Patent Application
20130260625
The present disclosure relates to the field of clothes dryers. It more particularly relates to an improved method and device for lint removal from clothes dryers. Still more particularly, the present disclosure relates to the use of substrates in the lint screen of clothes dryers for enhancing the trapping of lint generated during the drying process.
In 1998, 56.2% of all U.S. households had an electric clothes dryer, and 17.9% had a gas dryer. There were approximately 74 million clothes dryers in use in the U.S. in 1998. Electric clothes dryers include a fan, a heater, a tumbler (for holding and drying clothes), a lint screen, and an exhaust air duct as the basic components. A dryer operates by pulling air into it through vents and any gaps in the dryer housing. A fan is used to assist with the pulling of air into the dryer, which increases the air velocity to 600 to 1000 standard feet per minute (SFPM) referenced to 25° C. and 29.92 inches Hg. The air is then drawn over either an electrical heater or a gas heater operating at a temperature of 300 to 400° C., which increases the air temperature. The warm air then enters the tumbler to contact the wet clothes. The air then exits the tumbler and is directed through a lint screen, which functions to capture lint in the air screen to help prevent it from building up in the exhaust duct work of the dryer. Lint is defined as predominately as fabric fibers that are expelled from a clothes load of wet clothes during the drying process. Lint may include synthetic and natural fibers types, as well as dust. The lint material refers to the material collected from the lint screen or the material accumulated inside the cabinet (housing) of the dryer. The lint screen typically has a steel screen with a 20 mesh (20 holes per linear inch of screen) screen opening in it. The air then passes through the circulation fan, which forces the air through an exit duct in the rear of the dryer. A dryer hose then takes the air from the air duct of the dryer and discharges it outside the building structure housing the dryer. Alternatively, the warm air may be vented through a water reservoir to cool it down, such that it can be vented inside the building structure housing the dryer.
A May 2003 report of the U.S. Consumer Product Safety Commission entitled “Electric Clothes Dryers and Lint Ignition Characteristics” estimated that there were approximately 15,600 clothes dryer fires resulting in 20 deaths, 370 injuries and $75.4 million in property damage in 1998. Lint begins to accumulate inside a dryer chassis upon first use, including the dryer's components, such as the heater and the dryer floor. This lint accumulation occurs even when the dryer's lint screen is cleaned after each usage, and the dryer is properly exhausted. Under normal operation, the airflow inside the exhaust vent of the dryer decreases dramatically as the lint screen becomes blocked with lint particles. The temperatures measured inside the heater box, heater intake and tumbler intake increase when the exhaust vent is partially blocked (75%) or fully (100%) blocked, and the temperatures inside the tumbler, blower and exhaust vent correspondingly decrease. The results of the study shows that lint, which accumulates inside the dryer, can ignite if the lint contacts certain areas of the heater housing, if the lint is in proximity to the heater, or if the lint is ingested by the heater box. The study also shows that lint can ignite if there is a blocked exhaust vent. Dryer heaters have a high-limit thermostat, however lint may ignite before the high-limit thermostat switches the heater element off or the high-limit thermostat may fail. The ignition temperature of lint is measured by its flash point, which is approximately 700° C.
During the clothes drying process, static cling, defined as the tendency of objects (clothes) to stick (cling) to other objects owing to static electricity, is highly prevalent. Static electricity occurs during the clothes drying process from clothes rubbing against each other (the triboelectric effect). Static cling is especially prevalent when humidity is low, which allows for static electricity to build up. Fabric softeners added during the washing process, and dryer sheets added during the drying process, may be used to reduce static cling in clothes during the washing and drying process.
Laundry detergents are generally sulfate based and are anionic in nature. Hence, they impart a residual anionic (negative) charge to clothing during the washing process. Fabric softeners are generally amine based and are cationic (positive) in nature. The positive cationic charge of fabric softeners help to neutralize the residual negative anionic charge imparted to clothing during the washing process. However, static electricity builds up during the drying process from clothes contacting each other and clothes pulling apart from each other during the tumbling process. Dryer sheets are also generally cationic in nature and help to neutralize the residual negative anionic charge in clothes from the washing process and the static cling (excess of negative charge) imparted to clothes during the drying process. Dryer generated lint tends to be positively charged or cationic in nature due to the use of fabric softeners and/or dryer sheets used during the washing and drying process, which creates an excess of positive charges relative to negative charges.
