Comprising a Heating Means"; U.S. Patent Application Publication No.
2004/0123489, published
on July 1, 2004 and entitled "Thermal Protection of Fabric Article Treating
Device"; U.S. Patent
Application Publication No. 2004/0134090, published on July 15, 2004 and
entitled "Fabric
Article Treating Device Comprising More Than One Housing"; U.S. Application
Publication No.
2004/0025368, published on July 29, 2004 and entitled "Fabric Article Treating
Apparatus with
Safety Device and Controller"; and U.S. Application Publication No.
2004/0025368, published on
February 12, 2004 and entitled "Fabric Article Treating Method and Apparatus".
In one aspect of the present invention, the spraying system is comprised of a
pump, a
nozzle, a source of benefit composition, and a conduit as described in further
detail below. The
conduit connects the source of the benefit composition to the pump whereby the
benefit
composition is discharged through the nozzle of the pump into a tumble dryer.
Alternatively, the
conduit connects the source of the benefit composition to the pump whereby the
benefit
composition is transported via conduit between the pump and nozzle and then
discharged into a
tumble dryer. It should be noted that the interior of the conduit may be of
any shape, non-limiting
examples of which include circular and/or oval shaped. It may also be
desirable to include a
check valve in the conduit before the nozzle. Non-limiting examples of minimum
working
pressures for the check valve are from about 0.1 psi to about 2 psi or from
about 0.5 psi to about I
psi.
The pump may be manually operated, and/or the pump may be automated. The pump
may be mechanically driven, electrically driven, or a combination thereof.
The spraying system may comprise: a housing or enclosure that contains a
source of the
fabric treatment composition, such as a reservoir or is in communication with
an external source
of the fabric treatment composition; an output device, such as a nozzle; a
controller, such as an
electronic control device with a processing circuit and input and output
circuits; one or more
sensors, such as a temperature sensor, light sensor, motion sensor, or the
like; one or more input
devices, such as a start switch and/or a keypad; one or more indicating
devices, such as color
lights or LED's; and a charging system if the fabric treatment composition is
to be electrostatically
charged before (or while) being delivered.
Reference will now be made in detail to suitable embodiments of devices for
delivering a
fabric treatment composition in accordance with one of the aforementioned
temperature or time
profiles, an example of which is illustrated in the accompanying drawings,
wherein like numerals
indicate the same elements throughout the views.
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FIGS. 2 - 5 illustrate one embodiment of an exemplary spray system which may
be used
in the present invention.
Referring now to the embodiment of FIG. 2, a "stand-alone" controller and
dispenser unit
(i.e., as a self-contained device), generally designated by the reference
numeral 10, is illustrated as
having two major enclosures (or housings) 20 and 50. In this embodiment, the
enclosure 20 acts
as an "inner housing" which is located in the interior of a fabric article
drying appliance (e.g., a
clothes dryer), while the enclosure 50 acts as an "outer housing" that is
located in the exterior of
the fabric article drying appliance. The enclosure 50 may be mounted on the
exterior surface of
the fabric article drying appliance door, however, it may instead be mounted
on any exterior
surface, non-limiting examples of which include: the side walls, the top
walls, the outer surface of
a top-opening lid, and the like, including a wall or other household structure
that is separate from
the fabric article drying appliance. Furthermore, the enclosure 20 may be
mounted on any interior
surface of the fabric article drying appliance, examples of which include, but
are not limited to:
the interior surface of the door, the drum of the fabric article drying
appliance, the back wall, the
inner surface of a top-opening lid, and the like.
Enclosure 50 may be permanently mounted to the exterior surface, or preferably
releasably attached to the exterior surface. Likewise, enclosure 20 may be
permanently mounted
to the interior surface, or releasably attached to the interior surface. One
configuration for such an
attachment is illustrated in FIG. 7, in which the door of the drying appliance
is generally
designated by the reference numeral 15.
When mounted on the interior surface of the door, for example, the enclosure
20 may be
constructed so as to have the appearance of being "permanently" mounted, such
that it seems to be
"built into" the door of a dryer unit (or other type of fabric article drying
appliance), without it
actually being truly constructed as part of the fabric article drying
appliance. On the other hand,
enclosure 20 perhaps may be more loosely mounted near the door, or along side
the interior
surface of the door, much like one of the embodiments 10 as depicted in FIGS.
2 - 5 that "hangs"
along a vertical door of the appliance. It will be understood that the term
"door," as used herein,
represents a movable closure structure that allows a person to access an
interior volume of the
dryer apparatus, and can be of virtually any physical form that will enable
such access. The door
"closure structure" could be a lid on the upper surface of the dryer
apparatus, or a hatch of some
sort, or the like.
It should be noted that the treating apparatus 10 may be grounded by way of
being in
contact with a grounded part of the fabric article drying appliance such as by
a spring, patch,
magnet, screw, or other attaching means, and/or by arc corona discharge, or by
way of dissipating
residual charge. One non-limiting way of dissipating the charge is by using an
ionizing feature,
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for example a set of metallic wires extending away from the source. In many
instances fabric
article drying appliances such as clothes dryers have an enameled surface. One
method of
grounding would be to ground to the enameled surface of the fabric article
drying appliance by
utilizing a pin that penetrates the non-conductive enamel paint for grounding
thereto. Another
method of grounding to the non-conductive surface of a fabric article drying
appliance comprises
the usage of a thin metal plate that is positioned between the fabric article
drying appliance and
the fabric article treating device which serves to provide a capacitive
discharge. Typical thickness
of such a plate is from about 5 microns to about 5000 microns.
In FIG. 2, a discharge nozzle 24 and a "door sensor" 22 are visible on the
inner housing
20, which also includes a benefit composition-holding reservoir 26 within an
interior volume of
the inner housing 20. The reservoir 26 may be used to hold a benefit
composition. The discharge
nozzle 24 can act as a fluid atomizing nozzle, using either a pressurized
spray or, along with an
optional high voltage power supply (not shown in FIG. 2) it can act as an
electrostatic nozzle.
