Information
-
Patent Grant
-
6262004
-
Patent Number
6,262,004
-
Date Filed
Wednesday, November 10, 199925 years ago
-
Date Issued
Tuesday, July 17, 200123 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
-
US Classifications
Field of Search
US
- 510 298
- 510 294
- 510 440
- 510 445
- 510 446
- 510 507
- 510 509
- 510 511
-
International Classifications
-
Abstract
A cleaning composition in solid state comprises a gas-releasing component as a cleaning agent, a solubility control component to limit the solubility of the cleaning composition, an alkalinity agent as a pH regulator, and optionally a water softener.
Description
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to cleaning systems, and, more specifically, methods, apparatus, and compositions for cleaning with water, including compositions and dispensers for controlling concentrations of cleaning agents delivered into water.
2. The Relevant Technology
Chemical cleaning agents, in one form or another, have long been used to remove dirt, oil, and particulate matter from a wide variety of articles. Cleaning improves the visual and tactile impression of an article, kills potentially harmful microbes, removes particles that interfere with breathing and vision, and may even extend the life of the article being cleaned. Things such as cookware, homes, automobiles, clothing, and the human body itself stand to benefit from the development of enhanced cleaning agents. Although the present invention contemplates cleaning systems useful for cleaning a wide variety of articles, it is particularly well-adapted for cleaning clothes, as in a washing machine.
Soaps and detergents are two of the most common cleaning agents presently used. While they are often used interchangeably, the words “soap” and “detergent” actually denote different classes of compounds.
Soaps are made by a process of saponification wherein a fatty acid reacts with a base to yield the salt of the fatty acid, i.e., a soap. Soap probably has its origin in reacting animal fats, or lard, with alkaline salts, such as wood ash. Today, they are largely synthesized from animal fats and plant oils. Molecules of soap owe their cleaning capacity to their amphiphilic structure, which includes a hydrophobic portion consisting of a long hydrocarbon chain, and a hydrophilic portion composed of an ionic group at one end of the hydrocarbon chain. Because of the hydrocarbon chain, a molecule of soap is not truly soluble in water. Numerous molecules of soap will suspend in water as micelles, or clusters of molecules with long hydrocarbon chains in the inner portions of the cluster, and ionic, water soluble ends facing the polar water.
Because these micelles form hydrophobic centers, they are able to dissolve other non-polar substances, like oils. Once the non-polar, oily dirt is dissolved within the micelles of soap, the ionic surfaces of the micelle repel each other, suspending the oil droplets and preventing them from coalescing. In this fashion, dirt and oil become trapped within the water soluble micelles, and wash away with the water.
A primary disadvantage of soaps is that they form insoluble salts (precipitates) with ions found in hard water. These salts, usually formed when Ca++ and Mg++ ions react with the carboxylate ends of soap molecules, precipitate out of solution as bathtub rings, grits, and other deposits. Water softeners that exchange Ca++ and Mg++ ions for more soluble Na+ ions can alleviate most of this problem.
Most laundry products and many household cleansers actually contain detergents, not soaps. A detergent is a compound with a hydrophobic hydrocarbon chain plus a sulfonate or sulfate ionic end (whereas soaps have carboxylic ends). Because detergents also have an amphiphilic structure, they also form micelles and clean in the same fashion as soaps. However, detergents have the advantage that most metal alkylsulfonates and sulfates are water-soluble. Therefore, detergents do not precipitate out of solution with metal ions found in water. As a result, detergents are not inhibited by hard water. In addition, detergents can be synthesized with continuous chain alkyl groups, which are more easily broken down, or biodegraded, into smaller organic molecules by the microorganisms in septic tanks and sewage treatment plants.
A drawback of most detergents is that they contain additives that take much longer to biodegrade. Some components containing phosphates must be treated in plants. Phosphates therefore promote algae growth, chocking bodies of water and streams. Another disadvantage of detergents is that they can leave behind an undersireable residue even after thorough rinsing.
Detergents are currently used in many household appliances, such as dishwashers and washing machines. Presently, a user must measure out a dose of detergent to add to the cleaning appliance before every cleaning cycle. Conventional packaging and use of detergents creates messy clutter, consumes time, and typically results in a waste of detergent from overdosing. In addition, most washing machines for clothing use a separate rinsing cycle in order to remove the residue. Thus, additional time, water, and heat energy are required to complete the washing process.
It would be a great advancement in the art to provide a novel cleaning system that uses a novel non-detergent composition of cleaner that leaves no residue and therefore, requires no rinsing cycle. Another improvement in the art would be to provide a cleaning agent that is completely biodegradable. Still another improvement would be if this cleaning agent were made from all natural materials. It would also be a great advancement in the art to provide a new method for making a non-detergent cleaning agent. It would be another advancement in the art to provide a cleaning agent that cleans better than the detergents presently on the market. Furthermore, it would be an improvement in the art to simplify the cleaning process and ameliorate the resultant mess with improved, preferably measurement-free or automatic, dosing over many cleaning cycles.
OBJECTS AND BRIEF SUMMARY OF THE INVENTION
In accordance with the invention as embodied and broadly described herein, an apparatus, composition, and method are disclosed, in suitable detail to enable one of ordinary skill in the art to make and use the invention. In certain embodiments, an apparatus for dispensing cleaning agents in accordance with the present invention includes a vessel comprising a cavity with a cartridge support for mounting a replaceable cartridge.
In one embodiment, the cartridge comprises a novel composition of cleaning agent for cleaning, and solubility control component for controlling the equilibrium concentration of the cleaning composition in solution, further described below. A water source supplies water into the cavity, and a water feed conveys water from the cavity to a cleaning appliance such as a brush, wand, dishwasher, or washing machine for clothing. The apparatus provides a cleaning agent solution in water to the cleaning appliance.