As discussed above, lint screens are used to capture lint during the drying process to try to prevent build up on the internal air flow surfaces of the dryer and the exhaust duct. However, lint screens are not effective in capturing all of the lint generated during the drying process. Lint material released from the drying process will have inherent charges due to the rubbing of surfaces and their triboelectric characteristics. In addition, lint screens will trap equally charged lint particles that will electrically repel and will scatter and accumulate over any surface. The lint trap should be cleaned prior to or after each drying cycle by removing the layer of lint on the screen. A partially blocked or fully blocked lint screen increases the accumulation of lint on upstream dryer components, and in particular on the dryer heating elements. Often time, users of dryers forget to or consciously ignore cleaning the lint screen after each dryer cycle. Moreover, lint screens may be difficult to clean because the lint becomes so embedded in the screen hole openings that it becomes difficult to remove. The difficulty of removal may be the result of not only physically being imbedded in the screen hole openings of the lint screen, but also from the positively charged nature of the lint causing it to adhere to the lint screen.
Hence, a problem with the prior art drying process is that lint build up during the drying process increases the risk of dryer fires. Another problem with the prior art drying process is that lint screens are difficult to clean due to the buildup of static charge on the lint screen. A third problem with the prior art drying process is static charge build-up on the lint screen of the clothes dryer due to an excess of positive charge relative to negative charge.
Thus, there is a need for an improved method of capturing lint during the clothes drying process. There is also a need for an improved method of removing static charge from the lint screen (grounding the lint screen) and cleaning the lint screen of the clothes dryer.
To assist those of ordinary skill in the relevant art in making and using the subject matter hereof, reference is made to the appended drawings, wherein:
All numerical values within the detailed description and the claims herein are modified by “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
The present disclosure provides novel methods of capturing lint from the lint screen during a clothes drying process, compositions of lint capturing sheets and methods of making lint capturing sheets. The improved methods of capturing lint from the lint screen during a clothes drying process of the present disclosure offers significant advantages relative to prior art methods, including, but not limited to, improved ease of cleaning the lint screen of a clothes dryer, less static build up on the lint screen, reduced lint accumulation on the air flow passages both upstream and downstream of the lint screen, reduced propensity for dryer fires due to lint accumulation, improved ability to add both fragrance and disinfecting properties to clothes during the drying process, and less static build up on clothes during the drying process. The advantageous properties and/or characteristics of the disclosed methods of capturing lint from the lint screen during a clothes drying process are based, at least in part, on the use of a novel lint capturing sheet in the lint screen of the clothes dryer during a drying cycle. The lint capturing sheet disclosed herein may also be used in conjunction with a wand or other extensional device to function as a cleaning or wiping device/brush to remove lint from other difficult non-readily accessible air flow areas and surfaces internal to the clothes dryer. Two of such areas include the opening of the lint trap and the housing between the lint trap and the exhaust vent of the clothes dryer.
The triboelectric charging is the type of contact electrification in which certain materials become electrically charged after they come into contact with another different material and are then separated (such as through rubbing). The polarity and strength of the charges produced differ according to the materials, surface roughness, temperature, strain and other properties.
In the Triboelectric Series lists materials in order of the polarity of charge separation when they are touched with another object. The triboelectric series from most positively charged is as follows: +Air, Human skin, Leather, Rabbit's fur, Glass, Quartz, Mica, Human hair, Nylon, Wool, Lead, Cat's fur, Silk, Aluminum, Paper (Small positive charge), Cotton (no charge), 0 Steel(No charge), Wood (Small negative charge), Lucite, Amber, Sealing wax, Acrylic, Acetate, Rayon, Synthetic rubber, Polyester, Styrene (Styrofoam), Orlon, Plastic wrap, Polyurethane, Polyethylene, Polypropylene, Polyvinylchloride (PVC), Silicon, Teflon, Silicone rubber, Ebonite, −Most negatively charged.
Materials are often listed in order of the polarity of charge separation when they are touched with another object. The further apart the materials in the Triboelectric series, the greater the charge transferred. Laundry detergents are generally sulfate based and are anionic in nature. Hence, they impart a residual anionic (negative) charge to clothing during the washing process. Fabric softeners are generally amine based and are cationic in nature. The positive cationic charge of fabric softeners help to neutralize the residual anionic charge imparted to clothing during the washing process. However, static electricity builds up during the drying process from clothes contacting each other and clothes pulling apart from each other during the tumbling process.
