Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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ROLLED DRY CLEANING ARTICLE
FIELD OF THE INVENTION
The present invention relates to cleaning articles which are especially
adapted
for use in appliances such as laundry dryers.
BACKGROUND OF THE INVENTION
By classical definition, the term "dry cleaning" has been used to describe
processes for cleaning textiles using nonaqueous solvents. Dry cleaning is an
old art,
with solvent cleaning first being recorded in the United Kingdom in the
1860's.
Typically, dry cleaning processes are used with garments such as woolens which
are
subject to shrinkage in aqueous laundering baths, or which are judged to be
too
valuable or too delicate to subject to aqueous laundering processes. Various
hydrocarbon and halocarbon solvents have traditionally been used in immersion
dry
cleaning processes, and the need to handle and reclaim such solvents has
mainly
restricted the practice of conventional dry cleaning to commercial
establishments.
Together with the soil and stain removal aspects of a typical dry cleaning
process, there is also a consumer need for what can be termed fabric
"refreshment".
Thus, garments which have lint, hair or other solid debris clinging to their
surfaces, or
which may have adsorbed malodors, or which have become wrinkled or otherwise
lost their fresh appearance, are often subjected to conventional commercial
dry
cleaning processes mainly to reestablish their freshness aspect.
Attempts have been made to provide in-home dry cleaning systems. One type
of non-immersion, in-home system for cleaning and refreshing garments
comprises
multiple single-use Garner sheets containing various liquid or gelled cleaning
agents
and a re-usable plastic containment bag. The garments are placed in the bag
together
with a sheet, and then tumbled with heating in a conventional clothes dryer.
In one
embodiment of such in-home products, multiple single-use sheets and a single
multi-
use plastic bag are provided in a single package. Since the planar sheets are
relatively
large, they are folded for ease-of packaging. In use, a planar-folded sheet is
unfolded,
placed in the reusable bag together with the fabrics to be cleaned, and
tumbled in a
conventional hot air clothes dryer. During the heating/tumbling, the cleaning
composition is released from the sheet. Such release is most efficiently
achieved
when the sheet remains in a substantially open, unfolded configuration.
Unfortunately, it has been discovered that such sheets have a tendency to
partially or
completely re-close by re-folding along the "hard" creases which comprise
their
original packaging fold lines, thereby resulting in sub-optimal performance.
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Importantly, the proper control of wrinkle prevention and the removal of
malodor
components from the bag are both dependent on delivery of the intended amount
of
vaporizing cleaning liquid.
PCT Application US 96/02886, published October 3, 1996, to Max Davis,
discloses the problems associated with such sheet re-folding in an in-home,
non-
immersion cleaning/refreshment process. The patentee describes the use of
macroscopic holes punched through the sheets to help prevent re-folding.
However,
punching holes in the sheets requires an extra processing step during
manufacture, at
added expense. U.S. Patent 5,630,848, issued May 20, 1997 to Young, Bavely,
Roetker & Davis, discloses the use of HYDRASPUNO sheets and bespeaks the
advantage that re-folding is minimized, as compared with conventional non-
wovens.
However, the re-fold problem is not completely solved. Moreover, when the
HYDRASPUNO sheets are enrobed in a fibrous coversheet, as disclosed
hereinafter,
re-folding can again become problematic.
By the present invention, it has been discovered that cleaning/refreshment
sheets can be packaged such that, in-use, they are maintained in a
substantially open
configuration. This is achieved by rolling or rolling/folding the sheets. The
sheets
provide improved cleaning/refreshment and minimize the formation of water
marks on
the fabrics being treated. In particular, the risk of reduced performance from
inadequate delivery of vaporizing components from a dryer bag cleaning cloth
is
dramatically lowered by this packaging methodology. Moreover, the sheets
herein
can be packaged in pouches which are substantially smaller than pouches used
with
planar-fold sheets. This results in a savings of packaging material. These and
other
objects are secured herein, as will be seen from the following disclosure.
BACKGROUND ART
WO 97/00993A1, published January 9, 1997 to Weller, et al.; WO
97/00990A2, published January 9, 1997 to Tyerech, et ai.; GB 2,302,553A,
published
January 22, 1997 to Telesca, et al.; GB 2,302,878A, published February 5, 1997
to
Weller, et al.; and GB 2,302,879A, published February 5, 1997 to Sidoti, et
al. all
relate to in-dryer fabric cleaning. U.S. 4,532,722, issued to S. H. Sax,
August 6,
1985, relates to a fabric conditioning device for use in a laundry dryer. A
peracid-
containing dry cleaning composition is described in U.S. 4,013,575, issued to
H.
Castrantas, et al., March 22, 1977. Dry cleaning processes are disclosed in:
U.S.
5,591,236, issued January 7, 1997 to Roetker; U.S. 5,547,476, issued August
20,
1996, to Siklosi and Roetker; EP 429,172A1, published 29.05.91, Leigh, et al.;
and in
U.S. 5,238,587, issued 8/24/93, Smith, et al. Other references relating to dry
cleaning
compositions and processes, as well as wrinkle treatments for fabrics,
include: GB
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1,598,911; and U.S. Patents 4,126,563, 3,949,137, 3,593,544, 3,647,354;
3,432;253
and 1,747,324; and German applications 2,021,561 and 2,460,239, 0,208,989 and
4,007,362. Cleaning/pre-spotting compositions and methods are also disclosed,
for
example, in U.S. Patents 5,102,573; 5,041,230; 4,909,962; 4,115,061;
4,886,615;
4,139,475; 4,849,257; 5,112,358; 4,659,496; 4,806,254; 5,213,624; 4,130,392;
and
4,395,261. Sheet substrates for use in a laundry dryer are disclosed in
Canadian
1,005,204. U.S. 3,956,556 and 4,007,300 relate to perforated sheets for fabric
conditioning in a clothes dryer. U.S. 4,692,277 discloses the use of 1,2-
octanediol in
liquid cleaners. See also U.S. Patents 3,591,510; 3,737,387; 3,764,544;
3,882,038;
3,907,496; 4,097,397; 4,102,824; 4,336,024; 4,594,362; 4,606,842; 4,758,641;
4,797,310; 4,802,997; 4,943,392; 4,966,724; 4,983,317; 5,004,557; 5,062,973;
5,080,822; 5,173,200; EP 0 213 500; EPO 261 ?18; G.B. 1,397,475; WO 91/09104;
WO 91/13145; WO 93/25654 and Hunt, D.G. and N.H. Morris, "PnB and DPnB
Glycol Ethers", HAPPI, April 1989, pp. 78-82.
SUMMARY OF THE INVENTION
The present invention encompasses a fabric cleaning/refreshment article
comprising a flexible sheet carrier substrate releasably carrying a
cleaning/refreshment
composition, said sheet substrate being packaged in the form of a roll,
whereby said
sheet remains in an open configuration during its intended use. By "roll"
herein is
meant the article having a configuration of a generally "cylindrical twist" or
generally
"tubular" shape. As shown in the Figures, the tubular roll need not be
cylindrical in
cross-section, but can also be in a more rectangular shape rather in the
manner of a
bolt of fabric. The article can be formed into said "roll" by wrapping the
substrate
around on itself or around a core material used in the manner of a spindle or
mandrel
to assist in the formation of said "roll". The substrate can comprise a woven,
or
preferably non-woven, web material, most preferably a hydroentangled web. In
one
preferred embodiment, the substrate is encased in a coversheet. In a typical
article,
the surface area of the sheet substrate (total of both sides) is from about
360 cm2 to
about 3000 cm2.
The invention also encompasses a method for cleaning and refreshing fabrics,
preferably in a tumbling or a tumbling/heating apparatus, comprising placing
said
fabrics in a container together with the article herein which is in an
unrolled
configuration, closing said container, and tumbling said fabrics together with
said
unrolled article. In the home, this process is conveniently conducted in a hot
air
clothes dryer. The container can be a bag, preferably one which is heat
resistant and
vapor-venting, as disclosed hereinafter.
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The invention thus provides a dry cleaning composition in kit form,
comprising the following components:
(a) multiple rolled articles according to Claim 1;
(b) a reusable container suitable for use in a hot air clothes dryer; and
(c) an outer package containing said components (a) and (b).
