Note: Descriptions are shown in the official language in which they were submitted.
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IMPROVED CLEANING APPARATUS AND METHOD
Field of the Invention
[0001] The present invention relates to a cleaning apparatus that employs a
solid
particulate material. In operation, the apparatus may require the use of only
limited quantities
of energy, water and detergent. Most particularly, the invention is concerned
with a door for
use in such a cleaning apparatus that enables separation of said solid
particulate material
and wash liquor from a flow pathway.
Backdround to the Invention
[0002] Aqueous cleaning processes are a mainstay of conventional domestic and
industrial textile fabric cleaning methods. On the assumption that the desired
level of
cleaning is achieved, the efficacy of such conventional processes is usually
characterised
by their levels of consumption of energy, water and detergent. In general, the
lower the
requirements with regard to these three components, the more efficient the
washing process
is deemed. The downstream effect of reduced water and detergent consumption is
also
significant, as this minimises the need for disposal of aqueous effluent,
which is both
extremely costly and detrimental to the environment.
[0003] Such washing processes involve aqueous submersion of fabrics followed
by
aqueous soil suspension, soil removal and water rinsing. In general, within
practical limits,
the higher the level of energy (or temperature), water and detergent which is
used, the better
the cleaning. One key issue, however, concerns water consumption, as this sets
the energy
requirements (in order to heat the wash water), and the detergent dosage (to
achieve the
desired detergent concentration). In addition, the water usage level defines
the mechanical
action of the process on the fabric, which is another important performance
parameter; this
is the agitation of the cloth surface during washing, which plays a key role
in releasing
embedded soil. In aqueous processes, such mechanical action is provided by the
water
usage level in combination with the drum design for any particular washing
machine. In
general terms, it is found that the higher the water level in the drum, the
better the
mechanical action. Hence, there is a dichotomy created by the desire to
improve overall
process efficiency (i.e. reduce energy, water and detergent consumption), and
the need for
efficient mechanical action in the wash.
[0004] Various different approaches to the development of new cleaning
technologies
have been reported in the prior art, including methods which rely on
electrolytic cleaning or
plasma cleaning, in addition to approaches which are based on ozone
technology, ultrasonic
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technology or steam technology. Thus, for example, W02009/021919 teaches a
fabric
cleaning and disinfection process which utilises UV-produced ozone along with
plasma. An
alternative technology involves cold water washing in the presence of
specified enzymes,
whilst a further approach which is particularly favoured relies on air-wash
technology and,
for example, is disclosed in US2009/0090138. In addition, various carbon
dioxide cleaning
technologies have been developed, such as the methods using ester additives
and dense
phase gas treatments which are described in US7481893 and US2008/0223406,
although
such methods generally find greater applicability in the field of dry
cleaning. Many of these
technologies are, however, technically very complex.
[0005] In the light of the challenges which are associated with aqueous
washing
processes, the present applicant previously devised a new approach to the
problem that
allows the deficiencies demonstrated by the methods of the prior art to be
mitigated or
overcome. The method devised eliminated the requirement for the use of large
volumes of
water, but was still capable of providing an efficient means of cleaning and
stain removal,
whilst also yielding economic and environmental benefits.
[0006] Thus, in W02007/128962 there is disclosed a method and formulation for
cleaning
a soiled substrate, the method comprising the treatment of the moistened
substrate with a
formulation comprising a multiplicity of polymeric particles, wherein the
formulation is free of
organic solvents. The substrate may be wetted so as to achieve a substrate to
water ratio
of between 1:0.1 to 1:5 w/w, and optionally, the formulation additionally
comprises at least
one cleaning material, which typically comprises a surfactant, which most
preferably has
detergent properties. In embodiments, the substrate comprises a textile fibre.
The polymeric
particles may, for example, comprise particles of polyamides, polyesters,
polyalkenes,
polyurethanes or their copolymers, a particular example being nylon beads.
[0007] The use of this cleaning method, however, presents a requirement for
the nylon
beads to be efficiently separated from the cleaned substrate at the conclusion
of the cleaning
operation, and this issue was initially addressed in W02010/094959, which
provides a novel
design of cleaning apparatus requiring the use of two internal drums capable
of independent
rotation, and which finds application in both industrial and domestic cleaning
processes.
[0008] With a view to providing a simpler, more economical means for
addressing the
problem of efficient separation of the cleaning beads from the substrate at
the conclusion of
the cleaning process, however, a further apparatus is disclosed in
W02011/064581. The
apparatus of W02011/064581, which finds application in both industrial and
domestic
cleaning processes, comprises a perforated drum and a removable outer drum
skin which
is adapted to prevent the ingress or egress of fluids and solid particulate
matter from the
interior of the drum. The cleaning method requires attachment of the outer
skin to the drum
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during a first wash cycle, after which the skin is removed prior to operating
a second wash
cycle, following which the cleaned substrate is removed from the drum.
[0009] The apparatus and method of W02011/064581 is found to be extremely
effective
in successfully cleaning substrates, but the requirement for the attachment
and removal of
the outer skin detracts from the overall efficiency of the process and the
present inventors
have, therefore, sought to address this aspect of the cleaning operation and
to provide a
process wherein this procedural step is no longer necessary. Thus, by
providing for
continuous circulation of the cleaning beads during the cleaning process, it
has been found
possible to dispense with the requirement for the provision of an outer skin.
[0010] Thus, in W02011/098815, the present inventors provided an apparatus for
use in
the cleaning of soiled substrates, the apparatus comprising housing means
having a first
upper chamber with a rotatably mounted cylindrical cage mounted therein and a
second
lower chamber located beneath the cylindrical cage, and additionally
comprising at least one
recirculation means, access means, pumping means and a multiplicity of
delivery means,
wherein the rotatably mounted cylindrical cage comprises a drum having
perforated side
walls where up to 60% of the surface area of the side walls comprises
perforations
comprising holes having a diameter of no greater than 25.0 mm.
[0011] The apparatus of W02011/098815 is used for the cleaning of soiled
substrates by
means of methods which comprise the treatment of the substrates with
formulations
comprising solid particulate cleaning material and wash water, the methods
typically
comprising the steps of:
(a) introducing solid particulate cleaning material and water into the lower
chamber
of the apparatus;
(b) agitating and heating the solid particulate cleaning material and water;
(c) loading at least one soiled substrate into the rotatably mounted
cylindrical cage
via the access means;
(d) closing the access means so as to provide a substantially sealed system;
(e) introducing the solid particulate cleaning material and water into the
rotatably
mounted cylindrical cage;
(f) operating the apparatus for a wash cycle, wherein the rotatably mounted
cylindrical cage is caused to rotate and wherein fluids and solid particulate
cleaning material are caused to fall through perforations in the rotatably
mounted cylindrical cage into the lower chamber in a controlled manner;
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(g) operating the pumping means so as to transfer fresh solid particulate
cleaning
material and recycle used solid particulate cleaning material to separating
means;
(h) operating control means so as to add the fresh and recycled solid
particulate
cleaning material to the rotatably mounted cylindrical cage in a controlled
manner; and
(i) continuing with steps (f), (g) and (h) as required to effect cleaning of
the soiled
substrate.
[0012] As outlined above, the apparatus of W02011/098815 therefore includes
features
to introduce solid particulate cleaning material into the rotatably mounted
cylindrical cage
and also comprises at least one recirculation means to facilitate
recirculation of said solid
particulate material for its re-use in cleaning operations. In addition, the
apparatus of
W02011/098815 can include ducting comprising separating means for separating
the solid
particulate material from water and control means adapted to control entry of
the solid
particulate material into the cylindrical cage. In one disclosed embodiment,
the separating
means comprises a rigid filter material such as wire mesh located in a
receptor vessel above
the cylindrical cage, and the control means comprises a valve located in
feeder means,
preferably in the form of a feed tube attached to the receptor vessel, and
connected to the
cage.
[0013] Although the apparatus disclosed in W02011/098815 provided considerable
improvements for the cleaning of soiled substrates with formulations
comprising solid
particulate cleaning material and wash water, there remain several drawbacks
associated
with using an apparatus of this type when separating the solid particulate
material from water
prior to its use and re-use in the cleaning operation. In particular,
separation of the solid
particulate material from the apparatus in W02011/098815 is carried out using
a separation
vessel external to the housing of the apparatus and above the cylindrical
cage. Placement
of the separating device in this position was considered to be necessary as
the solid
particulate material, in the form of beads, falls under gravity to the filter
material before
entering the cylindrical cage. In order to recirculate, the solid particulate
material was
pumped along a recirculation path that extends from the enlarged sump located
in the lower
chamber of the apparatus to the separating vessel above the cylindrical cage.
[0014] A long recirculation path for the solid particulate material
detrimentally impacts the
efficiency of the apparatus as more energy is expended for pumping and a
larger pump is
required to transport the solid particulate material along the recirculation
path. Furthermore,
as beads must be pumped in combination with water along the recirculation
path, water
usage within the apparatus is less than optimal as the total volume of water
required for
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recirculation is increased. In addition, the inclusion of a separating vessel
above the
cylindrical cage adversely increases the size of the apparatus, considerations
that are
particularly important for domestic washing machines.
[0015] In some embodiments, the present disclosure seeks to provide a cleaning
5 apparatus for use in the cleaning of soiled substrates with a solid
particulate material that
can ameliorate or overcome the above-noted problems associated with the prior
art.
Particularly, there is desired an apparatus and method for the cleaning of
soiled substrates
with a solid particulate cleaning material comprising an improved means of
separating said
solid particulate material and water prior to the introduction of said solid
particulate for use
in the cleaning operation. Specifically, there is desired an apparatus and
method for
separating solid particulate material and wash water which addresses some or
all of the
deficiencies of the apparatus and method disclosed in W02011/098815.
Summary of the Invention
[0016] In accordance with embodiments of the present invention there is
provided a door
for providing access to a rotatably mounted drum of a cleaning apparatus. The
door can
comprise a flow pathway for wash liquor and a multiplicity of solid particles
(also referred to
herein as "a solid particulate material") and a separator. The separator can
be arranged to
direct the multiplicity of solid particles from the flow pathway into the
drum. The separator
can be further arranged to direct a portion of the wash liquor from the flow
pathway to a
location other than into the drum.
[0017] Thus, in some advantageous embodiments, the separator can serve to
effectively
regulate or limit the amount of wash liquor entering into the drum thereby
maximising the
cleaning effect of the solid particulate material used in the cleaning
operation. Furthermore,
the overall size of the cleaning apparatus can be reduced by providing such a
separator as
part of the door.
