Cleaning method

• US 9,803,307 B2
• Filed: 01/16/2012
• Issued: 10/31/2017
• Est. Priority Date: 01/14/2011
• Status: Active Grant

• Current Assignee: Xeros Limited (Xeros Technology Group Plc)
• Original Assignee: Xeros Limited (Xeros Technology Group Plc)
• Inventors: Jenkins, Stephen Derek, Kennedy, Frazer John
• Primary Examiner(s): Ko, Jason
• Assistant Examiner(s): Bell, Spencer
• Application Number:
  US13/979,392
• Publication Number:
  US 20130283542A1
• Time in Patent Office: 2,115 Days
• Field of Search: None
• CPC Class Codes: C11D 17/046 Insoluble free body dispenser
• CPC Class Codes: C11D 2111/12 Soft surfaces, e.g. textile
• CPC Class Codes: C11D 3/1206 free metals, e.g. aluminium grit or flakes
• CPC Class Codes: C11D 3/1213 Oxides or hydroxides, e.g. Al2O3, TiO2, CaO or Ca(OH)2
• CPC Class Codes: C11D 3/124 Silicon containing, e.g. silica, silex, quartz or glass beads
• CPC Class Codes: C11D 3/14 Fillers; Abrasives ; Abrasive compositions; Suspending or absorbing agents not provided for in one single group of C11D3/12; Specific features concerning abrasives, e.g. granulometry or mixtures dyes, pigments C11D3/40
• CPC Class Codes: C11D 3/37 Polymers polymeric surface-active agents C11D1/008; polysaccharides C11D3/222
• CPC Class Codes: C11D 3/3715 Polyesters or polycarbonates
• CPC Class Codes: C11D 3/3719 Polyamides or polyimides
• CPC Class Codes: C11D 3/3726 Polyurethanes
• CPC Class Codes: C11D 3/3749 Polyolefins; Halogenated polyolefins; Natural or synthetic rubber; Polyarylolefins or halogenated polyarylolefins
• CPC Class Codes: C11D 3/382 Vegetable products, e.g. soya meal, wood flour, sawdust
• CPC Class Codes: C11D 7/02 Inorganic compounds
• CPC Class Codes: C11D 7/20 Water-insoluble oxides
• CPC Class Codes: C11D 7/44 Vegetable products
• CPC Class Codes: D06F 35/006 for washing or rinsing only
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers

Abstract

The invention provides a method for the cleaning of a soiled substrate, the method comprising treating the substrate with a non-polymeric solid particulate cleaning material and wash water, the treatment being carried out in an apparatus comprising a drum comprising perforated side walls and having a capacity of between 5 and 50 liters for each kg of fabric in the washload, wherein the solid particulate cleaning material comprises a multiplicity of non-polymeric particles at a particle to fabric addition level of 0.1:1-10:1 by mass, each of the particles being substantially cylindrical or spherical in shape, and wherein the drum comprising perforated side walls is rotated at a speed which generates G forces in the range of from 0.05 to 900 G. The non-polymeric particles may comprise particles of glass, silica, stone, wood, or any of a variety of metals or ceramic materials. Preferably the solid particulate cleaning material additionally comprises a multiplicity of polymeric particles each of which is substantially cylindrical or spherical in shape. Preferably, at least one detergent is employed in the cleaning process. The invention provides optimum cleaning performance as a result of improved mechanical interaction between substrate and cleaning media and is preferably used for the cleaning of textile fabrics. The method allows for significant reductions in the consumption of detergents, water and energy when compared with the conventional wet cleaning of textile fabrics, and also facilitates reduced washing-related textile fabric damage. The invention also envisages a cleaning composition comprising a solid particulate cleaning composition and at least one additional cleaning agent.