In one embodiment, the inner cavity (and hence the cartridge) of the canister is flooded with water from a water source. The cartridge then dissolves to an equilibrium concentration within the vessel, thus forming a cleaning solution comprising a cleaning agent and a solubility control component to control the concentration of the cleaning agent. The vessel is then purged of the solution, which enters the water feed to be carried into a cleaning appliance.
Enough cleaning solution should be delivered to the feed, to bring the cleaning composition to cleaning concentration when diluted in the washing appliance. Cleaning concentration is the amount of cleaning composition necessary to clean those items serviced by (e.g. placed within) the cleaning appliance during a wash cycle. In particular, a cleaning concentration for a washing machine is that concentration needed to clean a load of clothing. The amount of cleaning composition delivered to the feed is controlled by the amount of cleaning solution and the cleaning solution's equilibrium concentration. Therefore, the vessel should be configured to receive a predetermined amount of solution, and the solubility control in the cartridge should be configured to dissolve a predetermined equilibrium concentration of cleaning composition in the vessel.
As explained, a composition of cleaner in accordance with the present invention may include a mixture of a cleaning agent and a solubility control agent in a solid state. In some embodiments, the mixture may also comprise an additional alkalinity agent and a water softener. The principal cleaning agent is preferably a gas-releasing compound, e.g. sodium bicarbonate. Gas-releasing compounds clean by reacting with acids (soils) and by mechanical microscrubbing as they yield carbon dioxide. The solubility control agent is preferably a material resistant to dissolving in water, e.g., amorphous silica. These compounds control solubility by dissolving only an equilibrium concentration of composition in solution.
The alkalinity agent is preferably a basic compound found in nature, e.g., sodium sesquicarbonate (which actually contains sodium bicarbonate and sodium carbonate in a substantially 1:1 ratio). The alkalinity agent prevents the cleaning agent from releasing carbon dioxide too quickly by increasing the pH of the solution. The water softener is preferably a naturally occurring material capable of solvating hard water ions, e.g., natural zeolite. The water softener prevents hard ions from reacting with other components to form insoluble salts.
The composition of cleaner may be formulated and cured into various shapes; however, a cylindrical cartridge with an annular cross section is presently preferred. The annular shaped cylinder has an advantage over other shapes in that, as it dissolves, it retains approximately the same surface area, and hence the same dissolution rate. This is because the annular shape yields an interior surface that increases in area at approximately the same rate as that of the exterior surface decreases.
The amount of solubility control component in the composition determines the equilibrium concentration of the composition in a solution, e.g., water. Therefore, the amount of solubility control component should be sufficient to yield a predetermined equilibrium concentration of composition. Similarly, the amount of cleaning agent should be sufficient to provide a predetermined amount of gas in solution. The amount of alkalinity agent should be sufficient to provide a predetermined pH in solution. The amount of water softener should be sufficient to soften household water in solution.
In certain embodiments, a method for making a composition of cleaner in a solid state may include providing a solvent, providing a gas-releasing agent, and providing a solubility control component. The method may also include providing an alkalinity agent. The fabrication process may typically include applying energy, mixing, and testing the composition for an azeotrope. Completion of the process may include casting the composition in a shape selected to control surface area, cooling the composition, and curing the composition.
In other embodiments, a method for using an apparatus for delivering solvated cleaning agents to a cleaning appliance may include providing a dispensing apparatus, shutting off a water supply, opening the dispensing apparatus, installing a shaped block of a cleaning agent, and closing dispensing apparatus. Thereafter, the method may include turning water supply on, running wash cycles, and selectively dissolving a portion of the cleaning agent at a controlled rate with each fill cycle.
In certain embodiments of the present invention, a method for delivering cleaning solution to a cleaning appliance may include flooding a dispensing apparatus with a solvent, dissolving a portion of a hardened charge of cleaning agent, equilibrating a solution of cleaning agent, and flushing the dispensing apparatus. The method may include delivering a cleaning agent solution to a cleaning appliance, cleaning through basic reactions and gas release, and draining waste from the cleaning appliance.
These and other objects, features, and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of apparatus and methods possible in accordance with the invention, which are, therefore, not to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1
is a perspective view of a cleaning appliance provided with an apparatus in accordance with the invention;
FIG. 2
is a perspective view of a cleaning appliance having a built-in vessel and control in accordance with the invention;
FIG. 3
is a perspective view of an apparatus in accordance with the invention;
FIG. 4
is a partially-cutaway perspective view of one embodiment of the apparatus of
FIG. 3
;
FIG. 5
is a side elevation section view of one embodiment of the apparatus of
FIG. 3
;
FIG. 6
is a perspective view of the fill and purge system suitable for the apparatus of
FIG. 3
;
FIG. 7
is a cutaway perspective view of an alternative embodiment of the apparatus of the invention;
FIG. 8
is a schematic diagram of a method for connecting a cleaning apparatus to an apparatus suitable for the invention;
FIG. 9
is a schematic diagram of a method for using a cleaning system in accordance with the invention;
FIG. 10
is a schematic diagram of a method for carrying out a wash cycle according to the invention;
FIG. 11
is a perspective view of a replaceable cartridge in accordance with the invention;
FIG. 12
is a schematic diagram of components that may form a composition suitable for the present invention;
FIG. 13
is a schematic diagram of one embodiment of a composition according to the invention, including the components shown in
FIG. 12
;
FIG. 14
is a schematic diagram of steps that may form a cleaning process according to the invention;
FIG. 15
is a schematic diagram of one embodiment of a cleaning process according to the invention, including the steps shown in
FIG. 14
;
FIG. 16
is a schematic diagram of steps that may be used to make a cartridge according to the invention;
FIG. 17
is a schematic diagram of one embodiment of a process of making a cartridge according to the invention, including the steps shown in
FIG. 16
; and
FIG. 18
is a pictorial process diagram of steps that may be used to make a cartridge according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The presently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present invention, as generally is described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the apparatus, system, and method of the present invention, as represented in
FIGS. 1 through 18
, is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.