In a preferred mode, each article in such kit is individually packaged in a
retaining
pouch (i.e., a water-impermeable pouch or other equivalent container which
retains
the moisture and other components of the cleaning/refreshment compositions
used in
the articles during storage) preferably after being folded approximately in
half.
All percentages, ratios and proportions herein are by weight, unless otherwise
specified. All documents cited are, in relevant part, incorporated herein by
reference.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows the article of the present type in a spiral rolled
configuration
having a generally cylindrical cross-section.
Figure 2 shows the article of Figure 1 folded at approximately its mid-point
(101) and ready for placement in a retaining pouch.
Figure 3 shows the article in a flattened, rather than cylindrical, roll.
Figure 4 shows the article of Figure 3 folded at its mid-point for packaging.
Figure 5 shows an article which is folded, then rolled into a somewhat flat
configuration. Optionally, it could be folded and then rolled into a more
cylindrical
configuration.
Figure 6 is an exploded view of a sheet-form article ( I ) with coversheet
useful
in the present invention in a pre-assembled state.
Figure 7 is a perspective of the assembled cleaning/refreshing article (1).
Figure 8 is a perspective of the unrolled article loosely resting on a
notched,
vapor-venting containment bag which is in a pre-folded condition.
Figure 9 is a perspective of the unrolled article within the bag which is
ready
to receive fabrics or other articles to be treated in a hot air clothes dryer,
or similar
apparatus.
Figure 10 is a partial view of the notched wall of the bag and its disposition
relative to the closure flap.
Figu r I is a perspective of an un-notched vapor-venting bag containing a
loose, unrolle~ sheet-form article used in the manner of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
The individual materials employed to assemble the fabric cleaning/refreshment
articles of the present invention are commercially available. The terms used
herein to
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describe such materials have their conventional meanings. For purposes of
clarity,
certain terms used herein are defined in the text.
By "cleaning" herein is meant the removal of soils and stains from fabrics. By
"refreshment" herein is meant the removal of malodors and/or wrinkles from the
overall fabrics, or the improvement of their overall appearance, other than
primarily
removing soils and stains, although some soil and stain removal can occur
concurrently with refreshment. Typical fabric cleaning
refreshment/compositions
herein can comprise more water (95-99.9%, preferably greater than 95% up to
about
99%) and fewer cleaning ingredients than conventional cleaning or pre-spotting
compositions.
Carner - When used in the in-dryer step of the present process, the
cleaning/refreshment compositions are used in combination with an absorbent
carrier
substrate. The carrier releasably contains the compositions. By "reteasably
contains"
means that the compositions are effectively released from the carrier onto the
soiled
fabrics as part of the non-immersion cleaning/fabric refreshment processes
herein.
This release occurs by contact between the substrate and the fabrics and/or by
volatilization of the composition from the carrier substrate through the vapor-
permeable coversheet, or by a combination of vapor and liquid transfer.
It is highly preferred that the carrier be in the form of an integral pad or
sheet
which substantially maintains its structural integrity throughout the process.
Such
pads or sheets can be prepared, for example, using well-known methods for
manufacturing non-woven sheets, paper towels, fibrous batts, cores for
bandages,
diapers and catamenials, and the like, using materials such as wood pulp,
cotton,
rayon, polyester fibers, and mixtures thereof. Woven cloth pads may also be
used,
but are not preferred over non-woven pads due to cost considerations. Integral
Garner pads or sheets may also be prepared from natural or synthetic sponges,
foams,
and the like.
The carriers are designed to be safe and effective under the intended
operating
conditions of the present process. The carriers must not be flammable during
the
process, nor should they deleteriously interact with the cleaning or
refreshment
. composition or with the fabrics being cleaned. In general, non-woven
polyester-based
pads or sheets are quite suitable for use as the carrier herein.
The Garner used herein is most preferably non-tinting. By "non-tinting" herein
is meant a Garner which resists the shedding of visible fibers or microfibers
onto the
fabrics being cleaned, i.e., the deposition of what is known in common
parlance as
"lint". A Garner can easily and adequately be judged for its acceptability
with respect
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to its non-Tinting qualities by rubbing it on a piece of dark blue woolen
cloth and
visually inspecting the cloth for lint residues.
The non-Tinting qualities of sheet or pad carriers used herein can be achieved
by several means, including but not limited to: preparing the carrier from a
single
strand of fiber; employing known bonding techniques commonly used with
nonwoven
materials, e.g., point bonding, print bonding, adhesive/resin saturation
bonding,
adhesive/resin spray bonding, stitch bonding and bonding with binder fibers.
The size of the earner should not be so large as to be unhandy for the user.
Typically, the dimensions of the carrier will be sufficient to provide a
macroscopic
surface area (both sides of the carrier) of at least about 360 cm2, preferably
in the
range from about 360 cm2 to about 3000 cm2. For example, a generally
rectangular
carrier may have the dimensions (X-direction) of from about 20 cm to about 35
cm,
and (Y-direction) of from about 18 cm to about 45 cm.
The carrier is intended to contain a sufficient amount of the
cleaning/refreshment compositions to be effective for their intended purpose.
The
capacity of the carrier for such compositions will vary according to the
intended
usage. For example, pads or sheets which are intended for a single use in
cleaning/refreshing fabrics will require less capacity than such pads or
sheets which
are intended for multiple uses. For a given type of carrier the capacity for
the
cleaning or refreshment composition will vary mainly with the thickness or
"caliper"
{Z-direction; dry basis) of the sheet or pad. For purposes of illustration,
typical
single-use polyester sheets used herein will have a thickness in the range
from about
0.1 mm to about 0.7 mm and a basis weight in the range from about 30 g/m2 to
about
100 g/m2. Typical multi-use polyester pads herein will have a thickness in the
range
from about 0.2 mm to about 1.0 mm and a basis weight in the range from about
40 g/m2 to about 150 g/m2. Open-cell sponge sheets will range in thickness
from
about 0.1 mm to about 1.0 mm. Of course, the foregoing dimensions may vary, as
long as the desired quantity of the cleaning/refreshment composition is
effectively
provided by means of the carrier.
A preferred earner herein comprises a binderless (or optional low binder),
hydroentangled absorbent material, especia'iy a material which is formulated
from a
blend of cellulosic, rayon, polyester and optional bicomponent fibers. Such
materials
are available from Dexter, Non-Wovens Division, The Dexter Corporation as
HY~DRASPUN~, especially Grades 10244 and 10444. The manufacture of such
materials forms no part of this invention and is already disclosed in the
literature.
See, for example, U.S. Patents 5,009,747, Viazmensky, et al., April 23, 1991
and
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5,292,581, Viazmensky, et al., March 8, 1994, incorporated herein by
reference.
Preferred materials for use herein have the following physical properties.
Grade Optional
10244 Targets Range
Basis Weight gm/m2 SS 35-75
Thickness microns 355 100-1500
Density gm/cc 0.155 0.1-0.25
Dry Tensile gm/25 mm
1700 400-2500
CD 650 100-500
Wet Tensile gm/25 mm
MD* 700 200-1250
CD* 300 100-500
Brightness % 80 60-90
Absorption Capacity % 735 400-900 (H20)
Dry Mullen gm/cm2 1050 700-1200
*MD - machine direction; CD - cross direction
As disclosed in U.S. 5,009,747 and 5,292,281, the hydroentangling process
provides a nonwoven material which comprises cellulosic fibers, and preferably
at
least about 5% by weight of synthetic fibers, and requires less than 2% wet
strength
agent to achieve improved wet strength and wet toughness.
Coversheet - The coversheets which are optionally, but preferably, employed
herein to enrobe the carrier sheet are distinguished from the carrier
substrate sheets,
inasmuch as the coversheets are relatively non-absorbent to the liquid
cleaning/refreshment compositions as compared with the carrier sheets. The
coversheets are constructed from hydrophobic fibers which tend not to absorb,
"wick" or otherwise promote the transfer of fluids. While fluids can pass
through the
void spaces between the fibers of the coversheet, this occurs mainly when
excessive
pressure is applied to the article. Thus, under typical usage conditions the
coversheet
provides a physical barrier which keeps the absorbent carrier, which is damp
from its
load of aqueous cieaning/refreshment composition, from coming into direct
contact
with the fabrics being treated. Yet, the permeable coversheet does allow vapor
transfer of the cleaning/refreshment composition from the carrier through the
coversheet and into the containment bag, and thence onto the fabrics being
treated.