The laundering process typically uses a detergent and an optional cationic fabric softener. The detergent alone will generate anionic charged lint in the dryer, while the use of a detergent and a fabric softener will typically generate cationic charged lint in the dryer. The most common laundering methods include using a cationic softener in the rinse or adding cationic dryer sheets to the dryer. In these most common methods of washing and drying clothing, the lint formed in the dryer will be positively charged. The equally charged particles will repel each other and some will be trapped in the lint screen while others will scatter over the dryer housing, vents and exhaust duct work. The lint trapped in the lint screen is generally difficult to remove, and a significant percentage of lint passes through the lint screen and will deposit on the inside surface and flooring of the dryer. It has been unexpectedly discovered that the triboelectric series may be used as an indication of which non-woven substrates to be used on the lint screen will be advantageous for further facilitating the capturing of lint during the drying process on the lint screen. It has been discovered that that non-woven polyolefin and polyesters sheets are particularly advantageous. Non-woven polyester sheets are particularly advantageous because of being more absorbent than the hydrophobic polyolefin sheets, and therefore they increase the efficacy of aqueous solutions on the non-woven fabric for acting as a grounding material when used on the lint screen of the dryer. The grounding of the lint screen through the use of a non-woven substrate that is negative on the Tribolectric series, wherein the substrate is saturated in an aqueous solution including water soluble ingredients improves dramatically the capture of lint on the lint screen during the drying process. The water soluble ingredients increase the electrical conductivity of the water, which decreases its impedance and thus helps to ground the charge of the lint screen and the lint and dust which accumulates on it. Hence, it is advantageous that the lint capturing sheet provided herein be negatively charged through the proper selection of the non-woven fabric substrate and the aqueous solution with water soluble ingredients which saturate the non-woven in order to more effectively capture the positively charged dryer lint and dust.
In one exemplary embodiment of the present disclosure, a lint capturing sheet for assisting with capturing lint at the lint screen of a clothes dryer includes a non-woven fabric saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30. The lint capturing sheet is placed onto the dryer screen prior to starting a drying cycle. The lint capturing sheet may range in size from 3 to 12 inches in width and in length from 5 to 15 inches depending on the size and style of the dryer stainless steel dryer screen or trap. In one form, the lint capturing sheet may be unrolled from a non-woven fabric roll saturated in an aqueous solution wherein the roll may have perforation every 8 inches in length and may have a width of about 6 to 9 inches. The lint capturing sheet may range in thickness from 1 mil to 40 mil, or 1 mil to 15 mil, or 1.5 mil to 10 mil, or 2 to 8 mil.
In one form, a clip may be used for attaching the lint capturing sheet to the stainless steel lint screen/trap of the clothes dryer. The use of a clip is advantageous in dryers that have a top entry lint trap and the air blows from the bottom to the top of the dryer. The inverted configuration makes the clip necessary to avoid the lint capturing sheet from falling inside the housing of the dryer. For dryers with a top to bottom configuration, the air flow secures the lint capturing sheet to the lint trap, and thus typically no clip is required. Other methods for securing the lint capturing sheet to the lint trap may be contemplated, including, but not limited to, the use of adhesive strips to secure the sheet to the trap and the use of a magnetized substrate for the lint capturing sheet. With the use of an adhesive, adhesive build up may occur due to the high air temperature environment, which may cause the adhesive to fail. The use of magnetic lint capturing sheets may be used to secure the lint capturing sheet to the steel lint trap by inserting one or more magnetic materials into the substrate of the lint capturing sheet. In addition, a combination of an adhesive and a magnetized lint capturing sheet may be utilized for securing the lint capturing sheet to the steel lint trap. Alternatively, a magnetic adhesive may be used to secure the lint capturing sheet to the steel lint trap.