Claims

1. A method for the cleaning of a soiled substrate, said method comprising treating the substrate with at least a non-polymeric solid particulate cleaning material and wash water, said treatment being carried out in an apparatus comprising a drum comprising perforated side walls and having a capacity of between 5 and 50 liters for each kg of fabric in the washload, wherein said solid particulate cleaning material comprises a multiplicity of non-polymeric particles at a particle to fabric addition level of 0.1:

1-10;

1 by mass, each of said particles being substantially cylindrical or spherical in shape and having an average density in the range of 3.5-12.0 g/cm³ and an average volume in the range of 5-275 mm³, and wherein said drum comprising perforated side walls is rotated at a speed which generates G forces in the range of from 0.05 to 900 G.

2. The method as claimed in claim 1 wherein said non-polymeric particles comprise particles of glass, silica, stone, wood, or any of a variety of metals or ceramic materials, wherein said metal is optionally selected from zinc, titanium, chromium, manganese, iron, cobalt, nickel, copper, tungsten, aluminium, tin and lead, and alloys thereof, and wherein said ceramic material is optionally selected from alumina, zirconia, tungsten carbide, silicon carbide and silicon nitride.

7. The method as claimed in claim 1 wherein said particles comprised in said solid particulate cleaning material are cylindrical and have an oval cross section wherein the major cross section axis length is in the range of from 2.0-6.0 mm and the minor cross section axis length is in the range of from 1.3-5.0 mm, or wherein said particles comprised in said solid particulate cleaning material are cylindrical and have a circular cross section wherein the cross section diameter is in the range of from 1.3-6.0 mm, and wherein the length of said particles is optionally in the range of from 1.5-6.0 mm.

8. The method as claimed in claim 1 wherein said particles comprised in said solid particulate cleaning material are spherical and the diameter is in the range of from 2.0-8.0 mm, wherein said particles are optionally not perfect spheres and the diameter is in the range of from 2.2-5.5 mm, or wherein said particles are optionally perfect spheres and the diameter is in the range of from 3.0-7.0 mm.

9. The method as claimed in claim 1 wherein said non-polymeric particles comprise coated non-polymeric particles, wherein said non-polymeric particles optionally comprise a non-polymeric core material and a shell comprising a coating of a polymeric material, wherein said core optionally comprises a steel core and said shell optionally comprises a coating of nylon.

10. The method as claimed in claim 1 wherein said drum comprising perforated side walls comprises a rotatably mounted cylindrical cage and said method is optionally carried out at temperatures not exceeding 95°

C., optionally not exceeding 75°

C., optionally in the range of from 5-40°

C.

11. The method as claimed in claim 10 wherein said rotatably mounted cylindrical cage is comprised in said apparatus comprising a housing and an access means, allowing access to the interior of said cylindrical cage, and wherein said apparatus optionally comprises at least one of the following features:

(a) said rotatably mounted cylindrical cage is concentrically located within a rotatably mounted cylindrical drum having a greater diameter than said cage, wherein said cage and said drum are concentrically located within a stationary cylindrical drum having a greater diameter than said rotatably mounted drum, and wherein said rotatably mounted cylindrical cage and said rotatably mounted cylindrical drum are adapted to rotate independently;

(b) said rotatably mounted cylindrical cage is mounted in a first chamber within said housing, which also comprises a second chamber located adjacent said cylindrical cage, and said apparatus optionally additionally comprises at least one recirculation means and a multiplicity of delivery means and/or optionally additionally comprises a seal, removably attached to the outer surface of the cylindrical side walls of said rotatably mounted cylindrical cage, and adapted to prevent the ingress or egress of fluids and solid particulate matter from the interior of said cage, or comprises a pump, wherein said rotatably mounted cylindrical cage comprises a drum comprising perforated side walls, wherein up to 60% of the surface area of said side walls comprises perforations, and said perforations comprise holes having a diameter of no greater than 25.0 mm,

and wherein said access means optionally comprises a hinged door mounted in the housing which may be opened to allow access to the inside of the cylindrical cage and which may be closed in order to provide a substantially sealed system.