Those of ordinary skill in the art will, of course, appreciate that various modifications to the details of the figures may easily be made without departing from the essential characteristics of the invention. Thus, the following description of the figures is intended only as an example, and simply illustrates one presently preferred embodiment that is consistent with the invention as claimed.
Referring to
FIG. 1
, the present invention relates to an apparatus
10
for delivering cleaning compositions
11
in solvated form, that may be disposed between a water supply
12
and water feed
14
. In one preferred embodiment, the water feed
14
leads to a cleaning appliance
16
(e.g., a washing machine). The apparatus
10
may deliver a cleaning solution
17
of cleaning agent to a cleaning chamber
18
of the cleaning appliance
16
.
The apparatus
10
may be mounted to any suitable surface, such as a wall
19
near the cleaning appliance
16
, by a mount
20
, as shown in FIG.
1
. Those skilled in the art will appreciate that the mount
20
may take various forms, including a bracket system, a mount arm, a shelf, and various other forms capable of fixing the apparatus
10
to a surface. The water supply
12
preferably provides comparatively unheated water. A separate line
21
may convey heated water to the cleaning appliance
16
.
The water supply
12
and water feed
14
may also have valves
22
(
a
) and
22
(
b
) connected to allow a user to turn a water flow on and off. The valves
22
(
a
) and
22
(
b
) may take various forms known in the art, including ball valves, sliding spool valves, solenoid valves, and any other type of valve with a manual or electronic control whereby a user may control a flow of water flowing through the apparatus
10
. In particular, the valve
22
(
a
) may be situated on the water supply
12
to control flows into the apparatus
10
, and the valve
22
(
b
) may be positioned on the water feed
14
to control flows from the apparatus
10
to the cleaning appliance
16
.
In an alternative embodiment of the invention, best illustrated in
FIG. 2
, the apparatus
10
may be contained within the cleaning appliance
16
. A water mixer
24
combines flows from a line
21
conveying heated water and a line
25
supplying cold water. The apparatus
10
is preferably positioned downstream from the water mixer
24
, as depicted in
FIG. 2
, but may also be positioned on the line
21
or the line
25
. As with the previously described embodiment, the water feed
14
conveys solvated water from the apparatus
10
to the cleaning chamber
18
. The cleaning appliance
16
may have a hatch
26
to allow access to the apparatus
10
. Numerous other plumbing configurations, including a bypass system, could also be used according to methods known in the art.
Referring to
FIGS. 3 and 4
, one possible embodiment of the apparatus
10
of the present invention has a vessel
27
for containing water in an interior cavity
28
thereof. The vessel
27
may take any shape that maintains an interior cavity
28
to accommodate a cartridge
30
of solidified cleaning composition
11
. However, a cylindrical shape with an annular cross section is presently preferred. The vessel
27
may be constructed out of any air and water tight material, including metals, plastics, ceramics, composites, etc. The apparatus
10
further has an inlet port
32
formed in the vessel
27
to permit the ingress of water from a water supply
12
to the interior cavity
28
, and an outlet port
34
formed in the vessel
27
for flushing water from the interior cavity
28
into a water feed
14
. Thus, water flows into and out of the vessel
27
in the direction of the arrows shown in FIG.
4
.
In one embodiment of the present invention, best illustrated in
FIG. 4
, the vessel
27
includes a support
36
. The support
36
may be any structure that supports a cartridge
30
of solidified cleaning composition
11
, including an interior wall
38
of the vessel
27
itself However, in the presently preferred embodiment, the support
36
is a separate structure attached to the interior wall
38
of the vessel
27
such that it spans a cross section of the vessel
27
. The cartridge
30
may then rest on the support
36
when the vessel
27
is in the upright position, as illustrated in FIG.
3
. The support
36
may be configured to accommodate cartridges of different sizes and shapes.
Preferably, the support
36
is water permeable, and may be composed of a simple mesh to allow water to flow freely between the inlet and outlet ports
32
and
34
and the cartridge
30
while maintaining a separation therebetween. When the cartridge
30
is immersed in water, a cleaning solution
17
is formed and retained within the interior cavity
28
.
Flows through the inlet port
32
and outlet port
34
may converge in a mixing tube
40
. The mixing tube
40
may run through the interior cavity
28
and may also be U-shaped to connect the water supply
12
with the water feed
14
through the inlet and outlet ports
32
and
34
, respectively. Water may be conveyed through the inlet port
32
via an inlet fitting
42
, disposed on the outside of the vessel
27
with a fastener
43
to connect the water supply
12
. Although the fastener
43
may take any form selected to couple the inlet fitting
42
to the water supply
12
, threads
43
on the inlet fitting
42
, for engagement with similar threads on the water supply
12
, are preferable. The outlet port
34
may have an outlet fitting
44
, disposed on the outside of the vessel
27
, with a fastener
46
that may also take the form of threads
46
. It will be readily appreciated by those skilled in the art that the inlet fitting
42
and outlet fitting
44
may take any form adapted to connect a water supply
12
and a water feed
14
, respectively, and such forms are within the scope of the present invention.