The benefit composition can comprise a fluidic substance, such as a liquid or
a gaseous
compound, or it can comprise a solid compound in the form of particles, such
as a powder, or
solid particles in solution with a liquid. Reservoir 26 can be of essentially
any size and shape, and
could take the form, for example, of a pouch or a cartridge; or perhaps the
reservoir could merely
be a household water line for situations in which the benefit composition
comprises potable water.
The inner housing 20 and outer housing 50 are typically in electrical
communication. In
the embodiment of FIG. 2, a flat cable 40 (also sometimes referred to as a
"ribbon cable") is run
between the two housings 20 and 50, and travels along the inner surface of the
fabric article
drying appliance door 15 (see FIG. 7, for example), over the top of the door
15, and down the
exterior surface of the door 15.
FIG. 3 shows the same fabric article treating apparatus 10 from an opposite
angle, in
which the outer housing 50 is provided with an ON-OFF switch at 56. The flat
cable 40 is again
visible in FIG. 3, and along the surface of the inner housing 20 visible in
FIG. 3, a door mounting
strap 21 is visible. An end of the mounting strap is also visible in FIG. 2.
Certainly other
arrangements for attaching the inner housing 20 to a dryer door 15 (or other
interior surface) are
available without departing from the principles of the present invention, non-
limiting examples of
which include magnets, suction cups, and hooks.
Referring now to FIG. 4, the fabric article treating apparatus 10 is
illustrated such that the
reservoir 26 can be seen as an interior volume of the inner housing 20. In the
outer housing 50, a
set of batteries 52 can be seen, as well as a printed circuit board with
electronic components at 54.
It will be understood that any type of electrical power source could be used
in the present
invention, including standard household line voltage, batteries, or even solar
power.
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Referring now to FIG. 5, some of the other hardware devices are illustrated
with respect
to the inner housing 20. In the embodiment of FIG. 5, the discharge nozzle 24
acts as an
electrostatic nozzle, and thereby is coupled with a high voltage power supply
28, by use of an
electrical conductor not shown in this view. As shown in FIG. 6, a quick
disconnect switch 34 is
included for safety purposes, so that the high voltage power supply 28 can be
quickly shut down
if necessary. A pump 30 and a corresponding electric motor 32 are visible in
FIG. 5. Some type
of pumping apparatus is used regardless as to whether the discharge nozzle 24
is producing a
pressurized spray only, or an electrostatic spray that utilizes a high voltage
power supply 28.
FIG. 6 provides a block diagram of some of the electrical and mechanical
components
that may be included in a fabric article treating apparatus 10, suitable for
use with the present
invention. In this example embodiment, the high voltage power supply 28 is
provided in the inner
housing 20, which will be used to electrically charge the fluid that will be
dispensed through the
discharge nozzle 24, thus making this an electrostatic nozzle system. The
inner housing 20
utilizes a general body or enclosure to contain the devices needed within the
drying appliance,
and it will be understood that such components will generally be subjected to
relatively high
temperatures during the treatment cycle of the drying appliance. Consequently,
the more
sensitive electronic components will generally (but not always) be mounted in
a different location,
such as in the outer housing 50.
The flat cable 40 will bring certain command signals and electrical power into
the inner
housing 20, and will also receive electrical signals from sensors mounted in
the inner housing 20
and communicate those sensor signals back to the outer housing 50. A power
supply control
signal follows a wire 70 through the quick disconnect switch 34 to the high
voltage power supply
28. This signal can comprise a constant DC voltage, a constant AC voltage, a
variable DC
voltage, a variable AC voltage, or some type of pulse voltage, depending on
the type of control
methodology selected by the designer of the fabric article treating apparatus
10.
In one embodiment, the signal at 70 is a variable DC voltage, and as this
voltage
increases, the output of the high voltage power supply 28 will also increase
in voltage magnitude,
along a conductor 39 (e.g., a wire) that is attached to an electrode 38 that
carries the high voltage
to the nozzle 24, or into the reservoir 26. The voltage impressed onto the
electrode 38 will then
be transferred into the benefit composition. A constant output voltage DC high
voltage power
supply could optionally be used instead of the variable output voltage power
supply 28 of the
exemplary embodiment.
Once the benefit composition is charged within the reservoir 26 it will travel
through a
tube or channel 42 to the inlet of the pump 30, after which the composition
will be pressurized
and travel through the outlet of the pump along another tube (or channel) 44
to the discharge
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nozzle 24. For use in the present invention, the actual details of the type of
tubing used, the type
of pump 30, and the type of electric motor 32 that drives the pump, can be
readily configured for
almost any type of pressure and flow requirements. The electrical voltage and
current
requirements of the electric motor 32 to provide the desired pressure and flow
on the outlet of the
pump 30 can also be readily configured for use in the present invention.
Virtually any type of
pump and electric motor combination can be utilized in some form or another to
create a useful
device that falls within the teachings of the present invention, or a stand-
alone pump can be used
(i.e., without an associated electric motor).
It should be noted that some types of pumps do not require separate input and
output lines
or tubes to be connected thereto, such as peristaltic pumps, in which the pump
acts upon a
continuous tube that extends through an inlet opening and continues through a
discharge opening
of the pump. This arrangement is particularly beneficial for use with
electrostatically charged
fluids or particles that are being pumped toward the discharge nozzle 24,
because the tubing can
electrically insulate the pump from the charged benefit composition. It should
also be noted that
an alternative pumping device could be used, if desired, such as a spring-
actuated pumping
mechanism. A non-limiting example of a suitable peristaltic pump is the Model
10/30 peristaltic
pump, which may be obtained from Thomas Industries of Louisville, Kentucky.
If desired, the fabric article treating apparatus 10 can be enhanced by use of
certain
sensors, examples of which include but are not limited to a door (or lid)
sensor 22, a motion
sensor 36, a humidity sensor 46, and/or a temperature sensor 48.
FIG. 7 diagrammatically shows the general location of some of the components
of one of
the stand-alone embodiments of the fabric article treating apparatus 10 which
may be used with
the present invention. As discussed above, the electronics 54 and the
batteries 52 are located
within the outer housing 50, which is electrically connected to a flat cable
40 that carries power
supply and input/output signals between the outer housing 50 and the inner
housing 20.
