Patent Grant
9127389
Not applicable
Not applicable
1. Field of the Invention
The present invention relates to continuous batch washers or tunnel washers. More particularly, the present invention relates to an improved method of washing textiles or fabric articles (e.g., on clothing, linen, etc.) in a continuous batch multiple module tunnel washer wherein the textiles are moved sequentially from one module or zone to the next module or zone. These zones can include dual use zones, because the zones are used for both washing and rinsing. Alternatively, all of the modules could be part of multi-use zones (i.e., pre-wash, main wash, and rinse). After a final module, fabric articles are then transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water. In one embodiment, the dual use zone can function: 1) as a standing bath for washing the fabric articles and 2) as a rinse zone utilizing a counterflow water rinse. In one embodiment a final zone is a finishing zone, where finishing chemicals are transmitted to the fabric articles. In another embodiment, sour solution is transferred to the fabric articles (e.g., sprayed) while those fabric articles are in the extraction device. By using a multi-use zone or a dual use zone, the present invention eliminates a need for a separate wash module(s) and rinse module(s).
2. General Background of the Invention
Currently, washing in a commercial environment is conducted with a continuous batch tunnel washer. Such continuous batch tunnel washers are known (e.g., U.S. Pat. No. 5,454,237) and are commercially available (www.milnor.com). Continuous batch washers have multiple sectors, zones, stages, or modules including pre-wash, wash, rinse and finishing zone.
Commercial continuous batch washing machines in some cases utilize a constant counter flow of liquor. Such machines are followed by a centrifugal extractor or mechanical press for removing most of the liquor from the goods before the goods are dried. Some machines carry the liquid with the goods throughout the particular zone or zones.
When a counter flow is used, there is counter flow during the entire time that the fabric articles or textiles are in the main wash module zone. This practice dilutes the washing chemical and reduces its effectiveness.
A final rinse with a continuous batch washer has been performed using a centrifugal extractor or mechanical press. In prior art systems, if a centrifugal extractor is used, it is typically necessary to rotate the extractor at a first low speed that is designed to remove soil laden water before a final extract.
Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples, each listed patent hereby incorporated herein by reference.
The present invention provides an improved method of washing fabric articles in a continuous batch tunnel washer. The method includes the providing of a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that divide the interior into zones, including dual use zones or a multi-use zone.
Dual use or multi-use zones enable use of each of the modules for multiple functions: pre-wash, main wash, rinse, finishing. As part of the method, the fabric articles are moved from the intake to the discharge and through the modules in sequence. These modules include dual use modules that each function as both a wash module and a rinse module. The method of the present invention provides a counter flow of liquid in the washer interior during rinsing, including some interrupted counter flow. The counter flow is along a path that is generally opposite the direction of travel of the fabric articles.
At a final module, the fabric articles are transferred via the discharge to a water extraction device. The extractor is used to remove excess water from the fabric articles after they have been discharged from the continuous batch tunnel washer. As part of the method, a sour solution can be flowed through the fabric articles during the extracting of excess water.
The present invention thus provides a continuous batch washer tunnel washer apparatus that achieves very low water consumption and greater throughput. For example, typical water consumption is between about 0.3-0.36 gallons per pound (2.4-3.0 liters per kilogram) for light to medium soil and between about 0.42 and 0.6 gallons per pound (3.5-5.0 liters per kilogram) for heavy soil.
The present invention employs dual use modules for highly efficient soil and release and removal. With the present invention, there are no dedicated wash or rinse modules, other than the last module which can be dedicated to finishing chemicals. The modules other than the last module are thus dual use. Typically, the first 50-75 percent of the transfer rate (time between transfers) is a standing bath for wash. The last 25-50 percent is high velocity counterflow rinsing. For example, the flow to maintain high velocity can be between about 50 and 150 gallons per minute (g.p.m.) (189 and 568 liters per minute).
In a standing bath module, chemical equilibrium is achieved in less than one minute, preferably in less than 30-40 seconds (for example, between about one and three reversals). A reversal is a complete rotation of the drum.