[0018] In some embodiments the door can define therein a first flow path to
the separator
for wash liquor and said solid particles and can further define therein a
second flow path
from the separator for a portion of said wash liquor directed to a location
other than into the
drum. In some advantageous embodiments the door of the invention can be
adapted to
define at least two independent flow paths, including a first flow path for
wash liquor and
solid particles to the separator and a second flow path from the separator for
wash liquor
which does not enter the drum.
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[0019] In some embodiments the door can comprise a feed pipe for the passage
of said
wash liquor and said solid particles therethrough. In some embodiments said
feed pipe can
define a portion of said flow pathway.
[0020] In some embodiments the door can comprise an outlet downstream from the
separator for said wash liquor from said flow pathway directed to a location
other than into
the drum. In some embodiments the door can comprise an inner portion
comprising one or
more channels to direct said wash liquor to said outlet.
[0021] In some embodiments the separator can comprise a web or substrate
having a
plurality of apertures formed therein wherein said apertures are sized so as
to permit the
passage of wash liquor whilst preventing the passage of said solid particles
therethrough.
[0022] In some embodiments the separator can comprise an inlet, an outlet and
a curved
body portion disposed between said inlet and said outlet. In some embodiments
said curved
body portion comprises said web or substrate having a plurality of apertures
formed therein
wherein said apertures are sized so as to permit the passage of wash liquor
whilst preventing
the passage of said solid particles therethrough.
[0023] In other embodiments the separator can comprise an inlet, an outlet and
a body
disposed between said inlet and said outlet, said body comprising a first
planar wall member
joined to a second planar wall member at a common point wherein said second
planar wall
member is inclined with respect to said first planar wall member and wherein
said second
planar wall member comprises said web or substrate having a plurality of
apertures formed
therein wherein said apertures are sized so as to permit the passage of wash
liquor whilst
preventing the passage of said solid particles therethrough. In further
embodiments said
second planar wall member can be located upstream of said first planar wall
member. In this
context, the term upstream is used with reference to the direction of flow of
wash liquor and
solid particles through the separator.
[0024] In some embodiments the separator can comprise a plurality of apertures
sized
so as to permit the passage of wash liquor whilst preventing the passage of
said solid
particles therethrough wherein said apertures are further arranged to capture
lint and/or
fine particulate matter entrained in the wash liquor.
[0025] In some embodiments the separator can comprise a mesh.
[0026] In accordance with further embodiments of the present invention there
is provided
a cleaning apparatus for use in the cleaning of at least one soiled substrate
with a
multiplicity of solid particles (also referred to herein as "a solid
particulate material"), said
cleaning apparatus comprising:
(a) a housing containing a drum rotatably mounted therein;
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(b) a door moveable between an open position wherein said at least one soiled
substrate
can be placed within the drum and a closed position wherein the cleaning
apparatus is
substantially sealed;
(c) at least one delivery means for the addition of wash liquor;
(d) pumping means configured to pump wash liquor and a multiplicity of solid
particles
from a first location to the door;
wherein said door can comprise a flow pathway for said wash liquor and said
solid
particles and a separator arranged to direct the multiplicity of solid
particles from the flow
pathway into the drum. The separator can be further arranged to direct a
portion of the
wash liquor from the flow pathway to a location other than into the drum.
[0027] In some embodiments said pumping means can be configured to pump said
wash
liquor and said multiplicity of solid particles upwardly from said first
location to the door. In
some embodiments the separator can be arranged to receive an upward flow of
said wash
liquor and said solid particles from said first location and said separator
can be further
arranged to direct said multiplicity of solid particles into the drum from
said upward flow. In
some embodiments said first location can be in a lower portion of the housing.
In some
embodiments said lower portion of the housing can be beneath the drum.
[0028] In some embodiments the separator can be arranged to receive a downward
flow
of said wash liquor and said solid particles and wherein the separator is
further arranged to
direct said multiplicity of solid particles into the drum from said downward
flow.
[0029] In some embodiments the separator can be arranged to receive a
horizontal flow
of said wash liquor and said solid particles and wherein the separator is
further arranged to
direct said multiplicity of solid particles into the drum from said horizontal
flow.
[0030] In some embodiments the separator can be arranged to receive a flow of
said wash
liquor and said solid particles from said pumping means and can be further
arranged to direct
at least 1 percent of the total mass of the wash liquor from said flow to said
location other
than into the drum. In some embodiments the separator can be further arranged
to direct at
least 10 percent of the total mass of the wash liquor from said flow to said
location other
than into the drum. In some embodiments the separator can be further arranged
to direct at
least 40 percent of the total mass of the wash liquor from said flow to said
location other
than into the drum. In some embodiments the separator can be further arranged
to direct at
least 70 percent of the total mass of the wash liquor from said flow to said
location other
than into the drum. In some embodiments the separator can be further arranged
to direct at
least 90 percent of the total mass of the wash liquor from said flow to said
location other
than into the drum.
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[0031] In some embodiments the separator can be arranged to receive a flow of
said wash
liquor and said solid particles from said pumping means and can be further
arranged to direct
no greater than 99 percent of the total mass of the wash liquor from said flow
to said location
other than into the drum. In some embodiments the separator can be arranged to
receive a
flow of said wash liquor and said solid particles from said pumping means and
can be further
arranged to direct no greater than 90 percent of the total mass of the wash
liquor from said
flow to said location other than into the drum.
[0032] In some embodiments the separator can comprise an inlet arranged to
receive a
substantially vertical flow of said wash liquor and said solid particles from
said pumping
means and an outlet arranged to direct said solid particles into said drum
wherein at least
some of the solid particles, and preferably all of the solid particles, exit
said outlet at an
angle of between about 60 and about 120 to the flow of wash liquor and solid
particles
entering said inlet. In certain embodiments said angle at which the solid
particulate
material exits the separator outlet is about 90 to the substantially vertical
flow of wash
liquor and solid particles entering the separator via said inlet. In some
advantageous
embodiments the outlet of the separator can be arranged to direct the solid
particles into
the centre of the drum.
[0033] In some embodiments said flow pathway for said the wash liquor and said
solid
particles can extend directly from said pumping means to the door and from the
door into
the drum. In some advantageous embodiments pumping wash liquor and said solid
particles along said flow pathway can facilitate a shorter transport for the
solid particles to
enter the drum thereby reducing the demand on the pumping means of the
cleaning
apparatus.
[0034] In further embodiments said first location can comprise a sump. In some
embodiments the cleaning apparatus can comprise a flow path downstream from
the
separator so that wash liquor from said flow pathway directed to a location
other than into
drum can return to the sump.
[0035] In some embodiments the cleaning apparatus can further comprise a tub
wherein
said drum is mounted within the tub. In some embodiments said door can be
mounted to a
portion of the tub.
[0036] In some embodiments the tub includes said sump. In some advantageous
embodiments the provision of an integrated tub and sump can facilitate the
ease of
transport of the wash liquor and said solid particles from the sump to the
door.
[0037] In some embodiments the sump can comprise a first end proximate to said
door
and a second end distal to said door. In some embodiments the sump can
comprise a
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sloping floor arranged to direct said solid particles to said first end of
said sump. In some
embodiments said pumping means can be located proximate to said first end. In
some
advantageous embodiments the sump and the pumping means can be arranged to
facilitate
a more efficient delivery path for the solid particles.
[0038] In some embodiments said solid particles can be recirculated along a
recirculation
path from the lower portion of the housing to the rotatably mounted drum. In
some
advantageous embodiments the inclusion of a separator in the door of the
invention can
reduce the path length for reutilisation of the solid particles in the
cleaning operation.
[0039] In some embodiments said drum can comprise collecting and transferring
means
adapted to facilitate collection of said multiplicity of solid particles and
transfer of said solid
particles from said drum to a lower portion of the housing.
[0040] In some embodiments said drum can be mounted about a substantially
horizontal
axis.
[0041] In some embodiments said drum can comprise a rotatably mounted
cylindrical
cage comprising perforated side walls wherein said perforations can comprise
holes have
a diameter of no greater than 5.0mm. In some embodiments said perforations can
comprise holes have a diameter of no greater than 3.0mm.
[0042] In some embodiments said drum can have a capacity in the region of 10
to 7000
litres. In certain embodiments said drum can have a capacity in the region of
10 to 700
litres. In further embodiments said drum can have a capacity in the region of
30 to 150
litres.
[0043] In some embodiments the door (b) of the cleaning apparatus can comprise
any of
the features of the door herein described above.
[0044] In some embodiments the cleaning apparatus can be a washing machine. In
further
embodiments the cleaning apparatus can be a domestic washing machine such as a
machine configured for location in a private dwelling such as a house or
apartment. In other
embodiments the cleaning apparatus can be a commercial washing machine.
[0045] In some embodiments said at least one soiled substrate can comprise a
textile
material, in particular one or more garments, linens, napery, towels or the
like.
[0046] The multiplicity of solid particles or solid particulate material as
referred to herein is
distinguished from, and should not be construed as being, a conventional
washing powder
(that is laundry detergent in powder form). Washing powder is generally
soluble in the
wash water and is included primarily for its detergent qualities. The washing
powder is
disposed of during the wash cycle since it is sent to drain in grey water
along with removed
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soil. In contrast, a significant function of the multiplicity of solid
particles referred to herein
is a mechanical action on the substrate which enhances cleaning of the
substrate.
[0047] In some embodiments the multiplicity of solid particles can comprise or
can
consist of a multiplicity of polymeric particles.
5 [0048] In some embodiments the multiplicity of solid particles can
comprise or can
consist of a multiplicity of non-polymeric particles.
[0049] In some embodiments the multiplicity of solid particles can comprise or
can
consist of a mixture of polymeric solid particles and non-polymeric solid
particles.
[0050] In some embodiments the polymeric particles can be selected from
particles of
10 polyalkenes, polyamides, polyesters, polysiloxanes, polyurethanes or
copolymers thereof.
[0051] In some embodiments the polymeric particles can comprise particles
selected
from particles of polyalkenes or copolymers thereof.
[0052] In some embodiments the polymeric particles can comprise particles of
polyamide
or polyester or copolymers thereof.
[0053] In some embodiments the polyester particles can comprise particles of
polyethylene terephthalate or polybutylene terephthalate.
[0054] In some embodiments the polyamide particles can comprise particles of
nylon. In
further embodiments said nylon can comprise Nylon 6 or Nylon 6,6.
[0055] In some embodiments the non-polymeric particles can comprise particles
of glass,
silica, stone, wood, metals or ceramic materials.
[0056] In some embodiments the polymeric particles can have an average density
of
from about 0.5 to about 2.5 g/cm3.
[0057] In some embodiments the non-polymeric particles can have an average
density of
from about 3.5 to about 12.0 g/cm3.
[0058] In some embodiments the multiplicity of solid particles can be in the
form of
beads.