Referring now to
FIGS. 5 and 6
, and according to one embodiment of the present invention, the vessel
27
may have a bottom cap
48
with a base
50
and an annular wall
52
. The base
50
may be circular in shape and may be unitary with the annular wall
52
, which may extend perpendicular to the base
50
to fit into the interior cavity
28
of the vessel
27
. The annular wall
52
preferably includes threads
54
(
a
) to engage similar threads
54
(
b
) on the interior wall
38
of the vessel
27
. A user may affix the bottom cap
48
to the vessel
27
by twisting or screwing the threads
54
(
a
) and
54
(
b
) into an interlocking position, best illustrated in FIG.
5
. Other methods for affixing the bottom cap
48
to the vessel
27
, including latches, friction fittings, separate fasteners, and others, are known in the art.
The bottom cap
48
may form a water-tight seal with the vessel
27
when the wall
52
engages an o-ring
56
, held in place by a lip
58
disposed on the interior wall
38
of the vessel
27
. As shown in
FIG. 6
, the mixing tube
40
may extend through the base
50
of the bottom cap
48
and into the interior cavity
28
, to permit easy connection and disconnection of the water supply
12
and the water feed
14
.
In one preferred embodiment, the inlet port
32
has an intake system
74
connected to the mixing tube
40
for delivering water from the mixing tube
40
into the interior cavity
28
. This intake system
74
may take various forms, but a simple bent tube, hereinafter a separation tube
74
, as illustrated in
FIG. 6
, is presently preferred. As water runs through the mixing tube
40
from the water supply
12
to the feed
14
, the separation tube
74
diverts some water into the interior cavity
28
. If the mixing tube
40
and the separation tube
74
are unobstructed, the vessel
27
may fill completely with water. Alternatively, as illustrated in
FIG. 6
, a valve
76
, such as a check valve in the separation tube
74
, may limit flow into the interior cavity
28
. The valve
76
may also be positioned within the mixing tube
40
. In one embodiment, a valve
76
may be configured to allow only a predetermined amount of water to enter the interior cavity
28
, by means such as a flow control valve, or a metering valve, for example.
As shown in
FIG. 6
, the mixing tube
40
also has a delivery system
78
connected to the mixing tube
40
for delivering water from the interior cavity
28
back into the mixing tube
40
. The delivery system
78
may take various forms, but a siphon tube
78
is presently preferred. As water flows through the mixing tube
40
from the water supply
12
to the feed
14
, it encounters the siphon tube
78
, which decreases the cross-sectional area of the mixing tube
40
. The result is a venturi effect. An area of comparatively low pressure water forms about the siphon tube
78
to draw water out of the interior cavity
28
and into the mixing tube
40
. In this embodiment, the outlet port
34
is passive.
If the mixing tube
40
and the siphon tube
78
are unobstructed, the vessel
27
is continuously flushed as water circulates through the mixing tube
40
. However, in the embodiment illustrated in
FIG. 6
, a valve
80
, such as a check valve in the siphon tube
78
, may limit flow out of the interior cavity
28
. The valve
80
may also be positioned within the mixing tube
40
. The valve
80
may be configured to allow only a predetermined amount of water to leave the interior cavity
28
, such as a flow control valve, or a metering valve by way of example.
As shown in
FIG. 5
, the vessel
27
may also have a top cap
60
, which may be removable to allow access to the interior cavity
28
. The top cap
60
has a base
62
that is substantially circular with an annular wall
64
running perpendicular to the base
62
near its outer circumference. The inner portion of the wall
64
has threads
66
(
a
) that engage similar threads
66
(
b
) on the outer wall of the vessel
27
. A user may affix the top cap
60
to the vessel
27
by twisting or screwing the threads
66
(
a
) and
66
(
b
) together into an interlocking position. As with the bottom cap
48
, numerous methods for affixing the top cap
60
to the vessel
27
are within the scope of the present invention, including latches, friction fittings, separate fasteners, etc. The top cap
60
forms a water tight seal with the vessel
27
when the wall of the vessel
27
engages an o-ring
68
, held in place by a lip
70
disposed along the inner circumference of the base
62
.
Referring to
FIG. 7
, in an alternative embodiment, the inlet port
32
and the outlet port
34
of the vessel
27
may be configured with a flow-through design. In this embodiment, the inlet and outlet ports
32
and
34
are disposed on opposite ends of the vessel
27
, with the interior cavity
28
between the inlet and outlet ports
32
and
34
. The cartridge
30
may be held within the vessel
27
by separators
71
(
a
) and
71
(
b
) that are water permeable and preferably constructed of a mesh material. The separator
71
(
a
) separates the cartridge
30
from the inlet port
32
. The separator
71
(
b
), in turn, separates the cartridge
30
from the outlet port
34
.
Referring to
FIG. 8
, one method of connecting the apparatus
10
to the cleaning appliance
16
is shown. This method applies to several different cleaning processes. Although the apparatus
10
may be configured in several different ways for use with this method, the following descriptions for
FIGS. 8
,
9
, and
10
relate directly to the exemplary embodiments described in connection with FIGS.
1
and
3
-
6
.
In a typical cleaning appliance
16
of the type used to wash clothing, the water supply and the heated water line
21
connect directly to the cleaning appliance
16
. Thus, in a first step
84
, a user may be required to restrict the flow of water through the water supply
12
by closing the valve
22
(
a
) before disconnecting the water supply
12
from the cleaning appliance
16
. Then, in a second step
86
, a user may disconnect the water supply
12
from the cleaning appliance
16
. A user then connects the water supply
12
to the apparatus
10
via the inlet fitting
42
in a third step
88
. Then, in a fourth step
90
, a user connects the water feed
14
to the vessel
27
via the outlet fitting
44
and to the cleaning appliance
16
. In a fifth step
92
, a user may open the valve
22
(
a
) to turn the water back on.