At chemical equilibrium, the soil-release effects of chemical energy (alkali pressure) and mechanical action in this bath are essentially complete. The suspended soil is now efficiently removed (rinsed away) by high velocity counterflow.
The present invention provides fully controlled (metered) water. All water inlets are metered to achieve precise injection volume for the given function: wet-out in module 11, fresh water makeup, and high velocity rinsing. All water inlets, except for fresh water makeup, are preferably pumped. This arrangement eliminates any inconsistencies in water flow, which can frequently occur as a consequence of fluctuations in incoming water pressure. For example, pumped water for flow is maintained at a pressure of between about 25-30 p.s.i. (1.7-2.1 bars) and at a flow rate of between 75 and 150 gallons per minute (g.p.m.) (284 and 568 liters per minute). Although fresh water is always subject to water pressure fluctuations, the present invention minimizes such fluctuations by providing a stabilization tank.
The present invention provides high velocity counterflow. The high velocity counterflow is comprised of extracted water and fresh water. The flow rate of the high velocity counterflow water inlets is based typically on about 30 seconds of flow and the following soil classification specific ratio:
light soil—0.30-0.42 gallons per pound (2.5-3.5 liters per kilogram) of linen
medium soil—0.42-0.54 gallons per pound (3.5-4.5 liters per kilogram) of linen
heavy soil—0.54-0.66 gallons per pound (4.5-5.5 liters) per kilogram) of linen
A valve operation sequence at the beginning of counterflow increases counterflow velocity and thus rinsing efficiency. With the high velocity counterflow, a water injection valve opens first. Seconds later (for example, 5 seconds) the flow stop valve opens. This immediately increases the hydraulic head that powers the counterflow rinse.
The resulting flow rate provides maximum rinsing within the weir capacity, which is generally about 100 gallons per minute (379 liters per minute) for 150 pound (68 kilograms) capacity tunnel washers and 150 gallons per minute (568 liters per minute) for 250 pound (115 kilogram) capacity tunnel machines.
Each zone can have a maximum length of about 8 modules. This arrangement assures the affectiveness of the high velocity counterflow. High velocity counterflow zones can be sized and combined in the configuration required to meet any special temperature or disinfect time requirements.
The present invention provides high rinsing efficiency as a result of the rapid removal of suspended soil by high velocity counterflow and “top transfer effect,” namely, the draining action that leaves behind about half of the free water when the perforated scoop lifts the goods out of one bath and moves them to the next cleaner bath. This arrangement is equivalent to a drain and fill in a washer-extractor. These two effects (high velocity counterflow rinsing and top transfer effect) and their combined effect are seen in
The present invention enables the use of fewer modules. The present invention provides comparable performance for an eight module continuous batch washer or tunnel washer when compared to a ten module conventional tunnel washer.
In one embodiment, a recirculation pump flows water in a recirculation loop from the bottom of a first module's shell into the linen loading chute. By using the module's own water instead of fresh water, this device reduces the overall water consumption by approximately 1 L/Kg. The recirculation pump flows at a rate of between 60 and 100 gallons per minute (g.p.m.) (227 and 379 liters per minute) to provide a forceful stream of water. This forceful stream of water wets the entire load of linen in one cylinder reversal of approximately ten (10) seconds where prior art needed the entire transfer rate time, normally between one and one half and three (1.5 to 3) minutes. Thus, most of the transfer rate time in the first module can now be used as a working module where prior art tunnel washers or continuous batch washers used the first module only to wet the linen. Thus, the production rate of the continuous batch washer or CBW is increased between five and twenty (5 and 20) percent.
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:
In
The total number of modules 14-18 can be more or less than the five (5) modules shown in
Inlet end portion 12 can provide a hopper 19 that enables the intake of textiles or fabric articles to be washed. Such fabric articles, textiles, goods to be washed can include clothing, linens, towels, and the like. An extractor 20 is positioned next to the outlet end portion 13 of tunnel washer 11. Flow lines are provided for adding water and/or chemicals (e.g., cleaning chemicals, detergent, etc.) to tunnel washer 11.
