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The present invention relates to washing machines. More particularly, the present invention relates to an improved washing machine and method, the washing machine having multiple modules and wherein some modules have perforated scoops, some modules have outer shells and wherein some modules do not have scoops and/or shells.
Patents have issued for large commercial type washing machines typically referred to “tunnel washers” or “tunnel batch washers” or “continuous batch tunnel washers”. Examples can be seen in U.S. Pat. Nos. 4,236,393; 9,127,389 (US Patent Application Publication No. 2010/0269267); and U.S. Pat. No. 9,580,854 (US Patent Application Publication No. 2013/0291314), each of which is hereby incorporated herein by reference. Such tunnel washers have multiple modules. In U.S. Pat. No. 4,236,393, each module is a cylindrical casing having a peripheral wall with perforated areas. The '393 patent provides a continuous tunnel batch washer of modular construction with the number of modules varying depending upon installational requirements. Each module includes a drum rotatably supported and driven to oscillate in a predetermined manner during the washing cycle and to rotate unidirectionally during transfer of the load from one module to a succeeding module with a chute or trough arrangement extending between the modules for transferring the wash load from one module to a next successive module. The drum in each module is roller supported and chain driven from a common shaft with a plurality of independent motors driving the shaft by a belt drive with each module including a reduction gear driven from the shaft and having an output driving the sprocket chain for the oscillatable and rotatable drum. A programmed control device provides continuous control of each batch of articles being laundered as they progress to the successive module in the machine. In the '393 patent, all scoops are perforated. Perforated transfer scoops are also discussed in the above listed U.S. Pat. Nos. 9,127,389 and 9,580,854.
Some prior art washing machines are based on counter flow high velocity rinsing after standing bath washing (e.g., see U.S. Pat. No. 8,336,144 (US Patent Application Publication No. 2011/0225741), incorporated herein by reference). The counter flow starts in the last module, or typically the module before the last module, and flows at high velocity sequentially through each upstream module and finally exiting upstream (e.g., at the first module). This requires that all modules have an outer shell for the water to flow in and out. Additionally, there must be a barrier in the lower part of the shell to separate the water between drums. Each module can be a dual use module.
Another prior art tunnel washer type machine is a bottom transfer machine where the drum holding the fabric articles (linen) is also the drum holding the water. There is no outer shell. When the standing bath is finished, the linen (or fabric articles to be cleaned) and all the water is transferred to the next attached module or drum. In the middle of the machine, there are two or more drums that are fitted with an outer shell. The outer shell has a drain valve and water refill valve (i.e. a dilution zone). To achieve the dilution function, the drum is drained and refilled at least once. All of the fabric articles (e.g., linen) and water are transferred to the next contiguous module or drum which also has an outer shell. The water and fabric articles (e.g., linen) can be heated to between about 40 degrees and 80 degrees Celsius. Rinsing is done with counterflow in two or more downstream modules at low velocity typically about 20 to 50 gallons per minute or “GPM” (about 75.70 to 189.27 liters per minute) on a continuous basis. All modules can be single function modules.
The following table lists possibly relevant patents (each hereby incorporated herein by reference) directed to other washing machines including some tunnel washing machines.
The apparatus and method of the present invention improves the washing and rinsing functions of a bottom transfer type machine. The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, and a plurality of modules or drums that segment the interior. Fabric articles are moved from the intake to the discharge and through the modules in sequence. One or more modules define a wash zone for washing the fabric articles. One or more of the modules are rinse modules that have a perforated scoop, and some of the modules do not have a perforated scoop. A washing chemical may be added to one or more of the modules. After washing fabric articles, the fabric articles can be rinsed by counter flowing liquid in the washer interior at multiple locations along a flow path that is generally opposite the direction of travel of the fabric articles from the intake to the discharge.