One type of coversheet herein comprises a fibrous, permeable nonwoven or
woven fabric. Such nonwoven or woven fibrous coversheets offer advantages over
formed-film type coversheets known in the catamenials art. For example, formed-
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film coversheets (as described hereinafter) are often manufactured by
hydroforming
processes which are particularly suitable with polymer films such as
polyethylene.
While polyethylene can be used herein, there is some prospect that, due to its
lower
melting point, high dryer temperatures can cause its softening and/or melting
in-use.
This is particularly true if the article herein were to be released from the
containment
bag and fall into the hot dryer drum. While it is possible to prepare formed-
film
topsheets using nylon, polyester or other heat resistant polymeric sheets,
such
manufacture becomes somewhat more difficult and, hence, more expensive.
It has now also been determined that the coversheet herein should be of a
thickness which effectively provides the physical barrier function. Even
though made
from hydrophobic fibers, if the coversheet is too thin, fluid passage can
occur under
the intended usage conditions. Accordingly, it has now been determined that
the
thickness of the fibrous coversheet should preferably be at least about 7 mils
(0.18 mm), preferably from about 0.2 mm to about 0.6 mm. It has also been
determined that the fibers used in the coversheet are preferably hydrophobic
and
preferably have a melting point above about 240°C.
Fibrous coversheets for use herein can readily be made from non-heat
resistant fibers such as polyethylene. However, it has now been determined
that
preferred fibrous coversheets can be prepared using nylon (especially nylon-
6),
polyester, and the like, heat-resistant fibers which can withstand even
inadvertent
misuse in the present process. The flexible, cloth-like, permeable topsheets
made
therefrom are conventional materials in the art of nonwoven and woven fabric
making, and their manufacture forms no part of the instant invention. Nonwoven
fabrics for use as coversheets are available commercially from companies such
as
Reemay, Inc., Hickory, TN. Such coversheets also pick up solid dust particles,
vagrant lint and other fibers from the fabrics being treated in the present
process,
thereby enhancing the overall clean/refreshed appearance of the fabrics
following the
treatment herein.
Such nonwoven or woven fibrous sheet materials can be used in a flat single
layer or as multiple layers as the coversheet for the absorbent carrier core
herein. In
another embodiment, the absorbent core carrying the cleaning/refreshn~ent
comps rn is enrabed in a polyester or polyamide fibrous coversheet whicj gas
been r~ oiled or otherwise crimped to provide three dimensional bulk.
Optionally,
this coversheet may be further covered by a second coversheet in an uncrimped
configuration.
Such fibrous, preferably heat resistant and, most preferably, hydrophobic,
coversheets thus provide various embodiments of the article herein. Suitable
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combinations can be employed, according to the desires of the manufacturer,
without
departing from the spirit and scope of the invention. If desired, the
coversheet can be
provided with macroscopic fenestrations through which the lint, fibers or
particulate
soils can pass, thereby further helping to entrap such foreign matter inside
the article,
itself.
A typical spun-bonded fibrous coversheet herein is commercially available
from Reemay and has the following characteristics.
(a) Fabric Type - Non-woven, semi-dull, whitened homopolymer 100% virgin,
spun-bonded polyester.
(b) Fiber Type - 6.0 Denier straight, tri-lobal continuous fiber, copolymer
polyester.
Web Properties Target Ranee
a) Basis weight, roll average oz/yd2 0.54 0.52 to
0.59
b) Thickness 8 mil 7-8 mil
c) Fuzz level
As measured by Reemay sled/drag method based on 0-5 scale. 5 being no fizz
level.
Belt side 2.5 5,0 l.g
Jet side 3.4 5.0 2.6
As noted above, another type of coversheet which can be used with the
articles herein comprises the apertured "formed film" coversheets known in the
art
and from commercial use on catamenials. Apertured formed films are pervious to
the
liquid cleaning and/or refreshment compositions and vapors thereof, and yet
non-
absorbent. Thus, the surface of the formed film which is in contact with the
fabrics
remains relatively dry, thereby reducing water spotting and dye transfer. As
with the
fibrous coversheets, the apertured formed films capture and retain lint,
fibrous matter
such as pet hair, and the like, from the fabric being treated, thereby
enhancing the
cleaning/refreshment benefits afforded by the present articles. Suitable
formed films
are described in U.S. Pat. No. 3,929,135, entitled "Absorptive Structure
Having
Tapered Capillaries", issued to Thompson on December 30, 1975; U.S. Pat. No.
4,324,246, entitled "Disposable Absorbent Article Having A Stain Resistant
Coversheet", issued to Mullane and Smith on April 13, 1982; U.S. Pat. No.
4,342,314, entitled "Resilient Plastic Web Exhibiting Fiber-Like Properties",
issued to
Radel and Thompson on August 3, 1982; and U.S. Pat. No. 4,463,045, entitled
"Macroscopically Expanded Three-Dimensional Plastic Web Exhibiting Non-Glossy
Visible Surface and Cloth-Like Tactile Impression", issued to Ahr, Louis,
Mullane
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and Ouellete on July 31, 1984; U.S. Pat. No. 4,637,819 issued to Ouellette,
Alcombright & Curro on January 20, 1987; U.S. Pat. No. 4,609,518 issued to
Curro,
Baird, Gerth, Vernon & Linman on September 2, 1986; U.S. Pat. No. 4,629,642
issued to Kernstock on December 16, 1986; and EPO Pat. No. 0,165,807 of Osborn
published 8/30/89; all of which are incorporated herein by reference. The
apertures
in such coversheets may be of uniform size or can vary in size, as disclosed
in the
foregoing published documents, which can be referred to for technical details,
manufacturing methods, and the like. Such apertures may also vary in diameter
in the
manner of so-called "tapered capillaries". Such formed-film cover-sheets with
tapered capillary apertures preferably are situated over the carrier sheet
such that the
smaller end of the capillary faces the carrier sheet and the larger end of the
capillary
faces outward. This helps prevent bulk liquid transfer, thereby minimizing
water
spotting on the fabrics being treated. In the main, apertures in the formed
film
coversheets used herein can have diameters in the range of from about 0.1 mm
to
about 1 mm, or as disclosed in the aforesaid patent references.
As shown in Figure 6, an unrolled article ( 1 ) of the present type can be
assembled as a laminate comprising a topmost fibrous sheet ( 1 a), an
absorbent Garner
sheet as the core (lb) and a bottommost fibrous sheet (lc). The combination of
topsheet and bottomsheet comprises the "coversheet" in the preferred
embodiment of
the articles herein.
The assembled, unrolled laminate article ( 1 ) is shown in Figure 7. Figure 7
also shows the bond (lf) which extends around the periphery of the article.
The
purpose of this bond is to ensure that the absorbent carrier core maintains
its original
configuration relative to the coversheet when the article is being used in the
manner
of this invention. Stated simply, it has been discovered that if the absorbent
sheet
which comprises the core is not bonded to the "envelope" provided by the
coversheet
in-use, the Garner sheet tends to crumple and bunch-up inside the coversheet.
This
can interfere with the delivery of the cleaning/refreshment composition to the
fabrics
being treated.
Moreover, it has also been discovered that it is not preferred to tightly bond
the coversheet to the carrier sheet across - a entire face of the carrier
sheet. Tightly
bonding the coversheet closely to the cart ~~r sheet can allow some liquid
transfer to
occur through the coversheet. Accordingly, the carrier sheet is bonded to the
coversheet only in discrete areas. In one embodiment as shown in Figure 7,
this
bonding is only around the periphery of the article. In another embodiment,
spot-
bonding at discrete areas across the face of the article can be employed.
Various
other bond patterns can be used. Preferably, the bonding is done at no more
than
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about 50% of the area of the article, more preferably no more than about 10%
of.the
area of the article, most preferably no more than about 1 % of the area of the
article.