When the fabric articles, goods, linens are initially transferred into the modules 14, 15, 16, 17, 18, an interrupted counter flow for a part of the batch transfer time (i.e. the time that the fabric articles/linens remain in a module before transfer to the next successive module) is used. By using this interrupted counter flow for part (e.g., between about 50% and 90%, preferably about 75%) of the batch transfer time, each module 14, 15, 16, 17, 18 performs as a separate batch.
By halting counterflow when the modules 16, 17, 18 are functioning as main wash modules, this creates essentially a standing bath for the washing process and allows the cleaning chemicals to perform their function fully without any dilution from a counter flow. Counter flow returns for the last part (e.g., last 25%) of the transfer time and is pumped at a higher rate (e.g., between about three hundred (300) and four hundred (400) percent of the normal rate, or between about thirty-five (35) and one hundred five (105) gallons per minute (132 and 397 liters per minute), for example see
In
Textile washing apparatus 10 provides a tunnel washer 11. Tunnel washer 11 has an inlet end portion 12 and an outlet end portion 13. Tunnel washer 11 has an interior 31 that is divided into sections or modules. These modules can include modules 14, 15, 16, 17, 18, and can include additional modules.
Hopper 19 is positioned at inlet end portion 12. The hopper 19 enables the intake of fabric articles to be washed.
A water extracting device 20 (e.g., press or centrifuge) is positioned next to discharge 32. The extraction device 20 is used to remove excess water or extracted water from the fabric articles after they have been discharged from the tunnel washer 11 and placed within the extractor 20. Extraction devices 20 are commercially available, typically being a centrifuge or a press.
The modules 14-18 in
A water storage tank 21 can be a freshwater storage tank. A sour solution and/or finishing chemicals can be prepared by injecting tank 21 with a sour solution and/or finishing solution that is delivered via sour inflow line 22. Flow line 23 transmits the sour solution and/or finishing solution from tank 21 to the interior 33 of extraction device 20 as indicated by arrow 27. Finishing solutions can be any desired or known finishing solution, for example a starch solution or an antimold agent. An example of a starch solution is “Turbocrisp” manufactured by Ecolab, Inc., Textile Care Division of St. Paul, Minn. An example of an antimold agent is “Nomold” manufactured by Ecolab, Inc., Textile Care Division (www.ecolab.com).
An extracted water tank 24 can be positioned to receive extracted water from extraction device 20. Flow line 30 is a flow line that transfers water from extraction device 20 to tank 24. Water contained in tank 24 can be recycled via flow lines 28 or 29. A sour solution can be injected at 24 via sour inflow tank 25. Freshwater can be added to tank 24 via freshwater inflow 26. Flow line 28 is a recirculation line that transfers extracted water from tank 24 to hopper 19. Another recirculation flow line is flow line 29. The flow line 29 transfers extracted water from tank 24 to interior 31 of tunnel washer 11, beginning at final module 18 and then counterflow to modules 17, 16, 15, 14 in sequence.
For the continuous batch washing apparatus 10 of
The module 16 can have a temperature of around 160 degrees Fahrenheit (71 degrees Celsius). The module 17 can have a temperature of around 160 degrees Fahrenheit (71 degrees Celsius). The module 18 can also have a temperature of around 160 degrees Fahrenheit (71 degrees Celsius). The modules 14, 15, 16, 17, 18 can be dual use modules and thus can define a main wash and a rinse portion of tunnel washer 11.
In the example of
The modules 14-18 could have differing capacities. For example, the module 14 could be a ten (10) gallon (38 liter) module while the module 15 could be a forty (40) gallon (151 liter) module. The module 16 could be a sixty (60) gallon (227 liter) module. The module 17 could be a sixty-six (66) gallon (250 liter) module wherein the module 18 would have a capacity of about thirty-three (33) gallons (125 liters).