With the present invention, high velocity rinsing can replace a continuous counterflow. Because of the efficiency of the high velocity (e.g., 80 to 180 GPM (302.83 to 681.37 liters per minute)), fewer drums or modules are required for the same level of dilution. In some embodiments, there are a plurality of rinsing modules or rinsing drums. The rinsing modules or drums preferably have perforated scoops and outer shells to improve rinsing efficiency. In one embodiment of the apparatus of the present invention, only one rinsing module or drum is required.
To improve rinsing and washing, one or more modules may be dilution zone modules, which receive a flow stream from rinsing modules preferably via a booster pump. This dilution zone module or drum preferably has a perforated scoop to drain the free water when transferring to the next dilution zone module or drum. Drums or modules without shells (as shown in the drawings) preferably have scoops for fabric article (e.g., linen) transfer with no perforations. These are carryover modules. Thus, the linen and all water preferably go to the next downstream module or drum.
The improvements of the present invention include a much lower manufacturing cost, fewer modules or drums, and improved washing and rinsing functions.
The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. The fabric articles can be moved from the intake to the modules and then to the discharge in sequence. One or more of the modules can have a perforated scoop. In one embodiment, the present invention includes not counter flowing a rinsing liquid in the washer interior for a selected time interval. In one embodiment, counter flowing a rinsing liquid can occur along a flow path that is generally opposite the direction of travel of the fabric articles. In one embodiment, boosting the pressure of the counter flowing rinsing liquid occurs with a booster pump at one or more positions spaced preferably in between the intake and the discharge.
In one embodiment, multiple booster pumps can be provided, each pump boosting counter flowing rinsing liquid flow rate preferably at a different one of said modules.
In one embodiment, there can be multiple said modules preferably with perforated scoops.
In one embodiment, the booster pumps can be spaced apart preferably by more than one module.
In one embodiment, the booster pump preferably discharges liquid into a module that has an outer shell.
In one embodiment, the booster pumps preferably each discharge liquid into a module that does not have a perforated scoop.
In one embodiment, flow can be substantially halted for a time period that is preferably less than about five minutes.
In one embodiment, flow can be substantially halted for a time period that is preferably less than about three minutes.
In one embodiment, flow can be substantially halted for a time period that is preferably less than about two minutes.
In one embodiment, flow can be substantially halted for a time period that is preferably between about twenty and one hundred twenty (20-120) seconds.
The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The fabric articles can be moved preferably from the intake to the discharge. Washing chemical can preferably be added to the modules. After a selected time interval, counter flowing liquid can occur in the washer interior preferably along a flow path that is generally opposite the direction of travel of the fabric articles. Counter flowing water through the modules preferably effects a rinse of the fabric articles. Some of the modules can have an outer shell and some of the modules do not have an outer shell.
The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The fabric articles can be moved preferably from the intake to the discharge and through the modules in sequence. A washing chemical can preferably be added to the modules. The fabric articles can then be washed. The fabric articles can be rinsed preferably by counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles. One or more of the modules can be rinse modules that preferably have a perforated scoop. In one embodiment, some of the modules do not have a perforated scoop.
The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. The fabric articles can be moved preferably from the intake to the modules and then to the discharge in sequence. One or more of the modules can have a perforated scoop and one or more of the modules preferably has an outer shell. In one embodiment, one or more of the modules does not have a perforated scoop. In one embodiment, counter flowing a rinsing liquid can occur along a flow path that is generally opposite the direction of travel of the fabric articles. In one embodiment, the pressure of the counter flowing rinsing liquid can be boosted preferably with a booster pump at one or more positions spaced in between the intake and the discharge.
In one embodiment, there can be multiple of the modules with perforated scoops.
In one embodiment, the booster pump can discharge liquid into a module that preferably has an outer shell.
In one embodiment, the booster pump can discharge liquid into a module that preferably does not have a perforated scoop.
In one embodiment, flow can be substantially halted for a time period.
In one embodiment, flow can be substantially halted for a time period that is preferably less than about three minutes.
In one embodiment, flow can be substantially halted for a time period that is preferably less than about two minutes.
In one embodiment, flow can be substantially halted for a time period that is preferably between about twenty and one hundred twenty (20-120) seconds.