[0059] In some embodiments the solid particles can be reused one or more times
for
cleaning of said at least one soiled substrate in, with or by said cleaning
apparatus.
[0060] In some embodiments the wash liquor can be water. In some embodiments
the
wash liquor can comprise at least one detergent or detergent composition. In
some
embodiments the wash liquor can comprise one or more additives as detailed
further
hereinbelow.
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[0061] In further embodiments of the invention there is disclosed a method for
cleaning
at least one soiled substrate comprising the treatment of the substrate with a
multiplicity of
solid particles using the cleaning apparatus as herein described.
[0062] In some embodiments the method can comprise the steps:
a) loading said at least one soiled substrate into the drum and closing said
door;
b) introducing wash liquor to moisten the substrate and causing the drum to
rotate;
c) operating said pumping means to pump wash liquor and said multiplicity of
solid
particles from said first location to the door and introducing said
multiplicity of solid
particles into the drum via said separator.
[0063] In some embodiments said first location in the method of step c) can be
the lower
portion of the housing. In some embodiments said first location can be the
sump. In further
embodiments the method of step c) can comprise operating said pumping means to
pump
said wash liquor and said solid particles upwardly from said first location to
the door.
[0064] In some embodiments the method further comprises the step:
d) operating said cleaning apparatus for a wash cycle wherein wash liquor and
said multiplicity of solid particles can be transferred from the drum into a
lower
portion of the housing as said drum rotates.
[0065] In some embodiments the method further comprises the steps:
e) operating said pumping means so as to pump additional wash liquor and solid
particles from said first location to said door and to recirculate solid
particles used
in step c) for re-use in the cleaning operation; and
f) continuing with steps c), d) and e) as required to effect cleaning of the
at least
one soiled substrate.
[0066] In some embodiments the method can further comprise introducing at
least one
additional cleaning agent into said drum. In some embodiments the at least one
cleaning
agent can comprise at least one detergent composition. In some embodiments
said at
least one detergent composition can comprise cleaning components and post-
treatment
components. In some embodiments said cleaning components can be selected from
the
group consisting of: surfactants, enzymes and bleach. In some embodiments said
post-
treatment components can be selected from the group consisting of: anti-
redeposition
additives, perfumes and optical brighteners.
[0067] In some embodiments the method can further comprise introducing at
least one
additive into said drum wherein said at least one additive is selected from
the group
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consisting of: builders, chelating agents, dye transfer inhibiting agents,
dispersants,
enzyme stabilizers, catalytic materials, bleach activators, polymeric
dispersing agents, clay
soil removal agents, suds suppressors, dyes, structure elasticizing agents,
fabric
softeners, starches, carriers, hydrotropes, processing aids and pigments.
[0068] The composition of the wash liquor may depend at any given time on the
point
which has been reached in the cleaning cycle for the soiled substrate using
the apparatus
of the invention. Thus, for example, at the start of the cleaning cycle, the
wash liquor may
be water. At later point in the cleaning cycle the wash liquor may include
detergent and/or
one of more of the above mentioned additives. During a cleaning stage of the
cleaning
cycle, the wash liquor may include suspended soil removed from the substrate.
[0069] In some embodiments the method can be carried out so as to achieve a
wash
liquor to substrate ratio of between about 5:1 to 0.1:1 w/w in said drum.
[0070] In some embodiments the ratio of said multiplicity of solid particles
to substrate
being cleaned can be in the range of from about 0.1:1 to about 30:1 w/w.
Brief Description of the Drawinos
[0071] The invention will now be further illustrated by reference to the
following drawings,
wherein:
Figure 1 shows an external view of the cleaning apparatus according to an
embodiment of the invention;
Figures 2 shows a cross-sectional front view of the cleaning apparatus
according to
an embodiment of the invention;
Figure 3 shows a cross-sectional a side view of the cleaning apparatus through
section A-A of the image in figure 2 according to an embodiment of the
invention;
Figure 4 shows a further cross-sectional front view of the cleaning apparatus
including the drum according to an embodiment of the invention;
Figure 5A shows a side cross-sectional view of the door according to an
embodiment
of the invention;
Figure 5B shows a frontal view of the door according to an embodiment of the
invention;
Figure 6 shows an isometric cross-sectional view of the door according to an
embodiment of the invention;
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Figure 7 shows an exploded view of the door and a portion of the tub according
to
an embodiment of the invention;
Figure 8 shows an isometric view of the separator as used in a door or
apparatus to
an embodiment of the invention;
Figure 9 shows a cross-sectional view of a cleaning apparatus according to an
alternative embodiment of the invention.
Detailed Description of the Invention
[0072] The present inventors have addressed the issues associated with using a
cleaning
apparatus to clean soiled substrates with a solid particulate material and
particularly the
problems associated with the need to separate wash liquor from the solid
particulate material
prior to its use in said cleaning apparatus.
[0073] As described herein, "wash liquor" pertains to an aqueous medium used
in the
cleaning apparatus and can comprise water or water when combined with at least
one
cleaning agent such as a detergent composition and/or any further additives as
detailed
further hereinbelow.
[0074] Referring to Figure 1, there is provided a cleaning apparatus (10)
comprising a
housing (80). The housing (80) can comprise an upper portion (80A) and a lower
portion
(80B). In certain embodiments of the invention the housing (80) comprises
therein a rotatably
mounted drum. The drum can be in the form of a rotatably mounted cylindrical
cage (60). In
some embodiments the rotatably mounted cylindrical cage (60) is located in the
upper
portion of the housing (80A). In further embodiments the rotatably mounted
cage is mounted
in a casing or tub (70). The tub (70) can circumferentially surround a portion
of the rotatably
mounted cage (60) and can store wash liquor.
[0075] In certain embodiments of the invention the rotatably mounted
cylindrical cage (60)
can comprise perforated side walls (perforations are shown in Figure 3),
wherein said
perforations comprise holes have a diameter of from 2 to 25mm. In some
embodiments said
perforations can comprise holes having a diameter of from 2 to 10mm. In
further
embodiments said perforations can comprise holes having a diameter of no
greater than
5mm. In yet further embodiments said perforations can comprise holes having a
diameter of
no greater than 3mm.
[0076] In certain embodiments said perforations permit the ingress and egress
of fluids
and fine particulate materials of lesser diameter than the holes, but are
adapted so as to
prevent the egress of said solid particulate material.
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[0077] In other embodiments said perforations permit the ingress and egress of
fluids and
said solid particulate material.
[0078] In some embodiments of the invention the cleaning apparatus (10) can
comprise a
door (20) to allow access to the interior of the rotatably mounted cylindrical
cage (60). In
certain embodiments the door (20) can be hingedly coupled or mounted to a
portion of the
tub (70). The door (20) can be moveable between an open and a closed position.
When the
door (20) is moved to an open position, access is permitted to the inside of
the drum (60).
When the door (20) is moved to a closed position, the cleaning apparatus (10)
is
substantially sealed. Mounting the door (20) to a portion of the tub (70) can,
in some
embodiments, shorten the pumping flow path for when the wash liquor and solid
particulate
material is pumped through the door (20) and into the drum (60) from a sump
(50) located
in the lower portion of the housing (80B). Mounting of the door (20) to the
tub (70) instead
of, for example, mounting the door (20) to the housing or cabinet facilitates
the provision of
a simplified flow path from the sump to the door. If the door were to be
mounted to the
housing, a dynamic link would be required between the sump and the tub
increasing the
complexity of the arrangement.
[0079] In certain embodiments the rotatably mounted cylindrical cage (60) can
be mounted
about an essentially horizontal axis within the housing (80). Consequently, in
such
embodiments of the invention, said door (20) is located in the front of the
cleaning apparatus
(10), thereby providing a front-loading facility.
[0080] Rotation of said rotatably mounted cylindrical cage (60) can be
effected by use of
drive means, which typically can comprise electrical drive means, in the form
of an electric
motor. Operation of said drive means can be effected by control means which
may be
operated by a user.
[0081] In some embodiments the cleaning apparatus of the present invention
can be a
commercial washing machine. In certain embodiments said rotatably mounted
cylindrical
cage (60) can be of the size which is to be found in most commercially
available washing
machines and tumble driers, and can have a capacity in the region of 10 to
7000 litres. A
typical capacity for a domestic washing machine would be in the region of 30
to 150 litres
whilst, for an industrial washer-extractor, capacities anywhere in the range
of from 150 to
7000 litres are possible. A typical size in this range is that which is
suitable for a 50 kg
washload, wherein the drum has a volume of 450 to 650 litres and, in such
cases, said cage
(60) would generally comprise a cylinder with a diameter in the region of 75
to 120cm,
preferably from 90 to 110cm, and a length of between 40 and 100cm, preferably
between
60 and 90cm.
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[0082] In some embodiments the cleaning apparatus of the present invention can
be a
domestic washing machine. Typically said domestic washing machine can comprise
a
rotatably mounted cylindrical cage (60) having a capacity of from 30 to 150
litres. In some
embodiments, the rotatably mounted cylindrical cage (60) can have a capacity
of from 50 to
5 150 litres. Generally the cage (60) of said domestic washing machine will
be suitable for a 5
to 15kg washload. In such embodiments, the rotatably mounted cage (60) can
typically
comprise a cylinder with a diameter in the region of 40 to 60cm and a length
in the region of
25cm to 60cm. In some embodiments the cage can typically have 20 to 25 litres
of volume
per kg of wash load to be cleaned.
10 [0083] In some embodiments the housing (80) or cabinet of the cleaning
apparatus of the
present invention can have a length dimension of from about 40cm to about
120cm, a width
dimension of from about 40cm to about 100cm and a height of from about 70cm to
about
140cm.
[0084] In some embodiments the housing (80) or cabinet of the cleaning
apparatus of the
15 present invention can have a length dimension of from about 50cm to
about 70cm, a width
dimension of from about 50cm to about 70cm and a height of from about 75cm to
about
95cm. In further embodiments, the housing (80) or cabinet of the cleaning
apparatus can
have a length dimension of about 60cm, a width dimension of about 60cm and a
height of
about 85cm. In certain embodiments the cleaning apparatus of the present
invention can
be comparable in size to a typical front-loading domestic washing machine
commonly used
in the Europe.
[0085] In some embodiments the housing (80) or cabinet of the cleaning
apparatus of the
present invention can have a length dimension of from about 50cm to about
100cm, a width
dimension of from about 40cm to about 90cm and a height of from about 70cm to
about
130cm. In further embodiments the housing (80) or cabinet can have a length
dimension of
from about 70cm to about 90cm, a width dimension of from about 50cm to about
80cm and
a height of from about 85cm to about 115cm. In still further embodiments the
housing (80)
or cabinet of the cleaning apparatus can have a length dimension of from about
77.5cm to
about 82.5cm, a width dimension of from about 70cm to about 75cm and a height
of from
about 95cm to about 100cm. In yet still further embodiments the housing (80)
or cabinet of
the cleaning apparatus of the present invention can have a length dimension of
about 71cm
(28 inches), a width dimension of about 80cm (31.5 inches) and a height of
about 96.5cm
(38 inches). In some embodiments the cleaning apparatus of the present
invention can be
comparable in size to a typical front-loading domestic washing machine
commonly used in
the USA.