Compositions - The user of the present process can employ various
cleaning/refreshment compositions to practice the invention. However, one
potential
problem associated with many known fabric treatment compositions is their
tendency
to leave visible residues on fabric surfaces. Such residues are problematic
and are
preferably to be avoided herein since the present process does not involve
conventional immersion or rinse steps. Accordingly, the compositions used
herein
should, most preferably, be substantially free of various gelling agents,
polyacrylate-
based emulsifiers, polymeric anti-static agents, inorganic builder salts and
other
residue-forming materials, except at low levels of about 0.1%-0.3%, and
preferably
0%, of the final compositions. Water used in the compositions should
preferably be
distilled, deionized or otherwise rendered free of residue-forming materials.
Stated
otherwise the compositions herein should preferably be formulated so as to
leave
substantially no visible residue on fabrics or other solid surfaces being
treated
according to the practice of this invention.
Accordingly, in a preferred aspect of this invention there are provided
cleaning/refreshment/sanitization compositions which are substantially free of
quantities of materials which are sufficient to leave visible residues on the
treated
fabrics.
Aqueous Compositions
(a) Water -The preferred, low residue compositions herein may comprise
from about 90%, preferably from about 95.5% to about 99.9%, by
weight, of water.
(b) Surfactant - The compositions herein may optionally comprise from
about 0.05% to about 2%, by weight, of surfactants, such as MgAES
and NH4AES, amine oxides, ethoxylated alcohols and alkyl phenols,
anionics such as alkyl sulfates, and mixtures thereof. Nonionics such
as the ethoxylated C 10-C 16 alcohols, e. g., NEODOL 23-6.5, can be
used in the compositions. The alkyl sulfate surfactants which may be
used herein as cleaners and to stabilize aqueous compositions are the
Cg-C 1 g primary ("AS"; preferred C 10-C 14, sodium salts), as well as
branched-chain and random C 10-C20 alkyl sulfates, and C 10-C 18
secondary (2,3) alkyl sulfates of the formula
CH3(CH2)x(CHOS03-M+) CH3 and CH3 (CH2)y(CHOS03-M+)
CH2CH3 where x and (y + 1 ) are integers of at least about 7,
preferably at least about 9, and M is a water-solubilizing cation,
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12
especially sodium, as well as unsaturated sulfates such as oleyl sulfate.
Alkyl ethoxy sulfate (AES) surfactants used herein are conventionally
depicted as having the formula R(EO)xS03Z, wherein R is C 1 p-C 16
alkyl, EO is -CH2CH2-O-, x is I-10 and can include mixtures which
are conventionally reported as averages, e.g., (EO)2.5, (EO)6.5 and
the like, and Z is a cation such as sodium ammonium or magnesium
(MgAES). The C12-C16 alkyl dimethyl amine oxide surfactants can
also be used. A preferred mixture comprises MgAE I S/C 12 dimethyl
amine oxide at a weight ratio of about 10:1. Other surfactants which
improve phase stability and which optionally can be used herein
include the polyhydroxy fatty acid amides, e.g., C 12-C 14 N-methyl
glucamide. AS stabilized compositions preferably comprise 0.1%-
0.5%, by weight, of the compositions herein. MgAES and amine
oxides, if used, can comprise 0.01%-2%, by weight, of the
compositions. The other surfactants can be used at similar levels.
(c) Optionals - The compositions herein may comprise minor amounts of
various optional ingredients, including preservatives, bleach stabilizers,
perfumes, pH adjusters, buffers, and the like. If used, such optional
ingredients will typically comprise from about 0.05% to about 2%, by
weight, of the compositions, having due regard for residues on the
cleaned fabrics.
The following illustrates preferred ranges for cleaning/refreshment
compositions for use herein, but is not intended to be limiting thereof.
In reg diem % (wt.} Formula Range
Surfactant 0-2
Perfume 0-1. S
Water Balance
pH range from about 6 to about 8.
Preferred compositions for use in the in-dryer cleaning/refreshment process
herein are as follows.
Ingredient % wt. Range (% wt.l
Water 99.0 95.1-99.9
Perfume 0. 5 0-1. 5
Surfactant* 0. 5 0.05-2.0
Ethanol or Isopropanol 0 Optional to 4%
*Especially ethoxylated alcohols, as disclosed herein. The fabric refreshment
compositions may also contain anionic surfactants. Such anionic surfactants
are well-
CA 02295442 1999-12-16
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13
known in the detergency arts. Commercial surfactants available as TWEEN~,
SPAN~, AEROSOL OT~ and various sulfosuccinic esters are especially useful
herein.
Perfume - It has been determined that higher molecular weight, high boiling
point, malodorous chemicals tend to be retained on the fabrics, at least to
some
degree. These malodors can be overcome, or "masked", by perfumes. Accordingly,
it will be appreciated that the perfumer should select at least some perfume
chemicals
which are sufficiently high boiling that they are not entirely lost during the
process. A
wide variety of aldehydes, ketones, esters, acetals, and the like, perfumery
chemicals
which have boiling points above about 50°C, preferably above about
85°C, are
known. Such ingredients can be delivered to the fabrics being treated by means
of the
Garner substrate herein during the processes herein, thereby helping to reduce
the
user's perception of malodors. Non-limiting examples of perfume materials with
relatively high boiling components include various essential oils, resinoids,
and resins
from a variety of sources including but not limited to orange oil, lemon oil,
patchouli,
Peru balsam, Olibanum resinoid, styrax, labdanum resin, nutmeg, cassia oil,
benzoin
resin, coriander, lavandin and lavender. Still other perfume chemicals include
phenyl
ethyl alcohol, terpineol and mixed pine oil terpenes, linalool, linalyl
acetate, geraniol,
nerol, 2-(1,1-dimethylethyl)-cyclohexanol acetate, orange terpenes and
eugenol. Of
course, lower boiling materials can be included, with the understanding that
some loss
will occur due to venting.
Containment Bay - The compositions are loaded on the carrier substrate
which is preferably encased in the coversheet and the finished article is
stored in its
rolled configuration in a pouch until time-of use. The article is then
unrolled and
placed in a bag environment for use in a heated operating clothes dryer, or
the like, to
treat fabrics as a dry cleaning alternative or fabric refreshment process. The
warm,
humid environment created inside this bag volatilizes malodor components in
the
manner of a "steam distillation" process, and moistens fabrics and the soils
thereon.
This moistening of fabrics can loosen pre-set wrinkles, but it has now been
discovered that overly wet fabrics can experience setting of new wrinkles
during the
drying stage toward the end of the dryer cycle. Proper selection of the amount
of
water used in the process and, importantly, proper venting of the bag in the
present
manner can minimize wrinkling. Moreover, if the bag is not vented, the
volatilized
malodorous materials removed from the fabrics can undesirably be re-deposited
thereon.
In a highly preferred mode, the process of the present invention employs a
vapor-venting containment bag. The bag is preferably designed for multiple
uses and
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14
reuses, and is especially adapted for use by the consumer in any conventional
hot air
clothes dryer apparatus, such as those found in the home or in commercial
laundry/cleaning establishments. The bag is designed to vent water and other
vapors
(including malodorous materials) which emanate from within the bag when used
in
the manner described herein. The vapors released from the bag are thence
exhausted
through the air vent of the dryer apparatus.
As described more fully hereinafter, the preferred venting bag is provided
with a vapor-venting closure which provides one or more gaps through which
vapors
are released from the bag, in-use. In a preferred embodiment, the size of this
gap is
selected to provide controlled vapor release from the bag under the indicated
operating conditions. While other gap sizes and operating conditions can be
used, a
preferred balance between vapor containment within the bag to perform the
sanitization of the fabrics along with the cleaning/refreshment function and
vapor
release from the bag has now been determined using the principles disclosed
hereinafter.
Alternatively, the bag can be provided with a series of holes or other
fenestrations which provide vapor venting. However, such venting is not as
effective
as the vapor-venting closure.
