Patent Application
20150167221
Not applicable
Not applicable
1. Field of the Invention
The present invention relates to a method and apparatus for cleaning floor mats such as when using a continuous batch washer or tunnel washer.
More particularly, the present invention relates to the cleaning of particulate laden material (such as floor mats, sand laden beach towels, work uniforms laden with metal shavings, or jeans laden with pumice rock such as the pumice rocks used in garments washing such as stone washed jeans) in a multiple module washer (e.g., tunnel washer) wherein a specially configured recirculation arrangement transmits liquid from a module (e.g., first module) to an intake or hopper and wherein a pump and filter in between the module and intake effect a removal of particulate material such as sand, metal shavings, or rocks during such recirculation.
2. General Background of the Invention
The purpose of a floor mat is to wipe or otherwise remove sand and dirt from the feet of people. Hence, dirty floor mats can be laden with significant quantities of heavy dirt or sand. Towels can be laden with sand and thus pose a problem for a resort hotel laundry. Metal shavings from uniforms used in the metal work industry can cause problems for a laundry. Other items to be laundered can be laden with pumice rocks used in garment washing such as stone washed jeans.
One of the problems with washing floor mats embedded with sand (or with organic compounds) is that once the sand is released from the mat into the washing water, the sand collects inside the shell of the washing machine such as in many of the modules of the tunnel washer. Periodically, the machine is programmed to insert a purge pocket which drains the water and hopefully most of the sand and organic compounds. If the sand and organic compounds are not removed, they build up in the machine. This causes the mats to not be cleaned. The build up of organic compounds causes the mats to have an extreme odor.
Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples of such patented tunnel washers, each listed patent of the table being hereby incorporated herein by reference.
The present invention provides an improved method and apparatus for washing floor mats in a tunnel washer. By using a filter to filter a recirculation flow of fluid in the first module, most (e.g. 90 to 95%) of the sand and organic compounds are removed. This improves the performance of the washing machine, maintains the washing quality and eliminates any build up of sand or organic material.
By removing the sand in the first module, the washing machine stays clean and can be used to wash other materials such as linens. The present invention eliminates a laborious clean out of the interior of the washing machine.
The present invention includes a method of washing particulate laden material in a continuous batch tunnel washer. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid. The particulate laden material can be moved from the intake to the modules and then to the discharge in sequence. A washing chemical can be added to the volume of liquid, after a selected time period, and counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material. A volume of liquid can be recirculated from the first module to the intake via a recirculation flow line. Particulate matter can be removed from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake.
In one embodiment, there can be a pump in the recirculation flow line.
In one embodiment, the pump can be in between the first module and the filter.
In one embodiment, the pump can be in between the filter and the intake.
In one embodiment, the particulate matter can include sand.
In one embodiment, the filter can remove particles from the volume of fluid via centrifugal action.
The present invention includes a method of washing particulate laden material in a continuous batch tunnel washer. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The particulate laden material can be moved from the intake to the discharge. A washing chemical can be added to the modules to wash the particulate laden material with a combination of water and the washing chemical, after a selected time interval, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material in order to effect a rinse of the particulate laden material. Liquid can be recirculated from one of the modules to the intake via a recirculation flow line. Particulate material can be removed from the recirculating liquid with a filter.
In one embodiment, the present invention can further comprise boosting the flow rate in the recirculation flow line with a pump.
In one embodiment, the filter can filter sand as part of the particulate matter.
In one embodiment, the pump can be in between the module and the filter.
The present invention includes a particulate laden material washing apparatus. The apparatus of the present invention can include a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including at least an upstream, first module that can be next to the intake and at least one downstream module next to the discharge, and a volume of liquid. The particulate laden material can move from the intake to the modules and then to the discharge in sequence. One or more counter flowing liquid flowlines can counterflow liquid along a flow path that can be from a downstream module to an upstream module. A recirculating liquid flow line can connect from the first module to the intake. A filter after the liquid leaves the first module and before the liquid reaches the intake.
In one embodiment, the apparatus can further comprise a pump in the recirculating liquid flow line.
In one embodiment, the pump can be in between the first module and the filter.
In one embodiment, the pump can be in between the filter and the intake.
In one embodiment, the filter removes particulate matter that can include sand.
In one embodiment, the filter removes particulate matter that can include organic waste material.
In one embodiment, the filter removes particulate material using centrifugal force.
In one embodiment, the filter continuously removes particulate matter from the recirculating liquid flow line as fluid flows in said recirculating liquid flow line.