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[0086] Advantageously, the location of the separator in the door enables the
overall
dimensions of the washing machine to be reduced as separation of solid
particulate material
is no longer necessary at a position external to the housing such as is
adopted in comparable
bead cleaning washing machines known in the art. Furthermore, positioning of
the separator
in the door obviates the need to expand other areas of the housing to
accommodate the
separation device. Consequently, the apparatus of the present invention can
exhibit
dimensionality which is similar or equivalent to conventional domestic washing
machines.
[0087] The cleaning apparatus (10) of the present invention is designed to
operate in
conjunction with soiled substrates and cleaning media comprising a solid
particulate
material, which, in some embodiments, is in the form of a multiplicity of
polymeric or non-
polymeric particles. These polymeric or non-polymeric particles can be
efficiently circulated
to promote effective cleaning and the cleaning apparatus (10), therefore, can
include
circulation means. Thus, the inner surface of the cylindrical side walls of
said rotatably
mounted cylindrical cage (60) can comprise a multiplicity of spaced apart
elongated
protrusions affixed essentially perpendicularly to said inner surface. In some
embodiments,
said protrusions additionally comprise air amplifiers which are typically
driven pneumatically
and are adapted so as to promote circulation of a current of air within said
cage. Typically
said cleaning apparatus (10) can comprise from 3 to 10, preferably 4, of said
protrusions,
which are commonly referred to as lifters.
[0088] In some embodiments the cleaning apparatus (10) can comprise lifters
which can
collect the solid particulate material and transfer it to a lower portion of
the housing (80B).
Particularly said lifters can facilitate transportation of the solid
particulate material to a sump
(50) in said lower portion of the housing (80B). Referring now to Figure 4,
the lifters (68) can
comprise collecting and transferring means (68A) in the form of a plurality of
compartments.
The lifters (68) can be located at equidistant intervals on the inner
circumferential surface of
the rotatably mounted cylindrical cage (60).
[0089] The lifters (68) can comprise a first aperture allowing ingress of
solid particulate
material into a capturing compartment and a second aperture allowing transfer
of said solid
particulate material. The dimensions of the apertures can be selected in line
with the
dimensions of the solid particulate material, so as to allow efficient ingress
and transfer
thereof.
[0090] In operation, agitation is provided by rotation of said rotatably
mounted cylindrical
cage (60) of said cleaning apparatus (10). However, in some embodiments of the
invention,
there is also provided additional agitating means, in order to facilitate the
efficient removal
of residual solid particulate material at the conclusion of the cleaning
operation. In certain
embodiments, said agitating means can comprise an air jet.
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[0091] In some embodiments the cleaning apparatus (10) according to the
invention can
comprise at least one delivery means. The delivery means can facilitate the
entry of wash
liquor constituents (notably water and/or cleaning agents) directly (that is,
otherwise than by
way of the sump 50 and pumping means 52 as herein described below) to the
rotatably
mounted cylindrical cage (60) as required. In further embodiments, the
cleaning apparatus
(10) can comprise a multiplicity of delivery means. Suitable delivery means
can include one
or more spraying means such as spray nozzle (12) as illustrated in Figure 5A.
The delivery
means can deliver, for example, water, one or more cleaning agents or water in
combination
with said one or more cleaning agents. In some embodiments the delivery means
of the
cleaning apparatus (10) can be adapted to first add water to moisten the
substrate before
commencing the wash cycle. In some embodiments the delivery means can be
adapted to
add one or more cleaning agents during the wash cycle. In some embodiments,
the delivery
means can be mounted on a portion of the door (20).
[0092] In certain embodiments the housing (80) can include standard plumbing
features,
in addition to said multiplicity of delivery means, by virtue of which at
least water and,
optionally, cleaning agents such as surfactants, can be circulated and prior
to their
introduction to the rotatably mounted cylindrical cage (60).
[0093] The cleaning apparatus (10) can additionally comprise means for
circulating air
within said housing (80), and for adjusting the temperature and humidity
therein. Said
means may typically include, for example, a recirculating fan, an air heater,
a water atomiser
and/or a steam generator. Additionally, sensing means can also be provided for
determining,
inter alia, the temperature and humidity levels within the cleaning apparatus
(10), and for
communicating this information to control means which can be worked by an
operative.
[0094] In certain embodiments the rotatably mounted cylindrical cage (60) can
be mounted
in said tub (70). Referring to Figure 2, the tub (70) can comprise an upper
portion (70A) and
a lower portion (70B). The rotatably mounted cylindrical cage (60) can be
mounted in the
upper portion (70A) of the tub (70). The upper portion (70A) can be
dimensioned to support
the rotatably mounted cylindrical cage (60) and facilitate mounting thereof.
In certain
embodiments the upper portion (70A) of the tub can comprise a curved portion
(76) that can
circumferentially surround the rotatably mounted cage (60). The tub (70) can
further
comprise a first sidewall (71) and a second sidewall (73) extending from the
curved portion
(76). The first sidewall (71) and second sidewall (73) can be respectively
opposed to each
other and extend from the curved portion (76) to the base of the tub (72).
Furthermore, the
first and second sidewalls (71, 73) can each comprise a linear portion.
[0095] In some embodiments the lower portion (70A) of the tub (70) can include
a sump
(50). The sump (50) can function as a chamber for retaining the solid
particulate material.
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The sump (50) can further contain water and/or one or more cleaning agents.
The sump (50)
can further comprise heating means allowing its contents to be raised to a
preferred
temperature for use in the cleaning operation. The heating means can comprise
one or more
heater pads attached to the outer surface of the sump (50).
[0096] Thus, in some embodiments, the sump (50) may be integrally formed with
the tub
(70) such that the sump (50) and the tub (70) can comprise a single unit.
Advantageously,
the inclusion of a combined sump and tub arrangement in the above noted
embodiments
can facilitate the ease of transport of the solid particulate from the sump
(50) to the drum
(60).
[0097] In some embodiments the unitary nature of the tub (70) can enable the
upper
portion (70A) containing the drum (60) and the lower portion (70B) comprising
the sump (50)
to move together as one body in response to vibrations induced by rotation of
the drum (60).
The cleaning apparatus (10) can therefore further comprise one or more dampers
connected
to the tub (70) to reduce the extent to which vibrations from the drum are
transmitted to the
housing (80). The one or more dampers can be connected to the lower portion
(70B) of the
tub (70). As shown in Figure 2, the cleaning apparatus can comprise a first
damper (62)
connected to the first sidewall (71) and a second damper (64) connected to the
second
sidewall (73) of the tub (70). Thus, in some embodiments, the cleaning
apparatus can
comprise a plurality of dampers connected to the tub (70).
[0098] In certain embodiments, and as illustrated in Figures 2 and 3, the sump
(50) can be
defined in the lower portion (70B) of the tub (70) between a front wall (78),
a rear wall (74),
first and second sidewalls (71, 73) and the base (72) of the tub (70). In
further embodiments
the sump (50) can comprise a first end (56) and a second end (58). The first
end (56) can
be towards the front of the cleaning apparatus (10) adjacent to the front wall
(78) of the tub
(70) and proximate to the door (20). The second end (58) can be towards the
rear of the
cleaning apparatus (10) distal to the door (20) and adjacent to the rear wall
(74) of the tub
(70). In some embodiments the base of the tub (70) or the floor of the sump
(50) can be
sloped. The floor can be sloped such that the solid particulate material is
directed towards
the first end (56) of the sump (50). Thus, in some embodiments, the floor may
be inclined
downwardly from the second end (58) in the direction of the first end (56).
The inclusion of
the sloping floor can ensure that any solid particles residing in the sump
(50) are localised
predominantly in the region of the first end (56). Advantageously this feature
can facilitate
the effective emptying of the sump (50) and ease of recirculation of the solid
particulate
cleaning material.
[0099] In certain embodiments the sump (50) can be enlarged in comparison to
those
found in conventional domestic washing machines. In such embodiments the
distance
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between the drum (60) and the base (72) of the tub (70) can be at least 10cm.
Advantageously, this can allow for a greater capacity to retain the solid
particulate material
for use in the cleaning apparatus.
[00100] Typically, in some embodiments, the sump (50) can comprise said solid
particulate
material prior to first use of the cleaning apparatus (10). In operation,
water can be added to
the solid particulate material in the sump (50). When a threshold or desired
volume of water
is present in the sump (50), the water and solid particulate material can be
pumped through
the door (20) and into the rotatably mounted cylindrical cage (60). During the
wash cycle,
water and/or one or more cleaning agents can be added from the delivery means
into the
rotatably mounted cage (60) and ultimately any fluids can be transferred (e.g.
via
perforations in the walls of the rotatably mounted cage) to the sump (50).
Thus, during the
course of the wash cycle, the contents of the sump (50) can comprise water in
combination
with one or more cleaning agents and the solid particulate material.
[00101] The cleaning apparatus (10) can comprise pumping means (52) to pump
wash
liquor and the solid particulate material. In some embodiments pumping means
(52) can be
located in the lower portion of the housing (80B). In some embodiments the
pumping means
(52) can be located in or can be connected to the sump (50). In further
embodiments the
sump (50) can comprise pumping means (52). In some embodiments the pumping
means
(52) can be located proximate to the first end (56) of the sump (50). In
certain embodiments
the pumping means (52) can be located beneath the door (20). In certain
embodiments the
pumping means (52) can be adapted to pump wash liquor in combination with the
solid
particulate material from the sump (50) to the door (20). Positioning of the
pumping means
(52) proximate said first end of the sump (50) can advantageously facilitate a
short pumping
path for the introduction of the solid particulate material into the drum (60)
via the door (20).
[00102] The cleaning apparatus (10) can thus comprise means to recirculate the
wash
liquor and the solid particulate material. The solid particulate material can
be recirculated
from the lower portion of the housing (80B) to the upper portion of the
housing (80A).
Recirculation of the solid particulate material enables its re-use in the
cleaning operation. In
some embodiments, the solid particulate cleaning material can be recirculated
along a path
between the sump (50) and the rotatably mounted cylindrical cage (60). To
facilitate
transport of said solid particulate material along said recirculation path,
the cleaning
apparatus (10) can comprise ducting (40) extending from a lower portion of the
housing
(80B). The pumping means (52) can be adapted to pump said solid particulate
material and
wash liquor along said recirculation path via the ducting (40).