In
For each of the washers 46, there is a hopper 68 for enabling fabric articles, clothing, linens, etc. to be added to the washer. There are flow lines shown in the
In
In
In
These
The rinsing efficiency of the method and apparatus of the present invention is the result of two effects which can be called the “pulse flow effect” and the “top transfer effect.” The “pulse flow effect” is the rapid removal of suspended soil by high velocity and high flow rate (e.g. about 100 gallons per minute or g.p.m. (379 liters per minute)) counterflow. The “top transfer effect” is the draining action that leaves behind part (about half) of the free water when the perforated transfer scoop of the tunnel washer lifts the goods (textile articles) out of one bath and moves them to the next cleaner bath. This arrangement is equivalent to a drain and fill in a washer-extractor.
Formula times in a tunnel washer of the present invention are shorter than in a conventional tunnel. The dual use modules in a the tunnel washer of the present invention perform the same functions as that of both the wash modules and the rinse modules in a conventional tunnel. By the time that goods enter the finish module, they have undergone equal or better processing in the tunnel washer of the present invention than that of a conventional tunnel with the same number of wash modules as dual use modules in the tunnel washer machine of the present invention.
Conventional top transfer tunnels of six modules or less have one rinse module. Those with seven modules or more have two rinse modules. Hence, the ratio of rinse to wash modules changes with different size conventional tunnels. The ratio of rinse to wash functions in a PulseFlow tunnel is not influenced by tunnel size. Hence, it is possible to state, as a percentage, the difference in formula length for a conventional, top transfer tunnel, as recommended by the Textile Rental Services Association, and a PulseFlow tunnel, regardless of tunnel length. Based on current field data, this is 81%.
Table 1 below provides a list of processing times for conventional, top transfer tunnels and corresponding times for tunnels of the present invention, along with the transfer rates for a range of tunnel sizes.
For each of the following parameters, exemplary minimum and maximum ranges of values are provided:
Values for
The batch size (Lb) can be between about 90 and 150 pounds (41 and 68 kilograms).
The total water consumption in gallons for cotton can be between about 27 and 75 gallons (102 and 284 liters).
The total water consumption gallons for Poly can be between about 22.5 and 75 gallons (85 and 284 liters).
The transfer rate can be between about 2 and 6 minutes.
The percent (%) standing bath can be between about 50 and 75 percent.
The rinse time in minutes can be between about 0.5 and 3 minutes.
The total water consumption can be between about 0.3 and 0.5 gallons per pound (gal/lb) (3 and 4 liters per kilogram) for cotton.
The total water consumption can be between about 0.25 and 0.5 gallons per pound (gal/lb) (2 and 4 liters per kilogram) for poly.
The gallons of water entering hopper 19 (cotton and poly) can be between about 25 and 45 gallons (95 and 170 liters) for cotton and between about 15 and 28 gallons (57 and 106 liters) for poly.
The gallons of water during discharge from tunnel washer 11 (for cotton and poly) can be between about 50 and 65 gallons (189 and 246 liters) for both cotton and poly.
The gallons of water in interior of extraction device 20 before extraction (for cotton and poly) can be between about 50 and 70 gallons (189 and 265 liters) for cotton and between about 35 and 45 gallons (132 and 170 liters) for poly.
The gallons of water in interior of extraction device 20 after extraction (for cotton and poly) can be between about 9.9 and 16.5 gallons (37 and 62 liters) for cotton and between about 9 and 18 gallons (34 and 68 liters) for poly.
The gallons of water extracted from extraction device 20 to extracted water tank 24 (for cotton and poly) can be between about 40 and 55 gallons (151 and 208 liters) for cotton and between about 25 and 28 gallons (95 and 106 liters) for cotton.
The gallons of water from freshwater inflow 26 (cotton and poly) can be between about 27 and 75 gallons (95 and 284 liters) for cotton and between about 22 and 75 gallons (83 and 284 liters) for poly;
The gallons of rinse water can be between about 50 and 65 gallons (189 and 246 liters) for cotton or for poly.
The temperatures in
For
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.
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.
Priority of U.S. Provisional Patent Application Ser. No. 61/171,682, filed 22 Apr. 2009, incorporated herein by reference, is hereby claimed. Priority of U.S. Provisional Patent Application Ser. No. 61/298,818, filed 27 Jan. 2010, incorporated herein by reference, is hereby claimed.
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