Contained within the inner housing 20 are the reservoir 26, pump 30, electric
motor 32,
high voltage power supply 28, discharge nozzle 24, and various sensors that
may or may not be
included for a particular version of the treating apparatus 10. The electrical
conductor 39 is
depicted, which carries the high voltage to the nozzle 24, and this is one
configuration that could
be alternatively used instead of carrying the high voltage to the reservoir
26. The tubing 42 to the
inlet of the pump is illustrated, as well as the tubing 44 from the outlet of
the pump that provides
the benefit composition to the nozzle 24. It should be noted that the high
voltage power supply 28
is strictly optional within the teachings of the present invention; if spray
droplets/particles emitted
from the nozzle 24 are not to be electrostatically charged, then there is no
need for a high voltage
power supply within the inner housing 20.
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FIG. 8 illustrates an alternative embodiment for use with the present
invention, which
depicts a fabric article drying appliance generally designated by the
reference numeral 110. In
this mode of the present invention, the controller depicted in the stand-alone
embodiment of the
earlier figures is now integrated into the electronic control system of the
drying appliance 110. A
door 15 is illustrated in FIG. 8, which is the normal point of access by a
human user to the interior
drum volume of the drying appliance 110. A nozzle 24 is used to direct a
benefit composition
into the drum area, in which the drum is generally designated by the reference
numeral 114. A
supply pipe 44 brings the benefit composition to the nozzle 24, through a
control valve 120, that
can have an ON/OFF push button 56, if desired.
FIG. 9 illustrates an alternative stand-alone embodiment of the present
invention,
generally designated by the reference numeral 150. Components illustrated in
FIG. 9 include a
reservoir (or chamber) 26, an optional charging component 39 (such as an
electrode or other type
of electrical conductor that transports a high voltage to the reservoir or to
the nozzle), a discharge
nozzle 24, a pump unit 30, and a set of batteries 52. An electronic printed
circuit board 54 is
provided, which would typically include a microcontroller or other type of
control circuit. One or
more sensors may be included in such a device, as depicted at the reference
numeral 129, and may
include a pressure sensor, a door sensor 22, motion sensor 36, humidity sensor
46, and/or a
temperature sensor 48. In this embodiment 150, all of the components are
enclosed in a single
housing, and the entire unit is positioned within a fabric article drying
appliance, such as a
conventional clothes dryer found in a consumer's home.
The "single-housing" stand-alone unit 150 of FIG. 9 can incorporate all of the
electrical
and electronic components that are described herein with respect to FIG. 6 -
7.
In FIGS. 10 - 14, where like reference numerals indicate like elements, a
benefit
composition dispensing apparatus 1100 constructed in accordance with a third
embodiment of the
present invention is illustrated. The apparatus 1100 comprises two enclosures
or housings 1120
and 1150. Enclosure 1120 defines an "inner housing" located in an interior of
a fabric
enhancement apparatus such as a fabric article drying appliance, e.g., a
clothes dryer (not shown
in FIGS. 10 - 14), while the enclosure 1150 defines an "outer housing" located
outside of the
fabric article drying appliance. The fabric enhancement apparatus may also
comprise a laundry
apparatus or a laundry and drying apparatus. The enclosure 1150 may be mounted
on an exterior
surface of the fabric enhancement apparatus door (not shown), such as by
pressure sensitive,
thermally stable adhesive foam strips (not shown). Alternatively, the
enclosure 1150 may be
mounted on any other exterior surface of the fabric enhancement apparatus, non-
limiting
examples of which include: side walls, top walls, an outer surface of a top-
opening lid, and the
like. The enclosure 1150 may also be mounted on a wall or other household
structure that is
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separate from the fabric enhancement apparatus. Furthermore, the enclosure
1120 may be
mounted, such as by pressure sensitive, thermally stable adhesive foam strips
(not shown), on any
interior surface of the fabric enhancement apparatus, examples of which
include, but are not
limited to: the interior surface of the door, a drum of the apparatus, the
back wall, the inner
surface of a top-opening lid, and the like.
As illustrated in FIGS. 10 and 11, the inner housing enclosure 1120 comprises
a main
body 1121 comprising an integral front/side main section 1122 and a back plate
section 1123
secured to the main section 1122 via screws, adhesive, snap-fit elements or
the like. The sections
1122 and 1123 are preferably molded from a polymeric material. Housed within
the main body
1121 may be the following elements: a discharge nozzle 24; a door sensor 22
for sensing ambient
light when the door of the fabric enhancement apparatus is open such that the
sensor 22 is
exposed to ambient light; a motion sensor 36 (contained within the main body
1121 and not
visible from outside the main body 1121); a humidity sensor 46 (not shown in
Figs. 10 and 11);
and a temperature sensor 48. In this embodiment, the nozzle 24 is not combined
with a high
voltage power supply. The nozzle 24 functions as a fluid atomizing nozzle so
as to generate a
pressurized spray.
Referring to Figs. 10 - 12 and 15, the enclosure 1150 comprises a main body
1151 having
a back wall 1151 a, a first inner compartment 1151 b, for storing varying
lengths of unused cable
1140, to be described below, and a second compartment 1151c, for storing a
fluid pump 1130, a
motor 1132 for driving the pump 1130, batteries 52, a tube 1142 (to be
discussed below) and a
portion of a tube 1144 (to be discussed below). The enclosure 1150 further
comprises a cassette
door 1152 pivotably coupled to the main body 1151 such as by pins 1152a (only
one of which is
illustrated in Fig. 12), a printed circuit board 1160a and a face plate 1162.
The printed circuit
board 1160a is housed between the main body 1151 and the face plate 1162. The
face plate 1162
is coupled to the main body 1151 via screws, adhesive, snap-fit elements, or
like coupling
elements. The pivotable door 1152 comprises a pocket 1152b for receiving a
fluid reservoir
defined by a removable container 1170 filled with a benefit composition, which
composition may
comprise any one of the benefit compositions discussed in this document or the
documents noted
herein. The container 1170 may be formed from a polymeric material, paper,
foil, a combination
of these materials or a like material. The door 1152 is releasably held in a
closed position within
the main body 1151 via first and second flex arms 1153, which are coupled to
the main body
1151.