[00103] In certain embodiments of the invention, the cleaning apparatus (10)
can comprise
a door (20) wherein the door (20) comprises a separator (90) to facilitate
separation of liquid
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from solid particulate material in a flow pathway and particularly wherein
said liquid
comprises wash liquor.
[00104] In some embodiments the door (20) can be in the form of an assembly
comprising
several components. Referring now to Figures 1, 5A, 5B, 6 and 7 the door (20)
can comprise
5 an outer portion (22) and an inner portion (24). In some embodiments the
separator (90) can
be located in the inner portion (24) of the door (20). In some embodiments the
door (20) can
comprise a door ring (28), an inner face (28a) and an outer face (28b). The
inner portion
(24) of the door (20) can comprise a first segment (28c) and a second segment
(28d)
upstanding from the inner face (28a). The first segment (28c) and the second
segment (28d)
10 can each respectively comprise a sloping wall joined to a substantially
vertical wall. The
vertical walls of each segment (28c, 28d) can be spaced apart by a gap that
defines a
channel (26) extending from the centre of the inner portion (24). In further
embodiments the
door (20) can comprise a window (28e) enabling a user to see within the
rotabably mounted
cage (60) when the cleaning apparatus (10) is in use. In some embodiments
portions of the
15 door (20) can be constructed of transparent material. In this way, the
separator (90) can be
seen during the operation of the cleaning apparatus (10).
[00105] In certain embodiments the door (20) can comprise a separating
assembly (30).
The separating assembly (30) can be received by or coupled to the inner
portion (24) of the
door (20). In certain embodiments the separating assembly (30) can comprise a
feed pipe
20 (34) and a separator (90) wherein the feed pipe (34) is connected to the
separator (90). In
some embodiments there can be defined an internal space or cavity (31) within
the inner
portion (24) of the door (20) between the components of the separating
assembly (30) and
the inner face (28a).
[00106] In some embodiments, the separating assembly (30) can comprise a
connecting
element (32) that is sized and shaped to receive both the feed pipe (34) and
the separator
(90). Thus the connecting element (32) can comprise a first coupling member
(37a) and a
second coupling member (37b) adapted to respectively receive the first end and
the second
end of the feed pipe (34). The connecting element (32) can further comprise a
wall member
(36) which can extend alongside, and in spaced apart relation to, the feed
pipe (34). In
certain embodiments the connecting element (32) can comprise an upper surface
comprising a cut-out (38) dimensioned to receive the separator (90).
[00107] As shown in Figure 7, the inner portion (24) of the door (20) can be
dimensioned
such that it is received by a throat (77) of the tub (70) when the door (20)
is moved to a
closed position. The throat of the tub (70) can comprise an aperture (77A)
formed therein.
In some embodiments the feed pipe (34) of the separating assembly (30) can
comprise a
first end proximate the aperture (77A) formed in the tub (70) and a second end
connected
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to the separator (90). In some embodiments the first end of the feed pipe (34)
can be in
registry with the aperture (77A) of the tub (70).
[00108] In certain embodiments, when the door (20) is moved to a closed
position, wash
liquor in combination with the solid particulate material can be pumped from a
lower portion
of the housing (80B) to the separating assembly (30) via ducting (40). Thus,
in some
embodiments, the aperture (77A) of the tub (70) can be in alignment with an
end portion of
the ducting (40). When the door (20) is moved to a closed position a flow path
can therefore
be defined through ducting (40) and feed pipe (34) via aperture (77A). The
door (20) can
further comprise a sealing ring (42) disposed between the aperture (77A) and
the flow pipe
(34).
[00109] In certain embodiments, as noted above, the door (20) can comprise a
separator
(90). Referring now to Figure 8, the separator (90) can comprise an inlet (92)
and an outlet
(94). The inlet (90) can be adapted to receive wash liquor and said solid
particulate material
from the feed pipe (34).
[00110] The separator (90) can further comprise a body (96) extending between
the inlet
(92) and the outlet (94). The body (96) can comprise a plurality of apertures
(98) formed
therein. The plurality of apertures (98) can be sized and shaped to permit the
passage of
liquid therethrough but not the solid particulate material. In some
embodiments, each of said
of apertures (98) can have a length dimension in the region of from about 20mm
to about
40mm and a width dimension in the region of from about 1.5mm to about 3mm.
[00111] In further embodiments the separator can comprise a plurality of
apertures that are
arranged or dimensioned to capture lint and/or unwanted fine particulate
matter arising from
the cleaning process. In these embodiments a portion of the body of the
separator can
comprise or can be in the form of a mesh. In some embodiments the maximum
dimension
of the holes/apertures in the mesh are about 1.5mm or about 1mm or smaller.
Examples of
suitable mesh types that can be used include those with 12 holes per inch with
54.1% open
area or 18 holes per inch with 53.7% open area. In certain embodiments, the
apertures of
the separator are thus small enough to capture lint and/or other unwanted fine
particulate
matter entrained in the wash liquor.
[00112] In certain embodiments the body (96) of the separator (90) can
comprise a
substantially curved region and the plurality of apertures (98) can be formed
in said curved
region. In some embodiments the curved region of the body (96) comprises an
outer curved
portion (96b) and an inner curved portion (96a).
[00113] In further embodiments an alternative construction can be provided for
the body of
the separator (90). In such embodiments, the body (96) can comprise a first
planar wall
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member joined to a second planar wall member at a common point. The second
planar wall
member is angled or inclined with respect to the first planar wall member.
Preferably, the
second planar wall member is located upstream of said first planar wall member
wherein
upstream refers to the direction of flow of wash liquor and solid particles
through the
separator (90). Thus, the second planar wall member can be located nearer to
the outlet
(94) than the first planar wall member. A plurality of apertures (98) are
formed in a portion
of the second planar wall member. In some embodiments, the angle at which the
second
planar wall member is inclined with respect to the first planar wall member
can be between
about 60 and about 120 . In some embodiments the angle at which the second
planar wall
member is inclined with respect to the first planar wall member is about 90 .
[00114] In some embodiments, when the cleaning apparatus (10) is in use, wash
liquor
combined with the solid particulate material from the sump (50) is transported
to the
separating assembly (30) in the door (20). Thus wash liquor and the solid
particulate material
is pumped from the sump (50), along the ducting (40) and upwardly into the
feed tube (34).
Wash liquor and the solid particulate material can then continue substantially
vertically along
the feed tube (34) to the separator (90). Wash liquor is permitted to exit
through the plurality
of apertures (98) formed in the body (96) of the separator (90) however, as
the solid
particulate material is too large to exit via said apertures, the solid
particulate material is
deflected by the internal surface of the body (96) towards the outlet (94). In
this manner,
separation of at least a portion of the wash liquor from the solid particulate
material can be
achieved.
[00115] In some embodiments the separator (90) can direct at least 1 percent
by mass of
wash liquor entering via inlet (92) to a location so as to not enter the drum
(60) with the solid
particulate material. In certain embodiments the separator (90) can direct at
least 10 percent
by mass of wash liquor entering via inlet (92) to a location so as to not
enter the drum (60).
In further embodiments the separator (90) can direct at least 25 percent by
mass of wash
liquor entering via inlet (92) to a location so as to not enter the drum (60).
In yet further
embodiments the separator (90) can direct at least 40 percent, in still
further embodiments
at least 50 percent, in yet still further embodiments at least 70 percent and
in yet still further
embodiments at least 90 percent by mass of wash liquor entering via inlet (92)
to a location
so as to not enter the drum (60). In other embodiments the separator (90) can
direct at least
95 percent by mass of wash liquor entering via inlet (92) to a location so as
to not enter the
drum (60). In certain embodiments wash liquor is directed to a location so as
to not enter
the drum (60) via the plurality of apertures (98).
[00116] In some embodiments the separator (90) can be arranged to direct no
greater than
99 percent by mass of wash liquor entering via inlet (92) to a location so as
to not enter the
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23
drum (60) with the solid particulate material. Thus, in some embodiments, up
to 1 percent
by mass of wash liquor entering via inlet (92) is permitted to enter the drum.
In some
embodiments, the separator (90) can be arranged to direct no greater than 90
percent by
mass of wash liquor entering via inlet (92) to a location so as to not enter
the drum (60) with
the solid particulate material. Thus, in further embodiments, up to 10 percent
by mass of
wash liquor entering via inlet (92) is permitted to enter the drum. Thus in
some embodiments
a limited amount of the wash liquor from the flow pathway is permitted to
enter the drum.
The entry of a restricted amount of wash liquor into said drum can
advantageously facilitate
moistening of the soiled substrates for the cleaning operation.
[00117] In certain embodiments, wash liquor exiting the separator (90) through
the
plurality of apertures (98) can be directed into the cavity (31). The
separated wash liquor
can then flow along a downward flow path defined by the channel extending from
the
centre of the inner portion(24) of the door (20) and between the first and
second segments
(28c, 28d). The sloping walls of the first and second segments (28c, 28d) can
serve to
funnel fluid exiting from the plurality of apertures (98) of the separator
(90) into said
channel. In further embodiments separated wash liquor that does not enter the
drum (60)
can also flow along a further downward flowpath in the region between the feed
pipe (34)
and the wall member (36) of the connecting element (32).
[00118] Notably the action of the separator (90) in the present application is
distinguished
from the mode of operation of the bead separation vessel disclosed in the
above-cited prior
art document W02011/098815. In W02011/098815, the separation vessel comprises
a gate
valve and filtering arrangement to first enable water to drain from the mass
of solid
particulate material before the gate valve is actuated to release the solid
particulate material
into a delivery tube to be fed into the drum. Thus the flow of solid
particulate material is first
arrested to allow water to drain before the solid particulate material can be
delivered to the
drum. By contrast, the cleaning apparatus of the present application can, in
some
embodiments, provide a direct pathway from the lower portion of the housing
(80B) and into
the drum (60) as there is no requirement to intercept the solid particulate
material along said
pathway for the purpose of draining water.
[00119] In some embodiments, the door (20) can comprise an outlet or drain
(44) to enable
wash liquor to be returned to a lower portion of the housing (80B) following
its passage
through the separator (90). The drain (44) can thus be positioned downstream
from the
separator (90) ((by comparison upstream of the separator (90) would encompass,
for
example, the feed pipe (34)). Furthermore, the drain (44) can provide a route
for said wash
liquor to flow to the sump (50). In certain embodiments the drain (44) can be
located
proximate to the aperture (77A) of the tub (70). The tub (70) can comprise a
recess (79)
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24
adjacent to said aperture (77A) to permit wash liquor to flow to the sump
(50). The inclusion
of such drainage means promotes efficient use of water in the apparatus.