The present invention includes a method of washing fabric articles that contain unwanted particulate matter. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid. The particulate laden material can be moved from the intake to the modules and then to the discharge in sequence. A washing chemical can be added to the volume of liquid, after a selected time period, can counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material. A volume of liquid can be recirculated from the first module to the intake via a recirculation flow line. Particulate matter can be removed from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake.
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:
Tunnel washer 11 has an inlet end portion 12 with hopper 26 and an outlet end portion 13. The tunnel washer 11 provides a plurality of modules 14-17. The first module is module 14. The second module is module 15. The third module is module 16. The final module is module 17. It should be understood that more than four (4) modules can be provided. Fluid impregnated mats that exit the outlet end portion 13 of tunnel washer 11 enter an extractor or press (not shown) via a discharge 27 such as a discharge flow line or chute. The extractor removes excess water from the mats to be cleaned and transmits that excess water to water tank 29. Water from tank 29 flows via flow line 32 in the direction of arrow 28 from tank 29 to tank 33. A valve 18 can be provided in flow line 32.
Make up water can be added to tank 33 via flow line 22. The flow line 22 has a valve 21. The flow line 22 receives water from a water source 19 such as a city water supply. The flow line 22 can be provided with a back flow preventer or check valve 37. A flow meter 20 can be provided in line 22. The tank 33 is provided with a drain valve 23 that enables water to be discharged from tank 33 via drain valve 23 into sewer 24 as indicated by arrow 25 in
A pump 30 can be used to transmit extracted water from tank 29 via flow line 32 to tank 33. Tank 29 has interior 31 for holding water that is routed to the tank 29 from the water extractor or press. Such water extractors or presses are commercially available.
Flow lines 34 and 35 enable water to be discharged from tank 33 to final module 17 or to any one of the modules 14, 15, 16 or to the hopper 26. Flow line 38 enables water to flow from line 35 to hopper 26. Flow line 39 enables water to flow from flow line 35 to module 14. Flow line 40 enables water to flow from flow line 35 to module 15. Flow line 41 enables water to flow from flow line 35 to module 16. Flow line 35 terminates at module 17. Flow line 34 also terminates at module 17. Pumps 36 can be used to provide pressure in the flow lines 34, 35.
Each of the flow lines 38, 39, 40, 41 and 34, 35 are provided with valves. Flow line 38 has valve 42. Flow line 39 has valve 43. Flow line 40 has valve 44. Flow line 41 has valve 45. Flow line 34 has valve 46. Flow line 35 has valve 47. Flow line 38 can have flow meter 48. Flow line 34 can have a flow meter 48.
Each of the modules 14, 15, 16, 17 can be provided with chemical injection such as alkaline injection 49, detergent injection 50 or other chemical injections such as finishing liquid, starch or any other washing or finishing chemical 63. Steam injection 51 can be provided at one or more of the modules 14, 15, 16 or 17 as indicated in
The flow lines 52, 57 recirculate fluid from the first module 14 to hopper 26. The flow line 52 can be provided with a pump 53. The flow line 57 could also be provided with a pump. Filter 54 is placed at the end of flow line 52 and at the beginning of flow line 57. Filter 54 is preferably a centrifugal filter that removes undesirable particulate matter such as sand, organic matter or the like and deposits it in sand container 55 as indicated by arrow 56. Filter 54 can be for example a centrifugal type filter such as is shown and described in any of the following US patents, each of which is incorporated herein by reference: U.S. Pat. Nos. 5,320,747; 5,338,341; 5,368,735; 5,425,876; 5,571,416; 5,578,203; 5,622,545; 5,653,874; 5,894,995; 6,090,276; 6,143,175; 6,167,960; 6,202,543; 7,000,782; and 7,032,760.
Counter flow can be provided from one module to a previous module. Counter flow line 58 enables counter flow from module 17 to module 16. Flow line 59 enables counter flow from module 16 to module 15. Flow line 62 enables counter flow from module 15 to module 14. Each of the modules 14, 15, 16, 17 is provided with a valved drain 23 for enabling discharge of fluid to sewer 24. Module 14 can be provided with overflow drain line 60 which discharges fluid through valve 61 to sewer 24.
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.
This application claims benefit of U.S. Provisional Patent Application Ser. No. 61/917,158, filed 17 Dec. 2013, which is hereby incorporated herein by reference. Priority of U.S. Provisional Patent Application Ser. No. 61/917,158, filed 17 Dec. 2013, which is incorporated herein by reference, is hereby claimed.
| Number | Date | Country | |
|---|---|---|---|
| 61917158 | Dec 2013 | US |