Extending through corresponding openings in the face plate 1162 are an ON-OFF
switch
1266c, a "refluff' key or switch 266d, and a dial 266a, which may comprise a
potentiometer,
which a user rotates to dial in a desired one of a strong, regular or light
setting corresponding to a
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strong, regular or light benefit level to be provided by a benefit composition
to at least one fabric
article during a fabric enhancement operation.
The cable 1140 is coupled to and extends between the enclosures 1120 and 1150.
The
cable 1140 may run along the inner surface of the fabric enhancement apparatus
door, over the
top of the door, and down the exterior surface of the door. Any unused length
of the cable 1140
can be manually inserted into the first compartment 1151b for storage.
The cable 1140 carries benefit composition from the fluid pump 1130 in the
outer
enclosure 1150 to the nozzle 24 in the inner enclosure 1120, see FIG. 14, and
electrical signals
from the sensors 36, 22, 46 and 48 mounted in the inner enclosure 1120 to a
microcontroller 1160
mounted to the printed circuit board 1160a in the outer enclosure 1150.
A first fitment 1172 is mounted to the main body 1151 via first and second
mounting
shelves 1155a and 1155b, see FIGS. 12 and 13, and is coupled to the tube or
channel 1142 (not
shown in FIG. 13), which, in turn, is coupled to the pump 1130. The first and
second shelves
1155a and 1155b are positioned on opposing sides of a flange 1172a of the
first fitment 1172 and
are snap fit, adhesively secured or bolted together so as to encompass the
flange 1172a. The
assembly comprising the shelves 1155a and 1155b and fitment 1172 is mounted to
the main body
1151 such that the shelves 1155a and 1155b are received within a slot 1151d
defined in the main
body 1151. The fitment 1172 is inserted into a second fitment 1170a forming
part of the fluid
container 1170 when the door 1152 is pivoted to its closed position and
functions to pierce or
otherwise penetrate the container 1170 so as to provide a pathway for the
benefit composition to
travel from the container 1170 to the tube 1142. From the tube 1142, the
benefit composition
travels to the inlet of the pump 1130, after which the composition is
pressurized and carried via
the tube or channel 1144 (shown in FIG. 12), which extends through the cable
1140, to the
discharge nozzle 24, where the benefit composition is discharged. In the
illustrated embodiment,
the pump 1130 and the motor 1132 comprises a single assembly, namely, a
piezoelectric pump,
one of which is commercially available from Par Technologies, LLC, under the
product
designation LPD-30S. Other suitable pumps which can be used in this or other
embodiments
include but are not limited to gear pumps and diaphragm pumps. One non-
limiting example of a
suitable diaphragm pump is model No. NF5RPDC-S with a DC motor available from
KNF
Neuberger, Inc. of Trenton, New Jersey.
The types of control signals used to control the electric motor 1132 can vary
according to
the design requirements of the apparatus 1100, and such signals will travel to
the motor 1132 via
an electrical conductor 1172. In the illustrated embodiment, the electrical
signal traveling along
conductor 1172 comprises a pulse-width modulated (PWM) signal controlled by
the
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microcontroller 1160. Of course, such a pulse-width modulated signal can also
be generated by
any appropriate controller or processor, or appropriate discrete logic.
As noted above, the enclosure 1150 comprises a second compartment 1151 c for
storing
batteries 52, which may comprise two AA batteries. In the illustrated
embodiment, the batteries
52 define a power source, which provide a DC voltage to a DC power supply
1158, see FIG. 14.
An example DC power supply comprises an integrated circuit chip commercially
available from
Maxim Integrated Products under the product designation "MAX1724EZK50-T." The
DC power
supply 1158 provides an output voltage to the microcontroller 1160.
A suitable microcontroller 1160 is a microprocessor manufactured by Atmel
Corporation
and sold under the product designation Atmega48-16A1. Alternatively, the
microcontroller 1160
may comprise a microprocessor manufactured by Atmel Corporation and sold under
the product
designation Atmega48-16AJ. Of course, other microcontrollers, microprocessors,
controllers, or
processors made by different manufacturers, or discrete digital logic could
alternatively be used.
The microcontroller 1160 includes on-board memory and input and output lines
for
analog and digital signals. The microcontroller 1160 also has a serial port
that can be interfaced
to an optional programmer interface using an RS-232 communications link. As
noted above, the
ON-OFF switch 1266c, and the refluff key 266d are coupled to the
microcontroller 1160, see FIG.
14. As also noted above, the motion sensor 36, door sensor 22, humidity sensor
46 and
temperature sensor 48 generate signals to the microcontroller 1160. As further
noted above, the
microcontroller 60 generates a pulse-width modulated (PWM) signal to the pump
motor 1132 via
the conductor 1172. An audio indicator 1300 is further coupled to the
microcontroller 1160 and
functions to indicate that a drying cycle has been completed, clothes have
been treated with the
benefit composition, an error occurred during the benefit composition dosing
cycle or the benefit
composition dispensing apparatus is out of fluid. The audio indicator 1300 is
mounted to the
. printed circuit board 1160, see FIG. 12.
Further coupled to the microcontroller 1160 are first, second, third, fourth
and fifth light
emitting diodes 1400a-1400e, see FIGS. 11-13. The diodes are coupled to the
face plate 1162 so
as to be visible to an operator when actuated, see FIG. 11. The first diode
1400a is actuated by
the microcontroller 1160 when the apparatus 1100 is activated via the ON-OFF
switch 1266c.