The lint capturing sheet disclosed herein may include an aqueous solution having from 90 to 100 vol. % water and from 0.0 to 10 vol. % of water soluble ingredients, or from 90 to 99.9999 vol. % water and from 0.0001 to 10 vol. % of water soluble ingredients, or from 95 to 99.99 vol. % water and from 0.01 to 5 vol. % of water soluble ingredients, or from 97 to 99.99 vol. % water and from 0.01 to 3 vol. % of water soluble ingredients, or 99 to 99.9 vol. % water and from 0.1 to 1 vol. % of water soluble ingredients. The water used in the aqueous solution may non-deionized water, such as tap water, or deionized water. However non-deionized water is advantageous because it is more conductive in nature. In one form, the lint capturing sheet may not include water soluble ingredients, but may be saturated with water.
The aqueous solution in the lint capturing sheet is used to assist with lint capture and also to provide anti-static properties to the lint screen, which facilitates the removal of lint from the screen. The lint capturing sheet disclosed herein may have a weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranging from 1:1 to 1:20 or 1:1 to 1:10, or 1:1 to 1:6, or 1:1 to 1:3. In one advantageous form, the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:3 to 1:6 so as to have little or no dripping of the aqueous solution from the dryer sheet.
Non-limiting exemplary water soluble ingredients that may be included in the aqueous solution include many types of ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof. Non-limiting exemplary non-ionic water soluble compounds are acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof. Non-limiting exemplary ionic water soluble compounds are salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof. In addition, any other material that when dried from an aqueous solution that helps ground the charge of the lint trap in the steel screen mesh and assists the transfer of the lint to the substrate of the proper triboelectric charge may be used.
The aqueous solution including the water soluble ingredients provides grounding to the lint capturing screen during the drying process. The water containing lint capturing sheet will neutralize any charges on the lint screen during the drying process. The water containing lint capturing sheet also provides adhesion to the lint screen without substantially blocking air flow through the lint screen. That is, the air velocity through the lint screen with the lint capturing sheet present on it will not decrease more than 5%, or not more than 10%, or not more than 15%, or not more than 20%, or not more than 25% less than the lint screen without the lint capturing sheet present on it. For example,
The lint capturing sheet includes a non-woven fabric. A non-woven fabric is defined as a sheet or web structure bonded together by entangling fibers or filaments (and by perforating films) mechanically, thermally or chemically. They are flat, porous sheets that are made directly from separate fibers or from molten plastic or plastic film. The non-woven fabric may be produced from a synthetic or a natural fiber by known processes for producing non-woven fabrics. For example, with the use of synthetic fibers, a melt blowing or spun bonding process may be used. The non-woven fabric may be made from synthetic fibers, such as polyethylene, polypropylene, polyester, polyamide, polyvinylchloride, and polyvinyl acetate. However, due to the prevalence of positive charged lint in the most common laundering processes, the non-woven fabrics most preferred will be those on the negative end of the triboelectric series. One particularly preferable non-woven fabric is a polyester non-woven. The non-woven fabric must also have a sufficiently high melt point so as to not melt during the drying process. It is preferable that the flash point of the non-woven fabric is greater than 700° C.
The lint capturing sheet may also include as part of the aqueous solution an antioxidant agent, also known as a corrosion inhibitor or an anti-corrosive agent, which functions to prevent rusting of the steel trap during a drying cycle. Non-limiting exemplary corrosion inhibitors include alkali benzoates, amines, phosphates, tin salts, hydrazines, and combinations thereof. The anti-corrosive agent may be included in the aqueous solution at from 0.01 to 1 vol. %, or 0.02 to 0.8 vol. %, or 0.04 to 0.6 vol. %, or 0.06 to 0.8 vol. %.
The lint capturing sheet may also include as part of the aqueous solution a disinfecting agent, also known as a disinfectant, which functions to kill bacteria during a drying cycle. Disinfecting agents kill or inhibit the growth of microorganisms such as bacteria, fungi, or protozoans. The disinfecting agent, or disinfectant volatilizes at elevated temperatures during a drying cycle and may be included in the aqueous solution at from 0.01 to 1 vol. %, or 0.02 to 0.8 vol. %, or 0.04 to 0.6 vol. %, or 0.06 to 0.8 vol. %. Non-limiting exemplary disinfecting/disinfectant agents include propylene glycol, triethylene glycol, hydrogen peroxide, triclosan, benzalkonium chloride, ethyl alcohol, propyl alcohol, formaldehyde, glutaraldehyde, sodium hypochlorite, calcium hypochlorite, chloramine, electrolyzed water, chlorine dioxide, peracetic acid, performic acid, phenolics, quaternary ammonium compounds, 2,4-dichlorobenzyl alcohol and combinations thereof. Non-limiting exemplary phenolics include o-phenylphenol, chloroxylenol, hexachlorophene, thymol, and amylmetacresol.