Referring to
FIG. 9
, a method for using the apparatus
10
, after connection to a cleaning appliance
16
through the steps described above, is disclosed. In a first step
94
, a user shuts off the water supply by closing the valve
22
(
a
). A user then opens the vessel
27
, by removing the top cap
60
, in a second step
96
. In a third step
98
, the cartridge
30
is placed in the interior cavity
28
of the vessel
27
. In a fourth step
100
, a user closes the vessel
27
by replacing the top cap
60
. A user may then turn the water supply on again, in a fifth step
102
, by turning on valve
22
(
a
). After the cartridge
30
has become depleted through use, a user may repeat steps
94
-
102
to install a new cartridge
30
for further washing.
FIG. 10
shows a possible washing cycle that incorporates the apparatus
10
. After the water supply
12
has been turned on in the step designated
102
above, a first step
112
occurs, wherein the interior cavity
28
, and hence the cartridge
30
, of the vessel
27
is flooded with water from the water supply
12
. Water from the water supply
12
enters the mixing tube
40
and is diverted through the separation tube
74
to reach the interior cavity
28
. The valve
76
restricts flow through the separation tube
74
after a predetermined amount of water is delivered into the interior cavity
28
. Since the portion of the cartridge
30
that dissolves is directly related to the amount of water in the cavity
28
, limiting the inflow of water ensures that approximately the same amount of cleaning composition
11
is dissolved every time the vessel
27
is flooded. In one embodiment, the valve
76
is configured to allow about 0.68 quarts into the interior cavity
28
.
Once the interior cavity
28
has flooded with water, a portion of the cartridge
30
(comprised of a cleaning composition
11
) dissolves in the water in a second step
114
. The cartridge
30
stops dissolving when the concentration of cleaner in the water reaches a predetermined equilibrium. As a result, a cleaning solution
17
is formed by a cleaning composition
11
dissolved in water. In one embodiment, the predetermined equilibrium concentration of the cartridge
30
is from 0.001% to 1% cleaning composition
11
, by weight in water. Even more preferred is an equilibrium concentration from 0.01% to 0.2% cleaning composition
11
by weight. An equilibrium concentration of about 0.12% cleaning composition
11
is most preferred.
The time it takes for the cartridge
30
to reach equilibrium concentration depends on the type of cleaning composition
11
, and the configuration of the cartridge
30
. Cartridges with more surface area will reach equilibrium more quickly than those with less surface area. In one presently preferred embodiment, the cartridge is cylindrical with an annular cross section. The annular shape is beneficial because, as the cartridge dissolves, it retains approximately the same overall surface area. The inner surface area increases at approximately the same rate as the exterior surface area decreases. In one presently preferred embodiment, the cartridge is configured to reach equilibrium concentration in approximately 17 minutes.
Once the cartridge
30
reaches equilibrium concentration, the cleaning solution
17
leaves the interior cavity
28
and enters the water feed
14
via the siphon tube
78
in a third step
118
. The valve
80
allows only a predetermined amount of cleaning solution
17
to be delivered into the water feed
14
. In a fourth step
120
, the water feed
14
leads to a cleaning chamber
18
of a cleaning appliance
16
, wherein the cleaning solution
17
is diluted by excess water to a concentration suitable for cleaning.
The concentration of cleaning composition
11
used for cleaning may be any concentration that cleans the items within the cleaning chamber
18
. In particular, cleaning concentration for a cleaning appliance
16
for washing clothing is that concentration needed to clean a load of clothing. However, a cleaning solution
17
that is diluted to a cleaning concentration from 0.0001% to 0.01% cleaning composition
11
by weight is presently preferred. Even more preferred is a cleaning concentration from 0.0014% to 0.002% cleaning composition
11
by weight. A cleaning concentration of about 0.0017% cleaning composition
11
by weight is most preferred.
Enough cleaning solution
17
should be delivered to the water feed
14
, such that the cleaning composition
11
is at cleaning concentration when diluted into the cleaning appliance
16
. The amount of cleaning composition
11
delivered to the water feed
14
is determined by the amount of cleaning solution
17
and the equilibrium concentration of the cleaning solution
17
. Therefore, the vessel
27
should be configured to receive a predetermined amount of solvent (e.g., water), and the cleaning composition
11
in the cartridge
30
should be configured to dissolve a predetermined equilibrium concentration of cleaning composition
11
in the vessel
27
.
Once the cleaning solution
17
has been delivered to the cleaning appliance
16
, a fifth step
122
occurs, wherein items to be cleaned are exposed to the cleaning solution
17
. This sixth step
122
may involve a number of different process steps, depending on the type of item to be cleaned. For example, items may be immersed in the cleaning solution
17
, lightly sprinkled with the cleaning solution
17
, exposed to cleaning solution
17
in gaseous form, stirred or tumbled through the cleaning solution
17
, exposed to other, additional agents, or any combination of these or other cleaning processes known in the art. In a sixth step
124
, the cleaning appliance
16
drains the cleaning solution
17
, together with removed impurities, from the cleaned items.
Referring to
FIG. 11
, the cartridge
30
is shown in greater detail. The cleaning composition
11
relates generally to any composition of cleaner. As shown in
FIG. 11
, the cleaning composition
11
may include a mixture of different agents evenly dispersed throughout the cartridge
30
in a solid or semi-solid form. The cartridge
30
need not be unitary, but may be made up of cleaning composition
11
in powder or granular form. However, the cartridge
30
is preferably unitary and configured to remain firmly in place within the vessel
27
. In one presently preferred embodiment, the cartridge
30
is cylindrical with an annular cross section, so that the time required for the cleaning composition
11
to dissolve remains relatively constant over multiple cycles of use.