The second diode 1400b is actuated by the microcontroller 1160 when the pump
1130 is pumping
benefit composition to the nozzle 24. The third diode 1400c is actuated by the
microcontroller
.1160 when the refluff key 266d has been activated. The fourth diode 1400d is
actuated by the
microcontroller 1160 when the spraying operation has been completed for the
corresponding
fabric enhancement operation cycle. The fifth diode 1400e is actuated by the
microcontroller
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1160 to generate a warning signal when the container is out of fluid, or the
fabric enhancement
cycle has been interrupted, which latter event may be detected via the door
sensor 22 sensing light
or the motion sensor 36 sensing no motion. The microcontroller 1160 may sense
that the
container 1170 is out of fluid by sensing a change in the current drawn by the
pump motor 1132.
Treatment Composition
A treatment material provides one or more fabric benefits including, but not
limited to,
softness, anti-soil re-deposition, stain or water repellency, color or
whiteness enhancement,
fragrance, enhanced absorbency, anti-static, anti-bacterial, wrinkle control,
shape/form retention,
and/or fabric abrasion resistance. Classes of materials that contain materials
that can provide such
benefits include, but are not limited to, cationic materials, nonionic
materials, other polymeric
materials, and particulate materials. Typically, the treatment material is
present, based on total
composition weight, at one of the following levels, at least about 0.5 wt %,
at least about 2 wt %,
from about 4 wt % to about 90 wt %, from about 4 wt % to about 50 wt %, or
from about 4 wt %
to about 10 wt %. Suitable treatment materials include but are not limited to
those disclosed in
WO 2004/12007, published on November 4, 2004 and entitled "Volatile Material
Delivery
Method"; WO 00/24856, published on May 4, 2000 and entitled "Fabric Care
Composition and
Method"; U.S. Patent Application Publication No. 2005/0022311 published on
February 3, 2005
and entitled "Fabric Article Treating System and Method"; U.S. Patent
Application Publication
No. 2005/0076534, published on April 14, 2005 and entitled "Fabric Article
Treating Device and
System with Static Control".
The fabric treatment composition used in conjunction with the present
invention may
include a perfume. The perfume may comprise at least about 0.005 wt. %, about
0.005 wt. % to
about 10 wt% or about 0.1 wt. % to about 2 wt. % of a material such as a
perfume that comprises
at least about 30 wt.%, about 35 wt % to about 100 wt. %, about 40 wt % to
about 100 wt.% or
about 40 wt % to about 70 wt.% of a perfume material having a boiling point of
less than or equal
to about 250 C at 1 atmosphere; a fabric treatment material; an optional
carrier and the balance
being one or more adjunct ingredients such as disclosed in copending
application WO
2004/12007.
The fabric treatment composition used in conjunction with the present
invention may also
include from about 0.5 to about 20% of fabric softeners or fabric hand
modifiers non-limiting
examples of which include diester quaternary ammonium compounds,
polyquaternary ammonium
compounds, triethanolamene esterified with carboxylic acid and quaternized
materials, amino
esterquats, cationic diesters, betain esters, betaines, silicone or silicone
emulsions comprising
amino silicones, cationic silicones, quat/silicone mixtures, functionalized
polydimethyl siloxanes
CA 02565228 2009-04-29
18
("PDMS"), amine oxides, silicone co-polyols, cationic starches, sucrose fatty
esters, polyethylene
emulsions, and mixtures thereof.
The fabric treatment composition used in conjunction with the present
invention may also
include from about 0.1 to about 1.2% of antistatic agents non-limiting
examples of which include
polyanilines, polypyrroles, poly acetylene, polyphenylene, polythiophenes,
ethoxylated
polyethyleneimines, and various commercial materials such as STATEXANTM WP,
STATEXAN
HA, or STATEXAN PES (available from LanXess-- a subsidiary of Bayer located in
Leverkusen,
GaYnanyl EIHOFATTM (available from Akso Nobel of Arnhem, Netherlands),and
mixtures
thereof.
The fabric treatment composition used in conjunction with the present
invention may also
include from about 0.005 to about 1:5% of malodor control agents non-limiting
examples of
which include substituted or unsubstituted cyclodextrins, porous inorganic
materials, starch,
olfactory odor blockers and mixtures thereof.
The fabric treatment composition used in conjunction with the present
invention may also
include from about 0.05 to about 0.5% of preservatives non-limiting examples
of which include
didecyl dimethyl anunonium chloride which is available under the trademark
UNIQUAT (from
Lonza of Basel Switzerland), 1,2-benzisothiozolin-3-one, which is available
under the trademark
PROXEL (from Arch Chemicals of Norwalk, Connecticut), dimethylol-5,5-
dimethylhydantoin
which is available under the trademark DANTOGUARD (from Lonza of Basel
Switzerland), 5-
Chloro-2-methyl-4-isothiazolin-3-one / 2-methyl-4-isothiazolin-3-one, which is
available under
the trademark KATHON (from Rohm and Haas of Philadelphia, Pennnsylvania), and
mixtures
thereof.
The fabric treatment composition used in conjunction with the present
invention may also
include from about 0.05 to about 5% of ethoxylated surfactants and/or
emulsifiers. These may
include, but are not limited to carboxylated alcohol ethoxylates, ethoxylated
quaternary
ammonium surfactants, ethoxylated alkyl amines, alkyl phenol ethoxylates,
alkyl ethoxylates,
alkyl sulfates, alkyl ethoxy sulfates, polyethylene glycol/polypropylene
glycol block copolymers,
fatty alcohol and fatty acid ethoxylates, long chain tertiary amine oxides,
alkyl polysaccharides,
polyethylene glycol ("PEG") glyceryl fatty esters and mixtures thereof.
Processes of Makiniz Fabric Treatment Compositions
The fabric treatment compositions of the present invention can be formulated
into any suitable
form and prepared by any process chosen by the formulator, non-limiting
examples of which are
described in U.S. Patent No. 6,653,275.
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Uniformity and Deposition Efficiency
It is desirable that a treatment composition applied during the drying process
be
uniformly distributed onto the fabric in the tumble dryer during the drying
process. It is also
desirable during the drying process that a treatment composition be deposited
on the fabric that is
in the tumble dryer rather than deposited elsewhere such as through the dryer
vent/lint screen.