[00120] In some embodiments, the outlet (94) of the separator (90) is arranged
such that,
following deflection from the internal surface of the body (96), the solid
particulate material
is directed into the rotatably mounted cylindrical cage (60). In some
advantageous
embodiments, said curved or angled (e.g. wherein the separator (90) comprises
a second
planar wall member inclined with respect to a first planar wall member) region
of the body
(96) of the separator (90) improves the separation of the solid particulate
material by
enabling wash liquor and solid particulate material to adopt different
directional paths. The
path of wash liquor exiting from the separator (90) via said apertures (98) is
shown by arrow
B and the path of solid particulate material exiting the separator (90) via
the outlet (94) is
shown by arrow A in Figure 8. In some embodiments the outlet of the separator
(94) can be
arranged to direct the solid particulate material into the centre of the drum
(60). In certain
embodiments at least some of the solid particulate material, and preferably
most or all of the
solid particulate material, exits the separator (90) via the outlet (94) at an
angle of between
about 60 and about 120 to the path of wash liquor and solid particulate
material entering
the separator at inlet (92). In certain embodiments said angle at which the
solid particulate
material exits the separator outlet (94) is about 90 to the path of wash
liquor and solid
particulate material entering the separator at inlet (92). In further
embodiments the path of
wash liquor and solid particulate material entering the separator at inlet
(92) is substantially
vertical.
[00121] Advantageously, the action of the separator (90) can facilitate the
direction of the
solid particulate material into the centre of the washload contained in the
cage (60) whilst
simultaneously facilitating the direction of wash liquor towards a convenient
return path for
drainage and/or re-use. Thus, separated wash liquor exiting via the plurality
of apertures
(96) can be directed into the cavity (31) and along a downward path through
the door (20)
and towards the sump (50).
[00122] In some embodiments, the separator (90) is removable from the
separating
assembly (30). Thus the separator (90) can, in some embodiments, be easily
detached from
the connecting element (32). Advantageously, this enables routine maintenance
to be
carried out on the separator (90) and facilitates its simple replacement if
such an operation
is necessary. In embodiments wherein the separator (90) is configured to
capture lint and
other unwanted fine particulate matter, the separator (90) can be periodically
removed and
inspected after each cleaning cycle or after a set number of cleaning cycles
performed with
the cleaning apparatus. If necessary, the separator (90) can be subjected to a
cleaning
operation following its removal from the separating assembly in order to
detach any
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unwanted materials that may have built up within the device. In such
embodiments the
separator can thus advantageously serve dual purposes by separating wash
liquor from
solid particles and in capturing lint and other unwanted fine particulate
matter.
[00123] An alternative embodiment of the cleaning apparatus (10B) is shown in
Figure 9.
5 The apparatus (10B) includes a housing (80) and drum (60) such as that
described above.
By contrast, the door (20B) of the apparatus comprises a shroud (22B) within
which an
alternative separating device (90B) is located. The shroud (22B) can be
configured to
provide a sealing arrangement such that wash liquor and solid particulate
material can only
enter and exit the door (20B) via flow paths defined therein. The separating
device (90B)
10 can be in the form of plate comprising a curved portion and a plurality
of apertures formed
therein. The apertures can have the same dimensions as those referred to for
the separating
device (90) above.
[00124] The separating device (90B) can receive a flow of wash liquor and
solid particulate
material from a feeding device (35) via ducting (40B). The ducting (40B) can
extend over a
15 top portion of the housing (80) and is connected to a pumping device
(not shown). The
feeding device (35) can be in the form of a feed nozzle. The feeding device
directs a flow of
wash liquor and solid particulate material towards the separating device (90B)
which enables
wash liquor to pass through. Solid particles are however directed into the
interior of the drum
(60) in the general direction of arrow B by virtue of the curved plate. In
some embodiments
20 the flow of wash liquor and solid particles can be directed towards the
separating plate at a
specified angle to improve separation. The angle at which the flow of wash
liquor and solid
particles are directed towards the plate for the embodiment illustrated in
Figure 9 is about
with respect to the vertical.
[00125] Wash liquor separated from the solid particles may contact one or more
interior
25 walls of the shroud (22B) before flowing in the general direction of
arrow A. In addition, the
door (20B) can further comprise a drain or ducting (44B) connected to the
shroud (22B) to
provide a return path for wash liquor to return to the sump (not shown).
[00126] The alternative described embodiment facilitates a different route for
delivery of
wash liquor and solid particulate to the door (20B). For example, wash liquor
and solid
30 particles can thus be pumped upwardly from the pumping device and over a
top portion of
the housing (80) before reaching the separator (90B) contained within the door
(20B).
Furthermore, wash liquor and solid particulate material pass through an
exterior portion of
the door (20B) to be received by the separator (90B) along a downward path.
[00127] Further arrangements are also permissible whereby the ducting (40B)
instead
extends around a side wall of the housing (80). In these embodiments, the
ducting (40B)
can first extend through an exterior side wall of the shroud (22B) before
extending upwardly
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26
and then curving downwardly to deliver wash liquor and solid particulate
material to the
separator (90B) in the manner described above. A wall of the shroud (22B) can
include
hinged sealing means through which the ducting (40B) can pass.
[00128] Although not shown in the Figures, other arrangements for the door
(20B) and
separator (90B) may be permissible to provide alternative flow paths for the
wash liquor and
solid particulate material. The separator (90B) and associated flow paths can
thus be
arranged so that the separator (90B) receives a horizontal flow of wash liquor
and solid
particles. Solid particles from said horizontal flow can be directed into the
drum by the
separator (90B).
[00129] Despite the existence of said alternative embodiments providing
different flow
paths, preferred arrangements for the invention are those associated with the
receipt of an
upward flow of wash liquor and solid particulate material by the separating
device. This type
of configuration can help to provide the most efficient pumping route for the
solid particles
to enter the drum.
[00130] The cleaning apparatus according to the invention is principally
designed for use in
the cleaning of substrates comprising a textile material, in particular one or
more garments,
linens, napery, towels or the like. The cleaning apparatus of the invention
has been shown
to be particularly successful in achieving efficient cleaning of textile
fibres which may, for
example, comprise either natural fibres, such as cotton, wool, silk or man-
made and
synthetic textile fibres, for example nylon 6,6, polyester, cellulose acetate,
or fibre blends
thereof.
[00131] The solid particulate material for use in the invention can comprise a
multiplicity of
polymeric particles or a multiplicity of non-polymeric particles. In some
embodiments, the
solid particulate material can comprise a multiplicity of polymeric particles.
Alternatively,
the solid particulate material can comprise a mixture of polymeric particles
and non-
polymeric particles. In other embodiments, the solid particulate material can
comprise a
multiplicity of non-polymeric particles. Thus the solid particulate material
in embodiments
of the invention can comprise exclusively polymeric particles, exclusively non-
polymeric
particles or mixtures of polymeric and non-polymeric particles.
[00132] The polymeric particles or non-polymeric particles can be of such a
shape and
size as to allow for good flowability and intimate contact with the substrate
and particularly
with textile fibre. A variety of shapes of particles can be used, such as
cylindrical,
ellipsoidal, spheroidal, spherical or cuboid; appropriate cross-sectional
shapes can be
employed including, for example, annular ring, dog-bone and circular. In some
embodiments, the particles can comprise generally cylindrical or spherical
beads.
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[00133] The polymeric particles or non-polymeric particles can have smooth or
irregular
surface structures and can be of solid, porous or hollow structure or
construction.
[00134] In some embodiments the polymeric particles can be of such a size as
to have an
average mass of about 1mg to about 70mg. In certain embodiments the polymeric
particles can be of such a size as to have an average mass of about 1mg to
about 50mg.
In further embodiments the polymeric particles can be of such a size as to
have an
average mass of about 1mg to about 35mg. In yet further embodiments the
polymeric
particles can be of such a size as to have an average mass of about 10mg to
about 30mg.
In still further embodiments the polymeric particles can be of such a size as
to have an
average mass of about 12mg to about 25mg.
[00135] In some embodiments the non-polymeric particles can be of such a size
as to
have an average mass of about 1mg to about 1g. In further embodiments the non-
polymeric particles can be of such a size as to have an average mass of about
10mg to
about 100mg. In still further embodiments the non-polymeric particles can be
of such a
size as to have an average mass of about 25mg to about 100mg.
[00136] In some embodiments the polymeric or non-polymeric particles can have
a
surface area of 10mm2 to 120mm2. In further embodiments the polymeric or non-
polymeric
particles can have a surface area of 15mm2 to 50mm2. In still further
embodiments the
polymeric or non-polymeric particles can have a surface area of 20mm2 to
40mm2.
[00137] In some embodiments the polymeric particles can have an average
density in the
range of from about 0.5 to about 2.5g/cm3. In further embodiments the
polymeric particles
can have an average density in the range of from about 0.55 to about 2.0g/cm3.
In still
further embodiments the polymeric particles can have an average density in the
range of
from about 0.6 to about 1.9g/cm3.
[00138] In certain embodiments the non-polymeric particles can have an average
density
greater than the polymeric particles. Thus, in some embodiments, the non-
polymeric
particles can have an average density in the range of about 3.5 to about
12.0g/cm3. In still
further embodiments, the non-polymeric particles can have an average density
in the
range of about 5.0 to about 10.0g/cm3. In yet further embodiments, the non-
polymeric
particles can have an average density in the range of about 6.0 to about
9.0g/cm3.
[00139] In some embodiments the average volume of the polymeric and non-
polymeric
particles is in the range of 5 to 275mm3. In further embodiments the average
volume of the
polymeric and non-polymeric particles is in the range of 8 to 140mm3 and in
still further
embodiments said average volume is in the range of 10 to 120mm3.
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[00140] In some embodiments the solid particles can have an average
particle
diameter of from 1.0mm to lOmm. In further embodiments the solid particles can
have an
average diameter of from 2.0mm to 8.0mm. In yet further embodiments the solid
particles
have an average diameter of from 2.0mm to 6.0mm. The effective average
diameter can
also be calculated from the average volume of a particle by simply assuming
the particle is
a sphere. The average is preferably a number average. The average is
preferably
performed on at least 10, more preferably at least 100 particles and
especially at least
1000 particles.
[00141] In some embodiments the solid particles can have a length of
from 1.0mm
to 10mm. In further embodiments the solid particles can have a length of from
2.0mm to
8.0mm. In yet further embodiments the solid particles can have a length of
from 2.0mm to
6.0mm. The length can be defined as the maximum 2 dimensional length of each 3
dimensional solid particle. The average is preferably a number average. The
average is
preferably performed on at least 10, more preferably at least 100 particles
and especially
at least 1000 particles.