In one mode, the present invention employs a vapor-venting containment bag
comprising an open end, a closed end and flexible side walls having inner and
outer
surfaces, the open end of said bag having a section of one side wall extending
beyond
said open end to provide a flexible flap, said flap having first fastening
device affixed
thereto, said flap being foldable to extend over a portion of the outside
surface of the
opposing side wall, said flap being affixable to the outer surface of the
opposing wall
of the bag by engaging said first fastening device on the inside face of the
flap with a
second fastening device present on the outside face of said opposing side
wall, said
first and second fastening devices, when thus engaged, forming a fastener,
thereby
providing a closure for the open end of the bag. Said first and second
fastening
devices are disposed so as, when engaged, to provide vapor-venting along said
closure, especially at the lateral edges of the closure. The bag herein is
most
preferably formed from film which is heat resistant up to at least about
204°C-260°C.
Nylor r,s a preferred film material for formiv .. the bag. In another
embodiment, the
edge :~f one wall of the bag is notched along a substantial portion of its
width to
facilitate and optimize vapor venting.
In an alternate mode, the flap can be folded to provide the closure, tucked
inside the opposing side wall, and secured there by a fastener. In this mode,
vapors
are vented along the closure and especially at the lateral edges of the
closure. In yet
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WO 98/58114 PCT/IB98/00928
another mode, the side walls are of the same size and no flap is provided.
Fastening
devices placed intermittently along portions of the inner surfaces of the side
walls are
engaged when the lips of the side walls are pressed together to provide
closure. One
or more vapor-venting gaps are formed in those regions of the closure where no
fastening device is present.
While the fastening devices herein can comprise chemical adhesives, the bag is
preferably designed for multiple uses. Accordingly, reusable mechanical
fasteners are
preferred for use herein. Any reusable mechanical fastener or fastening means
can be
used, as long as the elements of the fastener can be arranged so that, when
the bag is
closed and the fastener is engaged, a vapor-venting closure is provided. Non-
limiting
examples include: bags wherein said first and second fastening devices,
together,
comprise a hook and loop (VELCRO~-type) fastener; hook fasteners such as
described in U.S. Patent 5,058,247 to Thomas & Blaney issued October 22, 1991;
bags wherein said first and second fastening devices, together, comprise a
hook and
string type fastener; bags wherein said first and second fastener devices,
together,
comprise an adhesive fastener; bags wherein said first and second fastening
devices,
together, comprise a toggle-type fastener; bags wherein said first and second
fastening devices, together, form a snap-type fastener; as well as hook and
eye
fasteners, ZIP LOK~-style fasteners, zipper-type fasteners, and the like, so
long as
the fasteners are situated so that vapor venting is achieved. Other fasteners
can be
employed, so long as the vapor-venting is maintained when the bag is closed,
and the
fastener is sufficiently robust that the flap does not open as the bag and its
contents
are being tumbled in the clothes dryer. The fastening devices can be situated
that the
multiple vapor-venting gaps are formed along the closure, or at the lateral
edges, or
so that the gap is offset to one end of the closure. In yet another
embodiment, both
ends of the bag are provided with a vapor venting closure.
The design of the venting ability of the bag achieves a proper balance of the
above effects. A tightly-sealed, vapor impermeable "closed" bag will not purge
malodors and will overly moisten the fabrics, resulting in wrinkling. An
overly
"open" bag design will not sufficiently moisten the fabrics or soils to
mobilize heavier
malodors or to remove pre-existing fabric wrinkles. Further, the bag must be
"closed" enough to billow and create a void volume under water vapor pressure,
wherein the fabrics can tumble freely within the bag and be exposed to the
vapors.
The bag is designed with sufficient venting to trap a portion of water vapors
(especially early in the dryer cycle) but to allow most of the water to escape
by the
end of the cycle. Said another way, the rate of vapor release is, preferably,
optimized
to secure a balance of vapor venting and vapor trapping. A preferred bag
design
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16
employs a water vapor impermeable film such as nylon, with a the closure flap
(preferably with a hook-and-loop VELCRO~-type fastener) like that of a large
envelope. The degree of slack in the fold-over portion of the closure flap can
be
varied to provide a vapor-venting air gap or partial opening which controls
the rate of
vapor venting from of the bag. In another mode, a notch is cut along the edge
of the
side wall opposite the flap to further adjust the venting. The fastener
devices shown
in the Figures run only partly along the closure, thereby allowing venting to
also
occur at the lateral edges of the closure.
The following is intended to assist the formulator in the manufacture and use
of vapor-venting bags in the manner of this invention, but is not intended to
be
limiting thereof.
Bag Dimensions - Figure 9 shows the overall dimensions of a notched bag:
i.e., length (7) to fold line 27 5/8 inches (70.2 cm); width (8) of bag 26
inches
(66 cm), with a flap to the base of the fold line ( I I ) of 2 3/8 inches (6
cm). In the
Tests reported hereinafter, this bag is referred to by its open dimensions as
"26 in. x
30 in." (66.04 cm x 76.20 cm).
Figure 10 gives additional details of the positioning of the various elements
of
the notched bag. In this embodiment, all dimensions are the same for both the
left
hand and right hand sides of the bag. The dimensions herein are for an opened
bag
which is about 30 inches (76.2 cm) in overall length (including the flap) and
about 26
inches (66 cm) wide. The distance (9) from the lateral edge of the bag to the
outermost edge of the fastening device (3) located on the inside of the flap
(S) is
about 2 inches (5 cm). In this embodiment, the fastening device (3) on the
inside of
wall (2a) comprises the loop portion of a VELCRO~-type strip whose width (13)
is
about 0.75 inches (1.9 cm) and whose total length is about 22 inches (55.9
cm).
Fastening device (6) is similarly situated on the outside of wall 2(b) and
comprises
the hook portion of a 3/4 inch (1.9 cm) VELCRO~-type strip. Distance (9) can
be
decreased or increased to decrease or increase venting at the edges of the
flap when
the bag is closed and the fastener is engaged. The distance (10) between the
uppermost edge of the flap and the base of the notch is about 2 7/8 inches
(7.3 cm).
The distance (14) between the lateral edge of the bag and the lateral edge of
the
notch is about 0.25 inches (0.64 cm). The distance (I S) between the uppermost
edge
of the flap and the fold (11) is about 2 3/8 inches (6 cm). The distance (16)
between
the uppermost edge of the flap and the leading edge of the VELCRO~-type strip
(3)
afl'lxed to the flap is about 3/8 inches (0.95 cm). The distance (17) between
fold (11)
and the lowermost edge of the notch is about 1/2 inch (1.27 cm). This distance
also
can be varied to decrease or increase vapor venting. A range of 0.25-1.5
inches
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WO 98/58114 PCT/IB98/00928
17
(0.64-3.81 cm) is typical. The distance (18) between the uppermost edge of the
VELCRO~-type strip (6) and the bottom edge of the notch is about 3/4 inches
( 1.9 cm). The distance ( 19) between the bottommost edge of the VELCRO~-type
strip (3) and the fold (11) is about 1 1/4 inches (3.17 cm).
Figure 11 gives additional details of the dimensions of an un-notched
envelope bag of the foregoing overall size comprising sidewaIls (2a) and (2b).
Again,
each VELCRO~-type strip (3) and (6) is about 3/4 inches (1.9 cm) in width and
about 22 inches (55.9 cm) in length. Each strip is positioned so as to be
inboard from
each of the lateral edges of the finished bag wall and flap by about 2 inches
(5 cm).
The distance (12) between the leading edge of the sidewall (2b} to the base
edge of
the fastener strip (3) on the flap portion of the bag is about 2 1/2 inches
(6.35 cm).
The distance (20) between the base edge of the fastener strip (6} to the
leading edge
of the sidewall (2b) is about 2.25 inches (5.7 cm). The distance (21 ) between
the
leading edge of the fastener strip (6) to the leading edge of the sidewall is
about
1 3/8 inches (3.5 cm). The distance (22) between fold (11) and the base edge
of the
fastener strip (3) is about 2 inches (5 cm). The distance (23) between the
leading
edge of fastener strip (3) and the uppermost edge of the flap which is an
extension of
sidewall (Za) is about 0.25 inches (0.64 cm). Distance (24) is about 3 S/8
inches
(9.2 cm). As in the foregoing notched bag, the positioning and length of the
fasteners
can be adjusted to decrease or increase venting.