While not wishing to be limited by theory it is believed that some factors
which may possibly
influence both uniformity of distribution and deposition of the treatment
composition onto the
fabric in the drum of the tumble dryer include flowrate of the treatment
composition in the drum,
the droplet size of the treatment composition, the position of the spray in
the drum, the cone angle
of the spray in the drum, the linear velocity of the treatment composition in
the drum.
In accordance with the present invention, it is desirable that the uniformity
of distribution
(i.e.; Distribution Index) of the treatment composition on the fabric in the
drum of the tumble
dryer be at least about 35%, at least about 45%, at least about 50%, at least
about 60%, at least
about 70%, at least about 75%, or at least about 80%. It is desirable that the
deposition of the
treatment composition onto the fabric in the drum of the tumble dryer be at
least about 70%, at
least about 75%, or at least about 80%. It is also desirable that less than
about 10% of the
treatment composition be released from the dryer drum through the lint screen,
less than about 5%
of the treatment composition be released from the dryer drum through the lint
screen, or less than
about 1% of the treatment composition be released from the dryer drum through
the lint screen.
Method for Determining Cone Angle of a Spray
The following method may be used to measure the cone angle (width of a spray).
1. Measure the depth of the dryer drum to which the spray is to be applied.
Calculate the
distance that is 20% of the total length of the dryer drum depth.
2. The sprayer which is to be the source of the spray is mounted on a vertical
surface at the
height that corresponds to the vertical midpoint of the dryer drum with the
nozzle of the spraying
device aligned with the corresponding horizontal (perpendicular) axis.
TM
3. Assemble a Photron Fastcam PCI 2KC available from Motion Engineering of
TM TM
Indianapolis, Indiana in conjunction with a Magma CB2 and Dell Inspiron 8100.
Assemble a
halogen lamp to provide additional light when filming. Use a 25 mm lens to
video tape the spray
with high resolution. Align the video camera such that the field of view
includes the discharge of
the nozzle and extends to at least the 20% distance calculated in step I.
Further, insure that the
camera is aligned to capture the widest angle of the spray.
4. Activate the spray in the absence of dryer airflow.
5. Video tape the fluid spray at 1000 frames per minute against a black
background.
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6. Insert single frame pictures of the spray into Microsoft Visio wherein the
pictures are
zoomed in to 400%
7. To determine the cone angle using the picture from step 6, draw the
vertical line
corresponding to the point that is 20% of the length determined in step 1 so
as to intersect the top
and bottom boundaries of the spray. From the point where the vertical line
intersects the top
boundary of the spray, draw a line back to the discharge midpoint of the
nozzle of the sprayer.
Repeat this process for the lower boundary of the spray (i.e.; from the point
where the vertical line
intersects the bottom boundary of the spray, draw a line back to the discharge
midpoint of the
nozzle of the sprayer. The cone angle is the internal angle formed by the
intersection of these two
lines at the nozzle discharge.
Method for Determining Deposition of the Treatment Composition on the Fabric
and Deposition
of the Treatment Composition on the Lint Screen
Fabric Stripping:
1. Weigh fabrics until the total load weight is approximately 2.7 kg.
2. Turn on the washing machine set on a 10-min. agitation time and a high
water level,
approximately 21 gal fill.
3. Use approximately 160 grams of a liquid laundry detergent such as Liquid
TIDE .
4. Add the detergent to the washing machine water after it is approximately
1/4 full. Rinse the
laundry detergent bottle cap out with water running into the machine so as to
allow any
remaining detergent in the cap to run into the washing machine.
5. Once the tub is filled to approximately'/4 full, the fabrics are added to
the water in the
washing machine.
6. The wash cycle is allowed to proceed automatically through completion of
the final spin.
7. Steps #2 - 6 are repeated 3 more times, with the respective amounts of
detergent added to
the wash load as listed above.
8. After the 4`h cycle is complete, the fabrics are removed from the washing
machine and
dried using the high heat cycle of a dryer.
9. The fabrics are then stored in plastic bags until treatment.
Fabric Treatment:
Fabric Load - Each treatment consists of using twelve 1 yd. squares of
stripped fabric swatches
per load.
Treatment Process- The stripped fabric swatches are placed in the washing
machine, set on the
rinse cycle, wet and spun dry.
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Before placing damp fabrics into the tumble dryer, the following Dryer
Cleaning Procedure is
performed before each treatment. A 5% bleach solution is sprayed inside the
dryer on the front
and back walls and the dryer drum. The lint screen is removed prior to
spraying. The dryer is
thoroughly wiped down with paper towels. Once dryer cleaning is complete, the
lint trap of the
dryer is replaced and covered with a new 14" by 7" piece of white cotton knit
fabric secured on
the edges by masking tape. A suitable white cotton knit fabric is CW120
available from
Empirical Manufacturing Company of Cincinnati, Ohio. The damp fabrics are then
placed into
the dryer drum, and a drying cycle is completed. During the drying cycle, a
spray composition is
delivered into the dryer drum. Following the drying treatment cycle, the
fabrics are removed
from the dryer drum as is the covering over the lint screen for sampling and
analysis.
Fabric Sampling:
Lint screen - The fabric over the lint screen is sampled as follows:
1. The covering over the lint screen is sampled by removing it from the lint
screen.
2. Six circular samples measuring 40 mm in diameter are cut from the portion
of the lint
screen cover which was not covered by the masking tape.
3. The six samples cut from the lint screen cover are labeled and analyzed
according to the
swatch analysis described below.
Fabric Load (from the drYer) -
1. Six of the twelve, one square yards of fabric are sampled from each cycle.
2. Each fabric swatch is unfolded and a ruler used to measure in six inches
from the corner
of the swatch.
3. A 40 mm circle is cut from this area.
4. Sample swatches are labeled and analyzed.
Swatch Analysis:
Inductively Coupled Plasma Optical Emission Spectrometry (ICP) is used to
analyze the
samples. In order to determine spray performance, Yttrium (Y) is spiked into
the treatment
composition solution as a tracer element. Add 200 ppm of Y into the treatment
composition to be
tested. Spray the composition onto the fabric to be tested. After spraying,
cut samples from the
fabric. Digest the fabric samples via high pressure microwave to get into
acidic solution.