12. The method as claimed in claim 10 wherein a wash cycle comprises the steps of:

i. introducing a solid particulate cleaning material and water into a second chamber of said apparatus comprising said rotatably mounted cylindrical cage;

ii. agitating said solid particulate cleaning material and water;

iii. loading at least one soiled substrate into said rotatably mounted cylindrical cage via access means;

iv. closing the access means so as to provide a substantially sealed system;

v. causing the rotatably mounted cylindrical cage to rotate whilst introducing wash water and any required additional cleaning agent to uniformly wet out the substrate;

vi. introducing said solid particulate cleaning material and water into said rotatably mounted cylindrical cage and operating the apparatus for a wash cycle, wherein said rotatably mounted cylindrical cage continues to rotate and wherein fluids and solid particulate cleaning material are caused to fall through perforations in said rotatably mounted cylindrical cage into a second chamber in a controlled manner;

vii. transferring fresh solid particulate cleaning material and recycling used solid particulate cleaning material to separating means;

viii. adding said fresh and recycled solid particulate cleaning material to said rotatably mounted cylindrical cage in a controlled manner; and

ix. continuing with steps (vi), (vii) and (viii) as required to effect cleaning of the soiled substrate.

13. The method as claimed in claim 1 further comprising separating the solid particulate cleaning material from the substrate on completion of the washing process, recovering said solid particulate cleaning material and re-using said material in subsequent washes and wherein, optionally, following separation and recovery, said solid particulate cleaning material is subjected to a cleaning operation prior to re-use.

14. The method as claimed in claim 1 wherein said apparatus comprises circulation means, adapted to promote circulation of said solid particulate cleaning material.

15. The method as claimed in claim 1 which comprises performing, in sequence, the steps of:

a. washing;

b. first extraction of excess water;

c. first separation of particles of solid particulate cleaning material;

d. rinsing;

e. second extraction of excess water;

f. optionally repeating steps (d) and (e) at least once; and

g. second separation of particles of solid particulate cleaning material,

wherein steps (d) and (e) are optionally repeated up to 10 times, and wherein, optionally, said washing process is carried out at between 0.05 and 0.95 G, the rinsing water is added under similar conditions, then extracted at a higher G force of 5.5 to 350 G, and said separation of particles from the fabric is carried out at 0.05 to 0.95 G.

16. The method as claimed in claim 1 wherein at least one additional cleaning agent is employed, wherein said at least one additional cleaning agent is optionally pre-mixed with water and added to said drum comprising perforated side walls via separating means during the introduction of said solid particulate cleaning material and water into said drum comprising perforated side walls via recirculating means, wherein said at least one additional cleaning agent optionally comprises a detergent composition comprising cleaning components and post-treatment components, wherein said cleaning components are optionally selected from surfactants, enzymes and bleach, and wherein said post-treatment components are optionally selected from components anti-redeposition additives, perfumes and optical brighteners.

3. The method as claimed in 1 further comprising a multiplicity of polymeric particles, each of said particles being substantially cylindrical or spherical in shape and having an average density in the range of 0.5-2.5 g/cm³ and an average volume in the range of 5-275 mm³.

4. The method as claimed in claim 3 wherein said polymeric particles comprise foamed or unfoamed polymeric materials and/or said polymeric particles comprise linear or crosslinked polymers.

5. The method as claimed in claim 3 wherein said polymeric particles comprise beads of polyalkenes, polyamides, polyesters or polyurethanes, wherein said polyamide optionally comprises Nylon 6 or Nylon 6,6, optionally Nylon 6,6 homopolymer having a molecular weight in the region of from 5000 to 30000 Daltons, and wherein said polyester optionally comprises polyethylene terephthalate or polybutylene terephthalate.

6. The method as claimed in claim 3 wherein said the ratio of said non-polymeric particles to said polymeric particles is from 99.9 w/w %:

0.1 w/w % to 0.1 w/w %;

99.9 w/w %, optionally from 90.0 w/w %;

10.0 w/w % to 25.0 w/w %;

75.0 w/w %, optionally from 85.0 w/w %;

15.0 w/w % to 40.0 w/w %;

60.0 w/w %.