[00142] In some embodiments the polymeric or non-polymeric particles can be
substantially cylindrical or substantially spherical in shape.
[00143] In certain embodiments the cylindrical particles can be of oval cross
section. In
such embodiments, the major cross section axis length, a, can be in the region
of from 2.0
to 6.0mm. In further embodiments a can be in the region of from 2.2 to 5.0mm
and in still
further embodiments a can be in the region of from 2.4mm to 4.5mm. The minor
cross
section axis length, b, can be in the region of from 1.3 to 5.0mm. In further
embodiments b
can be in the region of from 1.5 to 4.0mm and in still further embodiments b
can be in the
region of from 1.7mm to 3.5mm. For an oval cross section, a> b. In certain
embodiments
the length of the cylindrical particles, h, can be in the range of from about
1.5mm to about
6mm. In further embodiments the length h can be from about 1.7mm to about
5.0mm. In
yet further embodiments the length h of the particle can be from about 2.0mm
to about
4.5mm. The ratio hlb can typically be in the range of from 0.5-10.
[00144] In certain embodiments the cylindrical particles can be of circular
cross section. The
typical cross section diameter, ck, can be in the region of from 1.3 to 6.0mm.
In further
embodiments d can be in the region of from 1.5 to 5.0mm and in still further
embodiments
can be in the region of from 1.7mm to 4.5mm. In certain embodiments the length
of such
particles, hc, can be in the range of from about 1.5mm to about 6mm. In
further embodiments
the length h, can be from about 1.7mm to about 5.0mm. In yet further
embodiments the
length of the particle h, can be from about 2.0mm to about 4.5mm. The ratio
kid, can
typically be in the range of from 0.5-10.
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[00145] In some embodiments of the invention the particles can be generally
spherical in
shape (but not a perfect sphere) having a particle diameter, cis, in the
region of from 2.0 to
8.0mm. In further embodiments cis can be in the region of from 2.2 to 5.5mm
and in still
further embodiments cis can be in the region of from about 2.4mm to about
5.0mm.
[00146] In certain embodiments of the invention the particles can be perfectly
spherical in
shape having a particle diameter, dps, in the region of from 2.0 to 8.0mm. In
further
embodiments dps can be in the region of from 3.0 to 7.0mm and in still further
embodiments
dps can be in the region of from about 4.0mm to about 6.5mm.
[00147] In some embodiments the polymeric particles can comprise polyalkenes
such as
polyethylene and polypropylene, polyamides, polyesters, polysiloxanes or
polyurethanes.
Furthermore, said polymers can be linear, branched or crosslinked. In certain
embodiments, said polymeric particles can comprise polyamide or polyester
particles,
particularly particles of nylon, polyethylene terephthalate or polybutylene
terephthalate,
typically in the form of beads. Said polyamides and polyesters are found to be
particularly
effective for aqueous stain/soil removal, whilst polyalkenes are especially
useful for the
removal of oil-based stains.
[00148] Various nylon homo- or co-polymers can be used including, but not
limited to,
Nylon 6 and Nylon 6,6. In some embodiments, the nylon can comprise Nylon 6,6
copolymer having a molecular weight in the region of from about 5000 to about
30000
Da!tons, such as from about 10000 to about 20000 Da!tons, or such as from
about 15000
to about 16000 Da!tons. Useful polyesters can have a molecular weight
corresponding to
an intrinsic viscosity measurement in the range of from about 0.3 to about 1.5
dl/g, as
measured by a solution technique such as ASTM D-4603.
[00149] In some embodiments the polymeric particles can comprise foamed
polymers. In
further embodiments the polymeric particles can comprise unfoamed polymers.
[00150] Optionally, copolymers of the above polymeric materials may be
employed for the
purposes of the invention. Specifically, the properties of the polymeric
materials can be
tailored to specific requirements by the inclusion of monomeric units which
confer particular
properties on the copolymer. Thus, the copolymers can be adapted to attract
particular
staining materials by including monomer units in the polymer chain which,
inter alia, are
ionically charged, or include polar moieties or unsaturated organic groups.
Examples of
such groups can include, for example, acid or amino groups, or salts thereof,
or pendant
alkenyl groups.
[00151] In some embodiments the non-polymeric particles can comprise particles
of glass,
silica, stone, wood, or any of a variety of metals or ceramic materials.
Suitable metals
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include, but are not limited to, zinc, titanium, chromium, manganese, iron,
cobalt, nickel,
copper, tungsten, aluminium, tin and lead, and alloys thereof. Suitable
ceramics include,
but are not limited to, alumina, zirconia, tungsten carbide, silicon carbide
and silicon nitride.
[00152] In further embodiments the present invention provides a method for
cleaning a
5 soiled substrate using the cleaning apparatus as herein described wherein
the method can
comprise the treatment of the substrate with a formulation comprising said
solid particulate
material and wash liquor.
[00153] In order to provide additional lubrication to the cleaning apparatus
and thereby
improve the transport properties within the system, wash liquor, which can be
water, is
10 added. Thus, more efficient transfer of the cleaning material to the
substrate is facilitated,
and removal of soiling and stains from the substrate occurs more readily. The
solid
particulate material can thus elicit a cleaning effect on the substrate and
water can simply
aid the transport of said solid particulate material. Optionally, the soiled
substrate may be
moistened by wetting with mains or tap water prior to loading into the
cleaning apparatus of
15 the invention. Wetting of the substrate within the apparatus of the
invention is preferable. In
any event, water can be added to the rotatably mounted cylindrical cage (60)
of the invention
such that the washing treatment is carried out so as to achieve a wash water
or wash liquor
to substrate ratio in the cage (60) which, in some embodiments is between 5:1
and 0.1:1
w/w. In certain embodiments the wash liquor to substrate ratio is between
2.5:1 and 0.1:1
20 w/w. In further embodiments the ratio is between 2.0:1 and 0.8:1. By
means of example,
particularly favourable results have been achieved at ratios such as 1.75:1,
1.5:1, 1.2:1 and
1.1:1. Most conveniently, the required amount of water can be introduced into
the rotatably
mounted cylindrical cage (60) of the apparatus according to the invention
after loading of
the soiled substrate into said cage.
25 [00154] In some embodiments the wash liquor to substrate ratio can be
maintained between
pre-determined limits throughout the wash cycle. The predetermined limits may
be different
in different stages of the wash cycle. In embodiments noted above wherein the
mass of
wash liquor separated from the solid particulate material by the action of the
separator is
less than 100 percent, an additional amount of water can migrate into the cage
(drum) (60)
30 during the addition of the solid particulate material through the
separating assembly (30).
However the amount of additional water permitted to enter the cage (60) is
regulated due to
the action of the separator (90) and the required wash liquor to substrate
ratio can be
effectively maintained throughout the wash cycle within an acceptable limit.
For example, if
the wash liquor to substrate ratio is between 2.5:1 and 0.1:1, the action of
the separator can
ensure that the extremes of this range are not exceeded during the wash cycle.
Advantageously the separator can therefore serve to maintain the desired wash
liquor to
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31
substrate ratio by substantially limiting excess water from entering the cage
during the wash
cycle.
[00155] Whilst, in some embodiments, the method of the invention envisages the
cleaning
of a soiled substrate by the treatment of a moistened substrate with only
solid particulate
material (i.e. in the absence of any further additives) optionally in other
embodiments the
formulation employed can additionally comprise at least one cleaning agent.
The at least
one cleaning agent can include at least one detergent composition. In some
embodiments
said at least one cleaning agent can be introduced into the drum of the
cleaning apparatus
before or following commencement of the wash cycle. In other embodiments said
particles
comprised in said solid particulate material can be coated with said at least
one cleaning
agent.
[00156] The principal components of the detergent composition can comprise
cleaning
components and post-treatment components. In some embodiments, the cleaning
components can comprise surfactants, enzymes and bleach, whilst the post-
treatment
components can include, for example, anti-redeposition additives, perfumes and
optical
brighteners.
[00157] However, the formulations for use in the method of the invention can
further
optionally include one or more other additives such as, for example builders,
chelating
agents, dye transfer inhibiting agents, dispersants, enzyme stabilizers,
catalytic materials,
bleach activators, polymeric dispersing agents, clay soil removal agents, suds
suppressors,
dyes, structure elasticizing agents, fabric softeners, starches, carriers,
hydrotropes,
processing aids and/or pigments.
[00158] Examples of suitable surfactants that can be included in the detergent
composition
can be selected from non-ionic and/or anionic and/or cationic surfactants
and/or ampholytic
and/or zwitterionic and/or semi-polar nonionic surfactants. The surfactant can
typically be
present at a level of from about 0.1%, from about 1%, or even from about 5% by
weight of
the cleaning compositions to about 99.9%, to about 80%, to about 35%, or even
to about
30% by weight of the cleaning compositions.
[00159] The detergent composition can include one or more detergent enzymes
which
provide cleaning performance and/or fabric care benefits. Examples of suitable
enzymes
include, but are not limited to, hemicellulases, peroxidases, proteases, other
cellulases,
other xylanases, lipases, phospholipases, esterases, cutinases, pectinases,
keratanases,
reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases,
tannases,
pentosanases, malanases, [beta]-glucanases, arabinosidases, hyaluronidase,
chondroitinase, laccase, and amylases, or mixtures thereof. A typical
combination can
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32
comprise a mixture of enzymes such as protease, lipase, cutinase and/or
cellulase in
conjunction with amylase.
[00160] Optionally, enzyme stabilisers can also be included amongst the
cleaning
components. In this regard, enzymes for use in detergents may be stabilised by
various
techniques, for example by the incorporation of water-soluble sources of
calcium and/or
magnesium ions in the compositions.
[00161] The detergent composition can include one or more bleach compounds and
associated activators. Examples of such bleach compounds include, but are not
limited to,
peroxygen compounds, including hydrogen peroxide, inorganic peroxy salts, such
as
perborate, percarbonate, perphosphate, persilicate, and mono persulphate salts
(e.g.
sodium perborate tetrahydrate and sodium percarbonate), and organic peroxy
acids such
as peracetic acid, monoperoxyphthalic acid, diperoxydodecanedioic acid, N,N'-
terephthaloyl-di(6-aminoperoxycaproic acid), N,N'-phthaloylaminoperoxycaproic
acid and
amidoperoxyacid. Bleach activators include, but are not limited to, carboxylic
acid esters
such as tetraacetylethylenediamine and sodium nonanoyloxybenzene sulphonate.