Referring to
FIG. 12
, the cleaning composition
11
may include a gas-releasing agent
128
that is water soluble, and a solubility control agent
130
that is only slightly water soluble. The gas-releasing agent
128
provides cleaning action. However, if the gas-releasing agent
128
is permitted to freely dissolve, the resulting cleaning solution
17
will have an unknown or uncontrolled concentration of gas-releasing agent
128
. Thus, it is desirable to add a solubility control agent
130
to the cleaning composition
11
to control its equilibrium concentration, and hence, the concentration of gas-releasing agent
128
in the cleaning solution
17
.
The cleaning composition
11
may be further enhanced through the addition of an alkalinity agent
132
and a softener
134
. The alkalinity agent
132
controls the pH of the cleaning composition
11
, and therefore the pH of the resultant cleaning solution
17
. The pH of the cleaning solution
17
must remain within a certain range because the pH controls the rate at which the gas-releasing agent
128
reacts. The gas-releasing agent
128
or the solubility control agent
130
may be configured to control the pH of the cleaning solution
17
, but a separate alkalinity agent
132
is presently preferred. The softener
134
prevents the formation of a residue on the items to be cleaned by solvating hard water ions. The gas-releasing agent
128
, the solubility control agent
130
, or the alkalinity agent
132
may be configured to solvate hard water ions, but a separate softener
134
is preferable.
Referring now to
FIG. 13
, an exemplary embodiment of the cleaning composition is shown. The gas-releasing agent
128
should not release gas in the solid state cleaning composition
11
, but it should be able to release gas in a cleaning solution
17
of the cleaning composition
11
at ambient temperature. The gas-releasing agent
128
need not react with other agents, but may simply decompose at ambient temperature to release gas. Those gas-releasing compounds that are both found in nature and biodegradable are preferred. In some embodiments, the gas-releasing agent
128
is a carbonate or bicarbonate. Sodium bicarbonate
136
(NaHCO
3
), for example, is occurs in nature and is completely biodegradable. Alternatively, sodium carbonate (Na
2
CO
3
) may act as the gas-releasing agent
128
. However, numerous other gas-releasing agents are known to those skilled in the art, and all are within the scope of the present invention.
The solubility control agent
130
should be either water insoluble or only slightly water soluble. Numerous compounds may serve this function, including but not limited to hydrophobic compounds. Those solubility control agents that are both found in nature and biodegradable are preferred. Amorphous silica
138
(H
2
SiO
3
) is presently preferred because it occurs in nature and is completely biodegradable.
The alkalinity agent
132
may be selected from, but is not limited to, a group consisting of alkali hydroxide, alkali hydride, alkali oxide, alkali carbonate, alkali bicarbonate, alkali phosphate, alkali borate, alkali salt of mineral acid, alkali amine, alkaloid, alkali cyanide, alkali metal, and alkali earth metal. Other alkalinity agents that tend to increase the pH of a neutral solution are familiar to those in the art, and are within the scope of the present invention. Those alkalinity agents that are both found in nature and biodegradable are preferred. Sodium sesquicarbonate
140
, which includes sodium bicarbonate and sodium carbonate in an approximately 1:1 ratio, is presently preferred because it occurs in nature and is completely biodegradable.
The softener
134
should preferably be selected to exchange soluble sodium or other ions for the insoluble calcium and magnesium ions. Those softeners that are both found in nature and biodegradable are preferred. A cleaning composition
11
wherein the softener
134
is natural zeolite
142
(Na
2
O·Al
2
O
3
·(SiO
2
)
x
·(H
2
O)
x
) is presently preferred because it occurs in nature and is completely biodegradable.
In one embodiment of the present invention, the cleaning composition
11
is intended to be dissolved in an apparatus for delivering solvated cleaning agents, wherein the cleaning composition
11
reaches equilibrium concentration before being flushed into a cleaning chamber and diluted to cleaning concentration. Therefore, the amount of each component in the cleaning composition
11
is preferably tailored to this purpose.
The amount of gas-releasing agent
128
in the cleaning composition
11
determines how much gas is released in a cleaning solution
17
of the cleaning composition
11
formed when the cleaning composition
11
dissolves in a solvent, e.g., water. Therefore, the gas-releasing agent
128
in the cleaning composition
11
should comprise an amount sufficient to release a predetermined amount of gas in a cleaning solution
17
of the cleaning composition
11
. A concentration of gas-releasing agent
128
from 20% to 60% by weight of the cleaning composition
11
is preferred. In one embodiment, the concentration of gas-releasing agent
128
is from 35% to 45% by weight.
The amount of solubility control agent
130
in the cleaning composition
11
determines the equilibrium concentration of the cleaning composition
11
in the cleaning solution
17
. Therefore, the amount of solubility control agent
130
in the cleaning composition
11
should be selected to yield a predetermined equilibrium concentration of cleaning composition
11
in the cleaning solution
17
. A concentration of solubility control agent from 5% to 35% by weight of the cleaning composition
11
is presently preferred. In one embodiment, the concentration of solubility control agent is about 20% by weight to yield an equilibrium concentration of the cleaning composition
11
that is approximately 0.12% by weight in water.
The amount of alkalinity
132
agent in the cleaning composition
11
affects the pH of the cleaning solution
17
. Therefore, the cleaning composition
11
should include an amount of alkalinity agent
132
selected to provide a cleaning solution
17
with a predetermined pH. A concentration of alkalinity agent
132
from 1% to 10% by weight of the cleaning composition
11
is presently preferred. In one embodiment, the concentration of alkalinity agent
132
is about 3% by weight, providing a cleaning solution
17
with a pH of about 8.8 after dilution inside the cleaning appliance
16
.
The softener
134
in the cleaning composition
11
softens the cleaning solution
17
by scavenging residue-forming ions. Therefore, the softener
134
should comprise an amount of cleaning composition
11
sufficient to soften household water. A concentration of softener
134
from 1% to 20% by weight of the cleaning composition
11
is presently preferred. In one embodiment, the concentration of the softener
134
is about 8% by weight.