Calibrate ICP for quantitative Y determination. Measure Y in solution. Back
calculate for
amount of Y on fabric and apply stoichiometric correction to determine amount
of treatment
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composition solution on the fabrics. The distribution of Y is representative
of the distribution of
the treatment composition solution.
Method for Determining Uniformity of the Treatment Composition (Distribution
Index) onto the
Fabric
Image analysis may be used to evaluate uniformity of spray distribution per
surface area
of a test sample. A number of digital images are acquired per sample by
imaging equipment and
analyzed by computer software. The software detects a spray deposition area
and provides a
count of the number of pixels comprising the stained areas in the image. By
comparison of the
number of pixels detected for all images taken per sample, a standard
deviation is calculated. A
smaller standard deviation correlates to a more uniform spray deposition. In
order to determine
spray uniformity, a fabric sample is sprayed with red dye (i.e.; 0.0 wt 5%
FD&C Red Dye #40 in
distilled water).
Image analysis is then conducted according to the following steps to evaluate
the
uniformity of distribution of spray on a sample.
(1) Backjzround calibrate ima2ing system and acguire digital image of sample
Background calibration, a well known technique for calibrating images using a
flat
neutral gray card, is applied to images before analysis to eliminate lighting
variance across the
field of view and minimize problems in image analysis due to spatial lighting
variance.
Additionally, to insure color consistency in the digital images taken at
different times (e.g. images
taken on different days), the images are also color corrected using a standard
color chart (Gretag
Macbeth 24 color chart).
After calibrating the background, place the fabric to be tested in a light
booth and fold
such that the particular area to be imaged is at the center of the light booth
directly between the
lamps and facing upwards towards the camera. A stencil in the size of the
field of view of the
camera (16cm by 20.5cm) is placed on the area to be imaged. A picture is
taken= in response to a
command from the operator when the sample is correctly positioned. Six images
are taken per
front-side and back-side of the fabric for a total of 12 images per fabric.
The picture is digitized (i.e. converted to a binary representation) in a
known manner.
Finally, the digital image data is transferred to a computing device. Many
other methods of
acquiring the digital image are well known to persons of ordinary skill in the
art. For example, a
sample to be analyzed may be submitted via the network, a file may be
retrieved from a database,
and/or a flatbed scanner may be used to digitize a photograph.
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(2) Electronically analyze the digital image to detect the areas of spray
deposition
The image is electronically processed by image analysis software (Optimas v6.5
available
from Media Cybernetics, Incorporated of Silver Spring, Maryland) based on a
reference intensity
threshold. The region of interest selected is the entire screen image. The
method for selecting the
intensity threshold setting is as follows. The background and color corrected
images of the fabric
(step 1 above) are converted to a single `gray' level image representation
that highlights the
difference between the red dyed areas and `clean' fabric areas. The method
used depends upon
the lighting, imaging system, and type and color of dye used vs. the
background fabric color. For
example the green channel can be used. Related approaches can also be used,
for example, an
intensity image from Red - Green, Red - Blue or other similar mathematical
combinations of the
Red, Green, and Blue color channels of an image can be used to create a single
channel `gray'
level image for thresholding that accentuates the differences between the dyed
and `clean' areas
of the fabric.
The software is calibrated to detect colored areas in pixels of the digital
images. To set
the threshold for pixel detection, a "clean", un-dyed white fabric is the
standard reference and is
imaged according to step (1). After converting to a single channel `gray'
level image
representation, the threshold is set for which zero pixels are detected for
all images for.that
"clean" sample, and such that increasing the threshold value any higher would
make the software
start detecting pixels on the "clean" sample. Pixels of a color intensity
value within the set
threshold are detected and counted by the image analysis software.
(3) Calculate standard deviation in percent of pixels detected for all images
per sample
The percent of pixels detected per area is obtained by mathematical
calculation using the
number of pixels detected divided by the number of total pixels per image.
Therefore for each
fabric analyzed, there are twelve values of percent of pixels detected. For
the twelve images per
fabric, the standard deviation of percent of pixels detected is obtained by
mathematical
calculation, according to
(X U)Z
N-1
where
6 = standard deviation
X; = percent of pixels detected per image
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,r = average value of the percent of pixels
N= number of values in the set of measurements
To more conveniently compare the uniformity of spray deposition across
fabrics, treatments, and
the like, a Distribution Index is created by a mathematical equation using the
standard deviation
value. This distribution index is a scale from 0 to 100.
0 < Distribution Index < 100
Distribution Value = 1 x 100
(a+1)
Wherein a higher distribution value correlates to a more uniform sample.