The lint capturing sheet may also include as part of the aqueous solution a fragrancing agent, also known as an aroma compound, which is a chemical compound that has a smell or odor, and functions to give a pleasant odor to clothes during the drying cycle. The fragrancing agent volatilizes at elevated temperatures during a drying cycle and may be included in the aqueous solution at from 0.01 to 1 vol. %, or 0.02 to 0.8 vol. %, or 0.04 to 0.6 vol. %, or 0.06 to 0.8 vol. %. Non-limiting exemplary fragrancing agents/aroma compounds include esters, linear terpenes, cyclic terpenes, aromatics, alcohols, ketones, fragrant aldehydes and combinations thereof.
As discussed above, the lint capturing sheet may include disinfecting and/or fragrancing agents as part of the aqueous solution. Both the disinfecting agent and the fragrancing agent volatilize at the elevated air temperatures during the drying cycle and provide disinfectant and/or aroma properties to the clothes being dried.
During the drying process, the lint capturing sheet also provides anti-static properties to the lint screen, which facilitates the removal of lint. The anti-static properties are provided through the use of the aqueous solution including the water and water soluble ingredients through prevention of formation and grounding of charges on the lint screen through the lint capturing sheet.
In an alternative embodiment of the present disclosure, a method of capturing lint from the lint screen during a clothes drying process includes the steps of: providing a lint capturing sheet comprising a non-woven fabric saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, placing the lint capturing sheet on a dryer lint screen prior to a clothes drying cycle, and removing the lint capturing sheet from the dryer lint screen after the clothes drying cycle to remove lint from the clothes drying process,.
The lint capturing sheet described above may be removed from the container in which it is stored in and then placed on the dryer screen of the clothes dryer. The lint capturing sheet may be placed flat on the dryer screen or alternatively it may not be placed flat on the screen. In one preferable form, the lint capturing screen would cover the entire surface area of the screen and would be placed on the upstream side of the lint screen relative to the hot air flow passing through the screen. In another form, the lint capturing screen would not cover the entire surface area of the screen, but would cover a majority of the screen. In either case sufficient adhesion to the lint screen is provided by the water soluble components. Alternatively, the lint capturing sheet may be secured to the dryer screen using a clip or other suitable means for securing the sheet to the screen.
As discussed above, the lint capturing sheet may include anti-corrosion, disinfecting and /or fragrancing agents as part of the aqueous solution. Both the disinfecting agent and the fragrancing agent volatilize at the elevated air temperatures during the drying cycle and provide disinfectant and/or aroma properties to the clothes being dried.
During the drying process, the lint capturing sheet also provides some anti-static properties to the lint screen, which facilitates the removal of lint. The anti-static properties are provided through the use of the aqueous solution including the water soluble ingredients through grounding of charges on the lint screen through the lint capturing sheet. The water present on the sheet tends to ground any charges (generated from detergent and clothes during the washing process) and on the laundry during the drying process. Hence, the moist triboelectric substrate will help to neutralize any static build-up in the lint screen or trap.
After the drying cycle is complete or prior to starting a new drying cycle, the user of the dryer may remove the lint capturing screen from the lint screen or trap along with the lint that it has captured. The lint capturing sheet may also be used to wipe the lint screen or trap to remove any residual lint that may be embedded in the openings.
In another alternative embodiment of the present disclosure, a method of making a lint capturing sheet includes the following steps: providing a non-woven fabric in roll form with perforations along the length of the roll to provide for ease of tearability of sheets from the roll, inserting the roll into a container such that the roll stands on one of its ends, placing into the container an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, and placing an openable cover onto the top of the container for sealing the container and for removal of a lint capturing sheet from the roll saturated in the aqueous solution. The non-woven fabric is preferably provided in roll form with perforations along the length of the roll. These perforations provide a means for the user to easily tear sheets from the roll in the transverse direction.