Water molecules may form complexes with these components and could be bound up within the cleaning composition
11
by virtue of the process of making the cleaning composition
11
. Water may comprise from 1 to 50% of the cleaning composition
11
by weight. Preferably, water comprises approximately 20% by weight of the cleaning composition
11
.
Referring to
FIG. 14
, after the items to be cleaned are exposed to the cleaning solution
17
in the fifth step
122
described in conjunction with
FIG. 10
, a number of processes occur. The basic cleaning solution
17
attacks the acids in dirt and oil. In a first reaction step
144
, the gas-releasing agent
128
reacts with dirt and oil. In a gas-releasing step
146
, gas is released. In a cleaning appliance
16
for washing clothing, dirt and oil would be dislodged from clothing in a removal step
148
due to reaction and the sudden release of gas. In a second reaction step
150
, the gas-releasing agent
128
continues to react with removed soils.
Simultaneously, in a scavenging step
152
, the softener
134
scavenges ions to prevent the buildup of residue on the articles to be cleaned. In addition, the alkalinity agent
154
keeps the pH of the cleaning solution
17
slightly basic. This serves two functions. First of all, it bridles the reaction of the gas-releasing agent
128
so that the gas evolves at a controlled rate and the cleaning solution
17
has time to become thoroughly intermixed with the articles to be cleaned. Second, the basic cleaning solution
17
reacts to neutralize acids in the soils. After the washing cycle is complete, the sixth step
124
described in conjunction with
FIG. 10
occurs, wherein the cleaning solution
17
drains out of the cleaning appliance
16
.
Referring to
FIG. 15
, an exemplary cleaning process utilizing the exemplary cleaning concentration of
FIG. 14
is shown. First, the sodium bicarbonate
136
and sodium sesquicarbonate
140
attack acids within the dirt and oils. The acid-base reactions have an emulsifying affect on the dirt and oils. Particularly, sodium bicarbonate
136
reacts with acids to generate carbon dioxide in an acid and base reaction: H
+
(aq)+NaHCO
3
(aq)Na
+
(aq) +H
2
O+CO
2
(g). Most oils and dirts found in clothing are slightly acidic, and so the sodium bicarbonate
136
may react with these dirts and oils to produce carbon dioxide. This tiny explosion of gas, as it bubbles out of solution, dislodges the dirt from clothes and other materials, allowing it to be washed away. The reaction yields sodium ions in solution, or the sodium salts of the oils and dirts of the reaction, water and carbon dioxide.
In this embodiment, the byproducts of the cleaning process appear in nature, so there is no need for the extensive treatment of phosphates and other non-biodegradable materials, as required by presently available detergents. Some of the sodium carbonate may also react to form carbon dioxide gas according to the following equation; Na
2
CO
3
+2H
+
2Na
+
+H
2
O+CO
2
However, the alkalinity agent
132
, which may include sodium carbonate, is added primarily to increase the pH of the cleaning solution
17
.
The alkalinity agent
132
provides a mildly basic solution to prevent the sodium bicarbonate
136
from reacting with excess hydrogen ions (H+) in aqueous solution. Without the alkalinity agent
132
, CO
2
would bubble out of solution too quickly as the sodium bicarbonate
136
reacts with random hydrogen ions. With a slightly alkaline cleaning solution
17
, in one embodiment approximately 8.8 pH, the sodium bicarbonate
136
reacts at a controlled pace, and preferably with the acids in the dirts and oils.
The softener
134
, which may be natural zeolite
142
, exchanges sodium ions (Na+) for magnesium (Mg++) and calcium (Ca++) ions: Mg
++
+Ca
++
+zeolitezeolite+4Na
+
. Sodium ions and sodium salts are readily water soluble and will not form precipitates. Without the softener, the Mg
++ and Ca
++
could react to form insoluble salts, precipitating out of solution and leaving a hard film behind, as shown by the following equations: NaHCO
3
+Mg
++
MgCO
3
, and NaHCO
3
+Ca
++
CaCO
3
.
Referring to
FIG. 16
, one possible method is shown for making the cleaning composition
11
in a solid state. Although
FIG. 16
depicts a solvent, a gas releaser, a solubility control agent, an alkalinity agent, and a solubility control agent, the cleaning composition
11
may be manufactured without these components or with additional, unnamed agents.
In a solvent step
168
, a solvent for dissolving the other agents is provided. In a gas-releasing agent step
170
, a gas-releasing agent
128
is added to the solvent. In a softener step
172
, a softener
134
is added to the solvent. In a solubility control agent step
174
, a solubility control agent
130
is added to the solvent. In an alkalinity agent step
176
, an alkalinity agent
132
is added to the solvent. The steps
170
through
176
need not occur in the exact order described. In certain embodiments, steps
170
through
176
may occur simultaneously.
In a mixing step, the gas-releasing agent
128
, the softener
134
, the solubility control agent
130
, and the alkalinity agent
132
are mixed into the solvent and preferably dissolved therein, by a mixing process such as stirring. In a sealing step
180
, the entire solution is sealed within a suitable container. In a heating step
182
, the solution within the sealed container is brought to a high temperature. In a testing step,
184
, the solution is tested for azeotrope. In a cooling step
186
, the solution is cooled, but remains in a liquid or semi-liquid state. In a pouring step
188
, the solution is poured into a curing vessel of the appropriate size and shape to form a cartridge
30
. In a curing step
189
, the solution is allowed to cure over time.
Referring to
FIG. 17
, an exemplary embodiment of the method of
FIG. 16
is shown. More specifically, the method of
FIG. 17
may be directly employed to obtain the cleaning composition
11
embodied in FIG.