EXAMPLES
Example Treatment ComQosition
The following are non-limiting examples of treatment compositions which may be
useful
in the present invention:
CHEMICAL NAME Weight %
A B C 0 E F G H
Di-tallowoylethanofester 6.500 2.17
dimethylammonium
chloride
Sucrose fatty ester 2.000 0.67
Propylene glycol n-butyl 2.000 2.00
ether
Propylene Glycol 4.000 4.00
Diethylene Glycol 0.10 0.10 0.10 0.10 0.10
H d enated castor oil 0.20 0.20 0.20 0.20 0.20 0.20
Ethoxylated 0.50 0.50 0.50 0.50 0.50 0.50
polyethyleneimine
Phenoxyethanol 0.100 0.10
Preservatives 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10
Stabilizers 0.100 0.20 0.20 0.20 0.20 0.20 0.20 0.20
Perfume 0.350 0.35 0.35 0.35 0.35 0.35 0.35 0.35
Pol ox eth lene 0.035 0.035
Lactic Acid 0.100 0.10
CaCI2- 6H20 0.210 0.21
Silicone co-polyol' 0.100 0.10
Silwet'"'r L7600
Silwet L7608 0.05 0.05 0.05 0.05
Silwet L 7001 1.25 2.50 2.50 1.00 1.25
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Acetylenic diols 1.00
Pol eth lene microemulsion 0.25 1.25
Hydroxy propyl cyclodextrin 0.25 0.25 0.25 0.25 0.25
Deionized Water Balance Balance Balance Balance Balance Balance Balance
Balance
TOTAL 100% 100% 100% 100% 100% 100% 100% 100%
CHEMICAL NAME Weight %
I J K L M N 0
Di-tallowoylethanolester dimethylammonium 1.00 2.17 12.00
chloride
Sucrose fatty ester 0.35 0.67 4.00
Propylene glycol n-butyl ether
Propylene Glycol
Diethylene Glycol 0.10 0.10
H dro enated castor oil 0.20 0.10 0.20 0.40 0.40
Ethoxylated polyethyleneimine 0.50 1.00 0.50 0.50
Phenoxyethanol 0.10 0.10 0.200
Preservatives 0.10 0.10 0.10 0.10 0.10 0.10 0.10
Stabilizers 0.20 0.20 0.20 0.100 0.20 0.20 0.20
Perfume 0.35 0.35 0.35 0.700 0.35 0.70 0.70
Pol ox eth lene 0.035 0.035 0.50
Lactic Acid 0.10 0.10 0.100
CaC12= 6H20 0.10 0.21 0.210
Silicone co-polyol' 0.10
Silwet L7600
Silwet L7608 0.05 0.05 0.05 0.05 0.05
Silwet L 7001 0.50 0.65 1.25 1.25 1.25
Acetylenic diols 1.00 1.00 1.00
Pol eth lene microemulsion 0.75
H drox propyl cyclodextrin 0.25 0.25 0.25 0.25
Deionized Water Balance Balance Balance Balance Balance Balance Balance
TOTAL 100% 100% 100% 100% 100% 100% 100%
Example Nozzle Placements
The following are non-limiting examples of nozzle placements which may be used
in a
tumble dryer:
A. Non-limiting examples of nozzle placements which may be used with a cross-
flow tumble
dryer (i.e.; where the drum typically rotates in a counter-clockwise motion,
and air flow typically
enters the tumble dryer through a rear panel in quadrant 602 and exits through
the rear panel of
the dryer in quadrant 601-- see Fig. 1).
Example 1 2 3 4 5 6 7 8 9 10 11 12 13
Number of 1 1 1 1 1 1 1 1 2 2 1 1 2
nozzles
Dryer panel' F F F F F F F F F F B B F/B
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Quadrant 2 0 0 0 2 2 3 3 1 1/2 2/4 2 0 2/0
Vertical 0 0 0 40 10 30 5 30 15/30 40/20 30 0 25/0
displacement3
(%)
Horizontal 0 0 0 20 30 10 5 20 10/15 40/5 10 0 20/0
displacement4
(%)
Nozzle angle 0 30 15 45 0 10 55 30 45/15 0/15 25 5 15/1
(degrees up D U D U U D D/D /U D D 5
("U") or down D/D
("D"))
Nozzle angle 0 20 55 15 5 15 25 45 45/0 30/45 10 15 0/10
(degrees left L L R R R L L L/ R/L R L / L
("L") or right
("R" ))5
1 Denotes nozzle placement on the front ("F") panel/door of the tumble dryer
or back ("B") panel
of the tumble dryer.
2 Abbreviated as follows: Referring to Fig. 1, "0" refers to the intersection
of line 640 with line
630. The number "1" refers to the first quadrant 601. The number "2" refers to
the second
quadrant 602. The number "3" refers to the third quadrant 603. The number "4"
refers to the
fourth quadrant 604.
3 Expressed as % of the total distance from the intersection of lines 630 and
640 to the edge of the
dryer drum (i.e.; the radius) when measured from the intersection of line 630
and line 640 along
line 640 in the direction required to land in the designated quadrant.
4 Expressed as % of the total distance from the intersection of lines 630 and
640 to the edge of the
dryer drum (i.e.; the radius) when measured from the intersection of line 630
and 640 along line
630 in the direction required to land in the designated quadrant.
Referenced as viewed from the front side of the dryer.
B. Non-limiting examples of nozzle placements which may be used with an axial
flow dryer
(i.e.; where the drum typically rotates in a clockwise motion and air flow
typically enters the dryer
through the rear panel of the appliance in the first quadrant 601 of Fig. I
and exits through the lint
screen in the front panel of the dryer below the door).
Example 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Number of I 1 1 1 1 1 1 1 1 1 2 2 1 1
Nozzles -
Dryer panel I F F F F F F F F F F F/B B B
Quadrant2 0 0 0 1 1 1 2 2 3 4 1/2 1/1 2 0
Vertical 0 0 0 30 15 5 40 5 10 10 25/10 40/15 20 0
displacement3
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27
(%)
Horizontal 0 0 0 40 20 5 20 5 20 20 10/15 20/10 10 0
displacement4
(%)
Nozzle angle 0 55 55 35 0 15 30 10 55 45 0/ 15 15/0 20 15
(degrees up U D D D U D D U U / D D/ U D
(U) or down
(D))
Nozzle angle 0 55 0 45 30 0 40 10 15 35 0/45 30/5 15 25
(degrees left R L L R R R L / R L/R R R
(L) or right
(R))5
~ Denotes nozzle placement on the front ("F") panel/door of the tumble dryer
or back ("B") panel
of the tumble dryer.
2 Abbreviated as follows: Referring to Fig. 1, "0" refers to the intersection
of line 640 with line
630. The number "1" refers to the first quadrant 601. The number "2" refers to
the second
quadrant 602. The number "3" refers to the third quadrant 603. The number "4"
refers to the
fourth quadrant 604.
3 Expressed as % of the total distance from the intersection of lines 630 and
640 to the edge of the
dryer drum (i.e.; the radius) when measured from the intersection of line 630
and line 640 along
line 640 in the direction required to land in the designated quadrant.
Expressed as % of the total distance from the intersection of lines 630 and
640 to the edge of the
dryer drum (i.e.; the radius) when measured from the intersection of line 630
and 640 along line
630 in the direction required to land in the designated quadrant.
Referenced as viewed from the front side of the dryer.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
within the scope of this invention.