[00162] Suitable builders can be included as additives andinclude, but are not
limited to, the
alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali
metal
silicates, alkaline earth and alkali metal carbonates, aluminosilicates,
polycarboxylate
compounds, ether hydroxypolycarboxylates, copolymers of maleic anhydride with
ethylene
or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and
carboxymethyl-
oxysuccinic acid, various alkali metal, ammonium and substituted ammonium
salts of
polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic
acid, as well as
polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid,
polymaleic acid,
benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble
salts thereof.
[00163] The additives can also optionally contain one or more copper, iron
and/or
manganese chelating agents and/or one or more dye transfer inhibiting agents.
[00164] Suitable polymeric dye transfer inhibiting agents for use in the
detergent
composition include, but are not limited to, polyvinylpyrrolidone polymers,
polyamine N-
oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole,
polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof.
[00165] Optionally, the detergent composition can also contain dispersants.
Suitable water-
soluble organic materials are the homo- or co-polymeric acids or their salts,
in which the
polycarboxylic acid may comprise at least two carboxyl radicals separated from
each other
by not more than two carbon atoms.
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33
[00166] Said anti-redeposition additives that can be included in the detergent
composition
are physico-chemical in their action and include, for example, materials such
as polyethylene
glycol, polyacrylates and carboxy methyl cellulose.
[00167] Optionally, the detergent composition can also contain perfumes.
Suitable
perfumes are generally multi-component organic chemical formulations which can
contain
alcohols, ketones, aldehydes, esters, ethers and nitrile alkenes, and mixtures
thereof.
Commercially available compounds offering sufficient substantivity to provide
residual
fragrance include Galaxolide (1,3,4,6,7,8-hexahydro-4,6,6,7,8,8-
hexamethylcyclopenta(g)-
2-benzopyran), Lyral (3- and 4-(4-hydroxy-4-methyl-pentyl) cyclohexene-1-
carboxaldehyde
and Ambroxan ((3aR, 5aS,9aS, 9bR)-3a,6,6, 9a-tetramethy1-2,4, 5, 5a, 7, 8,9,9b-
octahydro-1H-
benzo[e][1] benzofuran). One example of a commercially available fully
formulated perfume
is Amour Japonais supplied by Symrise AG.
[00168] Suitable optical brighteners that can be used in the detergent
composition fall into
several organic chemical classes, of which the most popular are stilbene
derivatives, whilst
other suitable classes include benzoxazoles, benzimidazoles, 1,3-dipheny1-2-
pyrazolines,
coumarins, 1,3,5-triazin-2-yls and naphthalimides. Examples of such compounds
include,
but are not limited to, 4,4'-bis[[6-anilino-4(methylamino)-1,3,5-triazin-2-
yl]amino]stilbene-
2,2'-disulphonic acid, 4,4'-bis[[6-anilino-4-[(2-hydroxyethyl)methylamino]-
1,3,5-triazin-2-
yl]amino]stilbene-2,2'- disulphonic acid, disodium salt, 4,4'-Bis[[2-anilino-4-
[bis(2-
hydroxyethyl)amino]-1,3,5-triazin-6-yl]amino]stilbene-2,2'-disulphonic acid,
disodium salt,
4,4'-bis[(4,6-dianilino-1,3,5-triazin-2-yl)amino]stilbene-2,2'-disulphonic
acid, disodium salt,
7-diethylamino-4-methylcoumarin, 4,4'-Bis[(2-anilino-4-morpholino-1,3,5-
triazin-6-
yl)amino]-2,2'-stilbenedisulphonic acid, disodium salt, and 2, 5-
bis(benzoxazol-2-
yl)thiophene.
[00169] Said above components can be used either alone or in a desired
combination and
can be added at appropriate stages during the washing cycle in order to
maximise their
effects.
[00170] In some embodiments the ratio of solid particulate material to
substrate is generally
in the range of from about 0.1:1 to about 30:1 w/w. In certain embodiments the
ratio of solid
particulate material to substrate is in the range of from about 0.1:1 to about
20:1 w/w. In still
further embodiments the ratio of solid particulate material to substrate is in
the range of from
about 0.1:1 to about 15:1 w/w and in yet further embodiments said ratio is in
the range of
from about 0.1:1 to about 10:1 w/w. In certain embodiments the ratio of solid
particulate
material to substrate is in the region of from about 0.5:1 to about 5:1 w/w.
In further
embodiments the ratio of solid particulate material to substrate is between
about 1:1 and
about 3:1 w/w and, in still further embodiments, around 2:1 w/w. Thus, for
example, for the
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cleaning of 5g of fabric, 10g of polymeric or non-polymeric particles could be
employed in
one embodiment of the invention.
[00171] In some embodiments the ratio of solid particulate material to
substrate can be
maintained at a substantially constant level throughout the wash cycle.
Consequently,
pumping of fresh and recycled or recirculated solid particulate material can,
in some
embodiments, proceed at a rate sufficient to maintain approximately the same
level of solid
particulate material in the rotatably mounted cylindrical cage throughout the
cleaning
operation, and to thereby ensure that the ratio of solid particulate material
to soiled substrate
stays substantially constant until the wash cycle has been completed.
[00172] The apparatus and the method of the present invention can be used for
either small
or large scale batchwise processes and finds application in both domestic and
industrial
cleaning processes. In some embodiments the present invention can be applied
to domestic
washing machines and processes.
[00173] In a typical wash cycle using the cleaning apparatus (10) of the
invention, soiled
substrates are first placed into the rotatably mounted cylindrical cage (60).
Then, an
appropriate amount of wash liquor (water, together with any additional
cleaning agent) can
be added to said rotatably mounted cylindrical cage (60) via the delivery
means. In some
embodiments, water can be pre-mixed with the cleaning agent prior to its
introduction into
the cage (60). Typically, water can be added first in order to suitably wet or
moisten the
substrate before further introducing any cleaning agent. Optionally the water
and the
cleaning agent can be heated. Following the introduction of water and any
optional cleaning
agents, the wash cycle can commence by rotation of the cage (60). The solid
particulate
material and (further) wash liquor residing in the sump (50), which optionally
can be heated
to a desired temperature, is then pumped upwardly via ducting (40) and through
the
separating portion (30) of the door (20). Solid particulate material is
consequently propelled
from the outlet (94) of the separator (90) and into the centre of the washload
in the rotatably
mounted cylindrical cage (60).
[00174] During the course of agitation by rotation of the cage (60), water
including any
cleaning agents falls through the perforations in the cage (60) and into the
sump (50). In
certain embodiments a quantity of the solid particulate material can also fall
through
perforations in the cage (60) and into the sump (50). In other embodiments,
lifters disposed
on the inner circumferential surface of the cage (60) can collect the solid
particulate material
as the cage (60) rotates and transfer the solid particulate material to the
sump (50). On
transfer to the sump (50), the sloping floor (72) directs the solid
particulate material and
water plus any cleaning agents to the first end (56) of the sump (50)
proximate the door (20).
The sump (50), via the use of pumping means (52) proximate said first end
(56), again
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pumps wash liquor in combination with the solid particulate material upwardly
via ducting
(40) and through the separating portion (30) of the door (20). Consequently,
additional solid
particulate material can be entered into the cage (60) during the wash cycle.
Furthermore,
solid particulate material used in the cleaning operation and returned to the
sump (50) can
5 be reintroduced into the cage (60) and can therefore be re-used in either
a single wash cycle
or subsequent wash cycles. Wash liquor pumped upwardly from the sump (50)
through the
separating portion (30) with the solid particulate material and which does not
enter the
rotatably mounted cage (60) can be returned to the sump (50) via the drain
(44) in the door
(20) and recess (79) in the tub (70).
10 [00175] The cleaning apparatus (10) can perform a wash cycle in a
similar manner to a
standard washing machine with the cage (60) rotating at between 30 and 40 rpm
for several
revolutions in one direction, then rotating a similar number of rotations in
the opposite
direction. This sequence can be repeated for up to about 60 minutes. During
this period,
solid particulate material can be introduced and reintroduced to the cage (60)
from the sump
15 (50) via the separator (90) in the manner as described above.
[00176] As previously noted, the apparatus and method of the invention can
find particular
application in the cleaning of textile fibres. The conditions employed in such
a cleaning
system do, however, allow the use of significantly reduced temperatures from
those which
typically apply to the conventional wet cleaning of textile fabrics and, as a
consequence,
20 offer significant environmental and economic benefits. Thus, typical
procedures and
conditions for the wash cycle require that fabrics are generally treated
according to the
method of the invention at, for example, temperatures of between 5 and 95 C
for a duration
of between about 5 and 120 minutes in a substantially sealed system.
Thereafter, additional
time may be required for the completion of the rinsing and any further stages
of the overall
25 process, so that the total duration of the entire cycle is typically in
the region of about 1 hour.
The operating temperatures for the method of the invention can be in the range
of from about
10 to about 60 C and, in some embodiments, from about 15 to about 40 C.
[00177] The results obtained when cleaning with the apparatus of the invention
are very
much in line with those observed when carrying out conventional wet (or dry)
cleaning
30 procedures with textile fabrics. The extent of cleaning and stain
removal achieved with
fabrics treated by the method of the invention is seen to be very good, with
particularly
outstanding results being achieved in respect of hydrophobic stains and
aqueous stains and
soiling, which are often difficult to remove. The energy requirement, the
total volume of
water used, and the detergent consumption when using the cleaning apparatus of
the
35 invention are all significantly lower than those levels associated with
the use of conventional
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aqueous washing procedures, again offering significant advantages in terms of
cost and
environmental benefits.
[00178] Throughout the description and claims of this specification, the words
"comprise"
and "contain" and variations of them mean "including but not limited to", and
they are not
intended to (and do not) exclude other moieties, additives, components,
integers or steps.
Throughout the description and claims of this specification, the singular
encompasses the
plural unless the context otherwise requires. In particular, where the
indefinite article is
used, the specification is to be understood as contemplating plurality as well
as singularity,
unless the context requires otherwise.
[00179] Features, integers, characteristics, compounds, chemical moieties or
groups
described in conjunction with a particular aspect, embodiment or example of
the invention
are to be understood to be applicable to any other aspect, embodiment or
example
described herein unless incompatible therewith. All of the features disclosed
in this
specification (including any accompanying claims, abstract and drawings),
and/or all of the
steps of any method or process so disclosed, may be combined in any
combination, except
combinations where at least some of such features and/or steps are mutually
exclusive. The
invention is not restricted to the details of any foregoing embodiments. The
invention
extends to any novel one, or any novel combination, of the features disclosed
in this
specification (including any accompanying claims, abstract and drawings), or
to any novel
one, or any novel combination, of the steps of any method or process so
disclosed.
[00180] The reader's attention is directed to all papers and documents which
are filed
concurrently with or previous to this specification in connection with this
application and
which are open to public inspection with this specification, and the contents
of all such
papers and documents are incorporated herein by reference.