The construction of the preferred, heat-resistant vapor-venting bag used
herein to contain the fabrics in a hot air laundry dryer or similar device
preferably
employs thermal resistant films to provide the needed temperature resistance
to
internal self sealing and external surface deformation sometimes caused by
overheated
clothes dryers. In addition, the bags are resistant to the chemical agents
used in the
cleaning or refreshment compositions herein. By proper selection of bag
material,
unacceptable results such as bag melting, melted holes in bags, and sealing of
bag
wall-to-wall are avoided. In a preferred mode, the fastener is also
constructed of a
thermal resistant material. As shown in the Figures, in one embodiment, 1 to 3
mil
(0.025-0.076 mm) heat-resistant Nylon-6 film is folded and sealed into a
containment
bag. Sealing can be done using standard impulse heating equipment. In an
alternate
mode, a sheet of nylon is simply folded in half and sealed along two of its
edges. In
yet another mode, bags can be made by air blowing operations. The method of
assembling the bags can be varied, depending on the equipment available to the
manufacturer and is not critical to the practice of the invention.
The dimensions of the containment bag can vary, depending on the intended
end-use. For example, a relatively smaller bag can be provided which is
sufficient to
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18
contain one or two silk blouses. Alternatively, a larger bag suitable for
handling a
man's suit can be provided. Typically, the bags herein will have an internal
volume of
from about 10,000 cm3 to about 25,000 cm3. Bags in this size range are
sufficient to
accommodate a reasonable load of fabrics (e.g., 0.2-S kg} without being so
large as to
block dryer vents in most U.S.-style home dryers. Somewhat smaller bags may be
used in relatively smaller European and Japanese dryers.
The bag herein is preferably flexible, yet is preferably durable enough to
withstand multiple uses. The bag also preferably has sufficient stiffness that
it can
billow, in-use, thereby allowing its contents to tumble freely within the bag
during
use. Typically, such bags are prepared from 0.025 mm to 0.076 mm (1-3 mil)
thickness polymer sheets. If more rigidity in the bag is desired, somewhat
thicker
sheets can be used.
In addition to thermally stable "nylon-only" bags, the containment bags herein
can also be prepared using sheets of co-extruded nylon and/or polyester or
nylon
and/or polyester outer and/or inner layers surrounding a less thermally
suitable inner
core such as polypropylene. In an alternate mode, a bag is constructed using a
nonwoven outer "shell" comprising a heat-resistant material such as nylon or
polyethylene terephthalate and an inner sheet of a polymer which provides a
vapor
barrier. The non-woven outer shell protects the bag from melting and provides
an
improved tactile impression to the user. Whatever the construction, the
objective is
to protect the bag's integrity under conditions of thermal stress at
temperatures up to
at least about 400-500°F (204°C to 260°C). Under
circumstances where excessive
heating is not of concern, the bag can be made of polyester, polypropylene or
any
convenient polymer material.
Vapor Venting Evaluation - In its broadest sense, the preferred vapor-venting
containment bag used herein is designed to be able to vent at least about 40%,
preferably at least about 60%, up to about 90%, preferably no more than about
80%,
by weight, of the total moisture introduced into the bag within the operating
cycle of
the clothes dryer or other hot air apparatus used in the process herein. (Of
course
most, if not .all, of organic cleaning solvents, if any, will also be vented
during
together with the water. However, since water comprises by far the major
portion of
the clearung/refreshment compositions '~ :in, it is more convenient to measure
and
report the venting as water vapor venting.)
It will be appreciated by those knowledgeable about the operation of hot air
clothes dryers and similar apparatus that the rate of venting will usually not
be
constant over the entire operating cycle. All dryers have a warm-up period at
the
beginning of the operating cycle, and this can vary according to the
specifications of
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19
the manufacturer. Most dryers have a cool-down period at the end of the
operating
cycle. Some venting from the containment bag can occur during these warm-up
and
cool-down periods, but its rate is generally less than the venting rate over
the main
period of the drying cycle. Moreover, even during the main period of the
cycle, many
modern dryers are constructed with thermostat settings which cause the air
temperature in the dryer to be increased and decreased periodically, thereby
preventing overheating. Thus, an average, rather than constant, dryer
operating
temperature in the target range of from about 50°C to about 85°C
is typically
achieved.
Moreover, the user of the present containment bag may choose to stop the
operation of the drying apparatus before the cycle has been completed. Some
users
may wish to secure fabrics which are still slightly damp so that they can be
readily
ironed, hung up to dry, or subjected to other finishing operations.
Apart from the time period employed, the Vapor-Venting Equilibrium
("VVE") for any given type of vapor-venting closure will depend mainly on the
temperature achieved within the dryer - which, as noted above, is typically
reported
as an average "dryer air temperature". In point of fact, the temperature
reached
within the containment bag is more significant in this respect, but can be
difficult to
measure with accuracy. Since the heat transmittal through the walls of the bag
is
rather efficient due to the thinness of the walls and the tumbling action
afforded by
conventional clothes dryers, it is a reasonable approximation to measure the
VVE
with reference to the average dryer air temperature.
Moreover, it will be appreciated that the vapor-venting from the containment
bag should not be so rapid that the aqueous cleaning/refreshment composition
does
not have the opportunity to moisten the fabrics being treated and to mobilize
and
remove the soils/malodors therefrom. However, this is not of practical concern
herein, inasmuch as the delivery of the composition from its carrier substrate
onto the
fabrics afforded by the tumbling action of the apparatus occurs at such a rate
that
premature loss of the composition by premature vaporization and venting is not
a
significant factor. Indeed, the preferred bag herein is designed to prevent
such
premature venting, thereby allowing the liquid and vapors of the
cleaning/refreshment
composition to remain within the bag for a period which is sufficiently long
to
perform its intended functions on the fabrics being treated.
The following Vapor-Venting Evaluation Test (VVET} illustrates the
foregoing points in more detail. Larger or smaller containment bags can be
used,
depending on the volume of the dryer drum, the size of the fabric load, and
the like.
As noted above, however, in each instance the containment bag is designed to
CA 02295442 1999-12-16
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achieve a degree of venting, or VVE "score", of at least about 40% (40 VVE),
preferably at least about 60% (60 VVE), up to about 90% (90 VVE).
VAPOR-VENTING EVALUATION TEST
Materials:
Envelope or "Standard", i.e., Control Containment Bag to be evaluated for VVE.
Carrier Substrate (15"x11"; 38.1 cm x 27.9 cm) I-II'DRASPUN~ carrier substrate
sheet from Dexter with (10444) or without (10244) Binder
Wool Blouse: RN77390, Style 12288, Weight approx. 224 grams
Silk Blouse: RN40787, Style 0161, Weight approx. 81 grams
Rayon Swatch: 45"x17" (114.3 cm x 43.2 cm), Weight approx. 60 grams
Pouch: 5 "x6.375" { 12.7 cm x 16.2 cm) to contain the Carrier Substrate and
water
De-ionized Water; Weight is variable to establish VVE.
Pretreatment of Fabrics:
1. The wool, silk, and rayon materials are placed in a Whirlpool dryer (Model
LEC7646DQ0) for 10 minutes at high heat setting, with the heating cycle
ranging from about 140°F-165°F to remove moisture picked up at
ambient
condition.
2. The fabrics are then removed from the dryer and placed in sealed nylon or
plastic bags (minimum 3 mil. thickness) to minimize moisture pick up from the
atmosphere.
Test Procedure:
1. Water of various measured weights from 0 to about 40 grams is applied to
the
Garner substrate a minimum of 30 minutes before running a vented bag test.
The substrate is folded, placed in a pouch and sealed.
2. Each fabric is weighed separately and the dry weights are recorded. Weights
are also recorded for the dry carrier substrate, the dry pouch containing the
substrate, and the dry containment bag being evaluated.
3. Each garment is placed in the bag being evaluated for vapor venting along
with the water-containing substrate (removed from its pouch and unfolded).
4. The bag is closed without expressing the air and placed in the Whirlpool
Dryer
for 30 minutes at the high heat setting, with tumbling per the standard mode
of operation of the dryer.