13
. In this illustrative method, the solvent is water. Enough water should be added to bring the mixture of components to a thick paste, such that they mix to an approximately homogenous consistency within a suitable vessel. In a water step
190
, a sodium bicarbonate step
192
, a natural zeolite step
194
, an amorphous silica step
196
, and a sodium sesquicarbonate step
198
, 29% water may be supplemented with 39% sodium bicarbonate
136
, 8% natural zeolite
142
, 21% amorphous silica
138
, and 3% sodium sesquicarbonate
140
.
In a mixing step
200
, the mixture may be stirred into solution. In a sealing step
202
, the solution may be sealed within an airtight container. In a heating step
204
, the solution may be heated to approximately 230° F. Testing for azeotrope may be performed in a testing step
206
. In a cooling step
208
, the solution may be permitted to cool to ambient temperature, while remaining in liquid or semi-liquid form. In a pouring step
210
, the solution may be poured into a curing vessel. In a curing step
212
, azeotrope may be permitted to cure to the solution, forming one or more properly shaped cartridges
30
of cleaning composition
11
.
Referring to
FIG. 18
, a method for making the cleaning composition
11
in a solid state, as described in connection with
FIG. 16
, is shown pictorially. The vessel used for mixing, heating, and cooling may be of a simple design. In the pouring step
188
, the solution may be poured into a mold with several indentations of the proper size and shape. As shown in
FIG. 18
, these indentations may be annular in shape to form a cartridge
30
with an annular cross section. After the curing step
189
, the cartridges
30
may be removed from the mold for use in the apparatus
10
.
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims
- 1. A cleaning composition in a solid state consisting of:a gas-releasing component as a cleaning agent selected from the group consisting of carbonates and bicarbonates, wherein the gas-releasing component is present in an amount from 20% to 60% by weight; a solubility control component to limit the solubility of the cleaning composition, wherein the solubility control component is present in an amount from 5% to 35% by weight; an alkalinity agent as a pH regulator, wherein the alkalinity agent is present in an amount from 1% to 10% by weight; and optionally a water softener to solvate metal ions in a solution of water.
- 2. The composition of claim 1, wherein the water softener is selected from the group consisting of ion exchange particles and salts of weak acids.
- 3. The composition of claim 1, wherein the water softener is natural zeolite.
- 4. The composition of claim 1, wherein the water softener is present in an amount sufficient to soften household water after the composition reaches an equilibrium concentration in a vessel, and the equilibrium concentration is diluted in a cleaning appliance.
- 5. The composition of the claim 1, wherein the water softener is present in an amount from about 1 to about 20% by weight.
- 6. The composition in claim 1, wherein the gas-releasing component is sodium bicarbonate.
- 7. The composition in claim 1, wherein the gas-releasing component is sodium carbonate.
- 8. The composition in claim 1, wherein the gas-releasing component is present in an amount sufficient to release an effective amount of gas after the composition reaches an equilibrium concentration in a vessel, and the equilibrium concentration is diluted in a cleaning appliance.
- 9. The composition in claim 8, wherein the effective amount of gas generated is from about 5% to about 9.5% by volume with respect to the volume of water.
- 10. The composition of claim 1, wherein the solubility control component is selected from the group consisting of insoluble salts, partially soluble salts, crystalline compositions, and silicates.
- 11. The composition of claim 1, wherein the solubility control component is amorphous silica.
- 12. The composition of claim 1, wherein the solubility control component is present in an amount sufficient to give the composition an equilibrium concentration in solution.
- 13. The composition of claim 12, wherein the equilibrium concentration is from about 0.0014% to about 0.002% by weight in water.
- 14. The composition of claim 1, wherein the alkalinity agent is selected from the group consisting of an alkali hydroxide, alkali hydride, alkali oxide, alkali sesquicarbonate alkali phosphate, alkali borate, alkali salt of mineral acid, alkali amine, alkaloid, and alkali cyanide.
- 15. The composition of claim 1, wherein the alkalinity agent is sodium sesquicarbonate.
- 16. The composition of claim 1, wherein the alkalinity agent is present in an amount sufficient to give a solution of the composition a pH greater than 7.
- 17. The composition of claim 16, wherein the pH is from about 7.8 to about 8.8.
- 18. A cleaning composition in a solid state consisting of:a gas-releasing component as a cleaning agent selected from the group consisting of carbonates and bicarbonates; a solubility control component which is an amorphous silica to limit the solubility of the cleaning composition; an alkalinity agent as a pH regulator selected from the group consisting of sodium sesquicarbonate, alkali hydroxide, alkali hydride, alkali oxide, alkali phosphate and alkali borate; and optionally a water softener which is a natural zeolite to solvate metal ions in a solution of water.
- 19. The composition of claim 18, wherein the gas-releasing component is present in an amount from 20% to 60% by weight.
- 20. The composition of claim 18, wherein the solubility control component is present in an amount from 5% to 35% by weight.
- 21. The composition of claim 18, wherein the water softener is present in an amount from 1% to 20% by weight.
- 22. The composition of claim 18, wherein the alkalinity agent is present in an amount from 1% to 10% by weight.
- 23. The composition of claim 18, wherein the alkalinity agent is present in an amount sufficient to give a solution of the composition a pH greater than 7.
- 24. The composition of claim 18, wherein the alkalinity agent is present in an amount sufficient to give a solution of the composition a pH from about 7.8 to about 8.8.
US Referenced Citations (6)
Foreign Referenced Citations (3)
Number |
Date |
Country |
2 109 398 |
Jun 1983 |
GB |
91 17232 |
Nov 1991 |
WO |
98 04672 |
Feb 1998 |
WO |