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
After the programmed number of reversals, the tunnel washer cylinder 126 preferably makes a complete rotation counter-clockwise as seen in
The counter-clockwise rotation preferably continues, as seen in
In
As the scoop 125 rotates preferably to near the top of the tunnel washer (
A fresh water source 17 enables fresh water to be added to tank 21 via flow line 18. Flow line 18 can have flow meter 19 and valve 20. Pump 22 enables a discharge of water from tank 21 via flow line 23. Flow line 23 can be provided with valve 24 and flow meter 25. Flow line 30 joins to flow line 18 at tee fitting 26. Line 30 has tee fittings at 27, 28, 29. Flow line 30 can have valve 31. In
Flow line 32 connects to flow line 30 at tee fitting 27. Flow line 32 can have valve 35 and flow meter 36. Flow line 32 discharges into hopper 16. Flow line 33 connects to flow line 30 at tee fitting 28. Flow line 33 can have valve 37. Flow line 34 connects to flow line 30 at tee fitting 29. Flow line 34 can have valve 38. In
Extracted water tank 54 receives water that is discharged from final module 9 (for
At junction or cross fitting 40, flow can be selected to go to sewer 49 via line 47 and valve 48. Flow can selectively go to line 43 or 44 from junction or cross fitting 40. Line 43 has valve 41 and pump 45. Line 43 transmits water to tank 21. Line 44 has valve 42 and pump 46. Line 44 also has a valve 51 and meter 52. Line 44 transmits water from junction or cross fitting 40 to module 5 in
In
Recirculation flow lines 59, 60 transmit flow from module 1 to hopper 16. Pump 61 receives flow from line 59 and discharges flow to line 60. In
In
In
In the seven (7) module tunnel washer 80 of
Modules 1, 3-4 and 6-7 have outer shells 91. Modules 2 and 5 do not have outer shells 91. An outer shell 91 enables addition of water, chemicals, bleach, and steam injection. The outer shells 91 are stationary. Those modules having a shell typically have a perforated scoop. Those modules with no shell do not have a perforated scoop.
Pump 78 transmits fluid/water via flow line 79 from tank 81 to module 6. Fluid/water in module 6 discharges via flow line 82 to module 4 and then counterflows to module 3 via counterflow line 83. Flow line 82 can have a pump 84. From module 3, fluid/water flows via flow line 85 to module 1. Flow line 85 can have pump 88. Modules 1 and 2 can have drains or drain lines 87 to sewer. Module 1 is a prewash and wash module. Module 2 is a carryover module. A flow line 89 can be provided for transmitting water/fluid from module 1 to hopper 16. Flow line 89 can be provided with a pump 92.
In
Module 6 is a dilution (drain) plus chemical addition (e.g., alkali) module. Module 7 is a rinse module. Module 8 is a dilution plus chemical addition (e.g., bleach) module. Modules 6, 7 and 8 have outer shells 91 and perforated scoops. Modules 9, 10, 11, 12 are carry over modules with no perforated scoops. Modules 96-98 are rinse modules. Module 99 is a ph adjustment and chemical addition (e.g., softener) module. Otherwise,
The present invention improves washing and rinsing functions as pulse flow velocity rinsing (e.g., flow lines 79, 82 and 85) replaces continuous counterflow. Because of the efficiency of the high velocity (e.g., about 80 to 180 GPM (about 302.83 to 681.37 liters per minute) in a preferred embodiment of the present invention), fewer modules or drums are required for the same level of dilution. The rinsing modules or drums 90 (see
Drums or modules without shells are carryover modules 101 (see
The following is a list of parts and materials suitable for use in the present invention:
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/339,457, filed 20 May 2016, which is hereby incorporated herein by reference. Priority of U.S. Provisional Patent Application Ser. No. 62/339,457, filed 20 May 2016, which is incorporated herein by reference, is hereby claimed.
Number | Date | Country | |
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62339457 | May 2016 | US |