5. At the end of 30 minutes the bag is removed from the dryer and each fabric,
the carrier substrate, the bag and the pouch are weighed for water weight gain
relative to the dry state. (A possible minor loss in weight for the
containment
bag due to dryer heat is ignored in the calculations.)
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21
6. The weight gain of each garment is recorded as a percent of the total
moisture
applied to the carrier substrate.
7. The remaining unmeasured moisture divided by the total moisture is recorded
as percent vented from the dryer bag.
8. When a series of total applied moisture levels are evaluated, it is seen
that
above about 1 S-20 grams of water the % vented becomes essentially constant,
and this is the Vapor-Venting Equilibrium value, or VVE, for the particular
bag venting design.
It can be seen from examining a series of VVET results at various initial
moisture levels that the water at lower initial levels is being
disproportionately
captured by the garment load, the headspace, and the nylon bag, such that
venting of
water and volatile malodors begins in earnest only after the VVE value is
achieved.
Since this occurs only when about 15-20 grams or more of water is initially
charged,
it is seen that a VVE of greater than about 40 is needed to avoid excessive
wetting of
garments; leading to unacceptable wet-setting of wrinkles, as discussed
herein.
Malodor and Wrinkle Removal
One assessment of the process using the vapor-venting bag herein with
respect to malodors comprises exposing the fabrics to be tested to an
atmosphere
which contains substantial amounts of cigarette smoke. In an alternate mode,
or in
conjunction with the smoke, the fabrics can be exposed to the chemical
components
of synthetic perspiration, such as the composition available from IFF, Inc.
Expert
olfactory panelists are then used to judge odor on any convenient scale. For
example, a scale of 0 (no detectable odor) to 10 (heavy malodor) can be
established
and used for grading purposes. The establishment of such tests is a matter of
routine,
and various other protocols can be devised according to the desires of the
formulator.
For example, garments to be "smoked" are hung on clothing hangers in a
fume hood where air flow has been turned off and vents blocked. Six cigarettes
with
filters removed are lighted and set in ashtrays below the garments. The hood
is
closed and left until the cigarettes have about half burned. The garments are
then
turned 180° to get even distribution of smoke on all surfaces. Smoking
is then
continued until all cigarettes are consumed. The garments are then enclosed in
sealed
plastic bags and allowed to sit overnight.
After aging for about one day, the garments are treated in the
cleaning/refreshment process using the venting bag. The garments are removed
promptly from the containment bag when the dryer cycle is finished, and are
graded
for malodor intensity. The grading is done by an expert panel, usually two, of
trained
odor and perfume graders. The malodor intensity is given a grade of 0 to 10,
where
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22
is full initial intensity and 0 is no malodor detected. A grade of 1 is a
trace
detection of malodor, and this grade is regarded as acceptably low malodor to
most
users.
In the absence of perfume ingredients in the cleaning cloth composition, the
grading of residual malodor intensity is a direct indication of degree of
cleaning or
removal of malodorous chemicals. When perfumed compositions are used, the
grading panelists can also determine a score for perfume intensity and
character
(again on a 0 to 10 scale), and the malodor intensity grading in this case
would
indicate the ability of the residual perfume to cover any remaining malodorous
chemicals, as well as their reduction or removal.
After the garment odor grading taken promptly after the cleaning/refreshment
process, the garments are hung in an open room for one hour and graded again.
This
one-hour reading allows for an end-effect evaluation that would follow cool-
down by
the garments and drying of the moisture gained in the dryer cycle treatment.
The
initial out-of bag grading does reflect damp-cloth odors and a higher
intensity of
warm volatiles from the bag, and these are not factors in the one-hour grades.
Further garment grading can be done at 24 hours and, optionally, at selected
later
times, as test needs dictate.
Likewise, fabric wrinkles can be visually assessed by skilled graders. For
example, silk fabric, which wrinkles rather easily, can be used to visually
assess the
degree of wrinkle-removal achieved by the present processes using the vapor-
venting
bag. Other single or multiple fabrics can optionally be used. A laboratory
test is as
follows.
DE-WRINKLING TEST
MATERIALS:
As above for V~rET.
De-ionized Water, Weight range (0-38 grams)
Pretreatment of Fabrics:
The silk fabric is placed in a hamper, basket, or drum to simulate normal
conditions that are observed after wearing. These storage conditions produce
garments that are severely wrinkled (well defined creases) and require a moist
environment to relax the wrin_les.
TEST f?OCEDURE:
I. One silk fabric is placed in a containment bag being tested.
2. Water (0-38 grams) is applied to the carrier substrate a minimum of 30
minutes before running the test, placed in a pouch and sealed.
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WO 98/58114 PCT/IB98/00928
23
3. The silk garment is placed in the test containment bag along with the water-
containing substrate (removed from its pouch and unfolded).
4. The bag is closed and placed in a Whirlpool Dryer (Model LEC7646DQ0)
for 30 minutes at high heat (48-74C cycle).
5. At the end of 30 minutes, the dryer bag is removed from the dryer
EVIMEDIATELY and the silk garment is placed on a hanger.
6. The silk garment is then visually graded versus the Control Garment from
the
same Pretreatment Of Fabrics.
In laboratory tests of the foregoing type, the in-dryer, non-immersion
clearung/refreshment processes herein typically provide malodor (cigarette
smoke
and/or perspiration) malodor grades in the 0-1 range for smoke and somewhat
higher
for perspiration malodors, thereby indicating good removal of malodor
components
other than those of sufficiently high molecular weights that they do not
readily "steam
vaporize" from the fabrics. Likewise, fabrics (silks) have wrinkles removed to
a
sufficient extent that they are judged to be reasonably suitable for wearing
with little,
or no, ironing.
PROCESS COMPONENTS
The use of the article with the vapor-venting bag, the compositions and the
processes of this invention are described in more detail hereinafter. Such
disclosure is
by way of illustration and not limitation of the invention herein.
Figure 8 illustrates one form of a pre-formed, notched containment bag in an
open configuration with the loose, unrolled article (1), first side wall (2a),
second
side wall (2b), first fastening device (3), side seal (4) for the bag and
flexible flap (5).
In use, flexible flap (S) is folded along fold line (11) to provide the vapor-
venting
closure for the bag.
Figure 9 shows the "envelope-style" notched bag in a finished configuration
and containing the loose, unrolled article (1). In-use, the fabrics to be
cleaned/refreshed are placed in the bag with the article (1} and flap (S) is
folded along
fold line {11) to engage first fastening device (3) with the opposing second
fastening
device (6} to fasten the flap, thereby providing a vapor-venting closure which
is
sufficiently stable to withstand tumbling in a hot air clothes dryer or
similar device.
Figure 10 shows a cut-away view of the corner of the notched containment
bag illustrating the interior of the first side wall (2a) and second side wall
(2b), first
fastening device (3), second fastening device (6), flap (5), and fold line
(11). The
distance between the edge of the bag (9) and the depth of the notch ( 11 ) in
second
side wall (2b) are dimensions which are set forth hereinabove.
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WO 98/58114 PCT/IB98/00928
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Figure 11 depicts an un-notched venting bag with the article (1) loosely
contained therein.
As noted above, the Bag Dimensions given hereinabove are for containment
bags which are designed to tumble freely within the drum of a conventional, U.
S.-
style in-home hot air clothes dryer having a drum volume of about 170-210
liters
(home size). The bag of the stated dimensions is designed to treat up to about
5 kg
fabric load in a single use. The dimensions can be adjusted proportionately
for larger
or smaller bags to achieve the desired ~ and to ensure effective use in dryers
with
larger or smaller drums. For example, the total volume of a containment bag
constructed for use in an average European home clothes dryer (or U.S.
"apartment"
size; ca. 90 liter drum volume) would be about 60% of the volume for an
average
U. S. dryer.
OVERALL PROCESS
The overall process is conveniently conducted in a tumbling apparatus,
preferably in the presence of heat. The nylon or other heat-resistant vapor-
venting
bag with the article herein plus aqueous cleaning/refreshment composition and
containing the fabric being treated is closed and placed in the drum of an
automatic
hot air clothes dryer at temperatures of 40°C-1 SO°C. The drum
is allowed to revolve,
which imparts a tumbling action to the bag and agitation of its contents
concurrently
with the tumbling. By virtue of this agitation, the fabrics come in contact
with the
article containing the composition. The tumbling and heating are carried out
for a
period of at least about 10 minutes, typically from about 20 minutes to about
60 minutes. This step can be conducted for longer or shorter periods,
depending on
such factors as the degree and type of soiling of the fabrics, the nature of
the soils, the
nature of the fabrics, the fabric load, the amount of heat applied, and the
like,
according to the needs of the user. During the step, greater than about 40%,
typically
40% to about 80%, of the moisture is vented from the bag.
With respect to the wrinkle-removing function of the process and
compositions herein, it will be appreciated that wrinkling can be affected by
the type
of fabric, the fabric weave, fabric finishes, and the like. For fabrics which
tend to
v--vkle, it is preferred not to overload the vapor-venting bag used herein.
Thus, for
with, for example, an operationa; ..apacity of up to about S kg of fabrics, it
may
b.; ~~st to process up to only about v0% of capacity, (i.e., up to about 3 kg)
of
fabrics to further minimize wrinkling.
The following examples further illustrate the invention, but are not intended
to be limiting thereof.
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WO 98/58114 PCT/IB98/00928
EXAMPLE I
A low residue liquid fabric cleaning/refreshment product for use preferably in
a vented dryer bag is prepared, as follows.
In redient % wt.
Emulsifier (TWEEN 20)* 0.5
Perfume 0. S
KATHON~* * 0.0003
Sodium Benzoate 0.1
Water Balance
*Polyoxyethylene (20) sorbitan monolaurate available from ICI Surfactants.
* *Preservative
A 10 1/4 in. x 14 1/4 in. (26 cm x 36 cm) carrier sheet of HYDRASPLJN~ is
prepared. The carrier sheet is covered on both sides with a topsheet and a
bottomsheet of 8 mil (0.2 mm) Reemay fabric coversheet material of the type
described hereinabove. The coversheet (i.e., both topsheet and bottomsheet)
are
bonded to the carrier sheet by a Vertrod~ or other standard heat sealer
device,
thereby bonding the laminate structure together around the entire periphery of
the
Garner sheet. The edges of the Garner sheet around its periphery are
intercalated
between the topsheet and bottomsheet by the bond. The width of the bond is
kept to
a minimum and is about 0.25 in. (6.4 mm).
The bonded laminate structure thus prepared is rolled somewhat loosely
around a cylindrical void into a generally tubular shape of about 26 cm length
and a
diameter of about 2-3 cm. The rolled article is then folded to half its length
at about
its mid-point by means of a thrusting blade which also serves to insert the
article into
a retaining pouch. It is observed that, with the rolling method herein,
essentially no
severely sharp creases are formed, and the final doubling of the rolled tube
is under
such stress that only in the very center of the bend are a few sharper creases
formed.
The result is that permanent refolding along crease lines is essentially
avoided, and
release of the cleaning/refreshment composition from the article in-use is
optimized.
Any plastic or flexible pouch which does not leak is suitable for use herein.
For example, a foil laminated pouch of the type used in the food service
industry can
be employed. Such pouches are well-known in the industry and are made from
materials which do not absorb food flavors. In like manner, the formulator
herein
may wish to avoid absorption of the perfume used in the cleaning/refreshment
composition by the pouch. Various pouches are useful herein and are
commercially
available on a routine basis. As a point of comparison, the pouch containing
the
rolled/folded article herein has overall dimensions of about 8.5 cm x 17.7 cm,
whereas
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26
a pouch for a similar planar-folded article is about 13 cm x 17.7 cm. A
savings in
material of about 30-40% is thus achieved.
23 Grams of the liquid product are poured onto the article within the pouch
and allowed to absorb into it for a minimum of 30 minutes, preferably for at
least
about 4 hours. The pouch is sealed immediately after the liquid product is
introduced
into the pouch and stored until time-of use.
As an entirely optional matter, the carrier sheet can also have holes punched
therethrough in order to further maximize its ability to maintain an open
configuration
in-use. Indeed, the holes can be punched through the entire article, including
the
coversheet, itself. For an article having the overall dimensions of about 27
cm x
37 cm, 16 round holes, each about 0.5 in. (1.27 cm) in diameter are evenly
spaced
across the HYDRASPUN carrier sheet. Slits or other perforations may be used in
like manner.
The fabric to be treated is placed into a 26 in. x 30 in. (66 x 76 cm) vapor-
venting nylon bag as shown in the Figures together with the sheet (which is
removed
from its storage pouch, unfolded and unrolled) releasably containing the
aforesaid
cleaning/refreshment product. The mouth of the bag is closed to provide vapor-
venting, and the bag and its contents are placed in the drum of a conventional
hot air
clothes dryer. The dryer is operated in standard fashion for 20-60 minutes at
a high
heat setting (an air temperature range of about 140-170°F; 60-
70°C). After the
tumbling action of the dryer ceases, the cleaned and refreshed fabric is
removed from
the bag. The used sheet is discarded. The fabric (which is preferably still
slightly
damp) is preferably hung on a conventional hanger to complete the drying
process
thereby further avoiding wrinkles.
EXAMPLE II
The article of Example I is prepared from a non-woven fabric (preferably
hydroentangled} but without the coversheets. The article is rolled, soaked in
10-35
grams of the cleaning/refreshment composition, and packaged for shipment, all
as
disclosed in Example I.
EXAMPLE III
Other compositions for use on a sheet substrate in a hot air clothes dryer in
the manner disclosed herein, are as follows.
INGREDIENT PERCENT (wt.} RANGE
NEODOL 23 - 6. 5 1.00 0. I -1. 5
BPP* 9.2 0-5
1,2-Octanediol 0.65 0-1.0
Perfume 1.00 0-1.5
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27
PEMULEN~ TR-1 * * 0.125 0-0. 2
KOH 0.063 0.024-0. I 0
KCl 0.075 0.02-0.20
KATHON~ CG 0.0003 0.0001-0.001
Water Balance Balance
*Butoxypropoxy propanol
**PEMIJLEN TR-2, B. F. Goodrich, may be substituted.
Besides the other ingredients, the foregoing compositions can contain
enzymes to further enhance cleaning performance. Lipases, amylases and
protease
enzymes, or mixtures thereof, can be used. If used, such enzymes will
typically
comprise from about 0.001 % to about 5%, preferably from about 0.01 % to about
1%, by weight, of the composition. Commercial detersive enzymes such as
LIPOLASE, ESPERASE, ALCALASE, SAVINASE and TERMAMYL (all ex.
NOVO} and MAXATASE and RAPIDASE (ex. International Bio-Synthesis, Inc.)
can be used.
If an antistatic benefit is desired, the compositions used herein can contain
an
anti-static agent. If used, such anti-static agents will typically comprise at
least about
0.5%, typically from about 2% to about 8%, by weight, of the compositions.
Preferred anti-stats include the series of sulfonated polymers available as
VERSAFLEX 157, 207, 1001, 2004 and 7000, from National Starch and Chemical
Company.
It will be understood that the articles herein can be modified without
departing
from the spirit and scope of this invention. For example, as shown in Figures
3 and 4,
a variation that can make the substrate a bit easier to fold and insert into
the pouch is
to elongate the spiral fold pattern out, such that the rolled fabric resembles
a "bolted"
roll of fabric. This bolting reduces the number of cross-sectional layers
versus a
circular spiral, thus causing less bunching and bulging along the center fold.
Another
variation is to fold the substrate first, preferably along its longest
dimension, and then
"bolt" or roll it as shown in Figure 5. This pattern and the internal bunching
of the
layers produce a "springiness" to help keep the spiral pattern pushed open and
prevent
the folds from reforming in-use. All such variations are encompassed by the
terms
"roll" or "rolled", as used herein. Alternatively, the rolled article can be
folded into
thirds, rather than half, to further minimize the use of packaging materials.
Various
logos, patterns, colors, and the like can be used to enhance the appearance of
the
articles.