As described above, the non-woven fabric may be produced from a synthetic or a natural fiber by known processes for producing such fabrics. For example, with the use of synthetic fibers, a melt blowing or spun bonding process may be used. The non-woven fabric may be made from synthetic fibers, such as for example, polyethylene, polypropylene, polyester, and polyamide or alternatively from natural fibers, of preferably negative triboelectric properties. The non-woven fabric provides a support means for capturing the lint in the air stream from the drying process, while still providing a structure that allows for air to pass through it. Hence, it functions as a lint removal filtering device.
The non-woven fabric in roll form is placed into a container such that the roll stands on one of its ends at the bottom of the container. The container is preferably cylindrical in shape and is preferably fabricated from a plastic or glass. Non-limiting exemplary plastics that may be used to form the container include polyethylene, polypropylene, polyvinyl chloride, and polyester. The outside diameter of the cylindrical plastic container is larger than the outside diameter of the non-woven fabric roll.
After the non-woven fabric roll is placed into the container with an open top, the aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the water soluble ingredients increase the electrical conductivity of the water, is inserted into the bottom of the container by means generally known in the art for adding liquids to a container. The weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, which allows for the aqueous solution to wick-up the non-woven fabric roll and to correspondingly saturate it with the aqueous solution. As described above, the lint capturing sheet disclosed herein may alternatively have a weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranging from 1:1 to 1:20, or 1:1 to 1:10, or 1:1 to 1:6, or 1:1 to 1:3. Non-limiting exemplary water soluble ingredients that may be included in the aqueous solution include many types including ionic and non-ionic water soluble compounds, acids, bases, salts, alcohols, glycols, polyglycols, polyvinyl alcohols, ethoxylated or propoxylated surfactants and any material that when dried from an aqueous solution will help the lint trapping sheet of a substrate adhere to the screen steel mesh.
The aqueous solution including the water soluble non-ionic ingredients provides grounding to the lint capturing screen during the drying process. The water containing lint capturing sheet will neutralize any charges on the lint screen during the drying process. Non-limiting exemplary water soluble ingredients that may be included in the aqueous solution include many types of ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof. Non-limiting exemplary non-ionic water soluble compounds are acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof. Non-limiting exemplary ionic water soluble compounds are salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof. In addition, any other material that when dried from an aqueous solution will help ground the charge of the lint trap in the steel screen mesh and help the transfer of the lint to the substrate of the proper triboelectric charge.
The aqueous solution including the water soluble ingredients provides grounding to the lint capturing screen during the drying process. The water containing lint capturing sheet will ground any charges on the lint screen during the drying process.
After the aqueous solution is placed into the container including the non-woven fabric roll, an openable cover is placed onto the top of the container for sealing the container and for removal of a lint capturing sheet from the roll saturated in the aqueous solution. The openable cover prevents the aqueous solution from volatilizing from the container during storage and allows the user to open the top and unwind a sheet from the roll and then tear it from the roll such that the lint capturing sheet may be placed in the lint trap of the clothes dryer. The openable cover may be formed from plastic or glass. Non-limiting exemplary plastics that may be used to form the openable cover include polyethylene, polypropylene, polyvinyl chloride, and polyester. The inside diameter of the openable cover is generally slightly larger the outside diameter of the cylindrical plastic container such that it forms a tight snap fit to the container, such that it will not leak.
In yet another alternative embodiment of the present disclosure, a method of making a lint capturing sheet includes the following steps: providing a non-woven fabric in sheet form, inserting a stack of the non-woven fabric in sheet form into a container such that the stack sits on the bottom of the container, placing into the container an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, and placing a openable cover onto the top of the container for sealing the container and for removal of a lint capturing sheet from the stack saturated in the aqueous solution. In this form, the lint capturing sheet is already pre-cut in a rectangular shape to fit within the container.
The following are examples of the present disclosure and are not to be construed as limiting.
300 g of a water solution of 0.01% sodium benzoate/benzoic acid was poured into a polyolefin cylindrical container. 20 g of non-woven polyester batting was rolled and inserted in the container. All the solution was wicked by the absorbent non-woven fabric. The roll felt moist to the touch, however, the aqueous solution didn't drip from the individual sheets. Total weight of a dry polyester sheet per 5×9 inch sheet was 1 gram. The material absorbed and wicked 10-15 g of water per sheet with no dripping. The wet sheet was easily applied to the steel lint trap/screen of a clothes dryer and easily adhered to it. The dryer was turned on and the wet sheet was progressively dried until the cycle was completed. The amount of lint recovered was 0.3 g per sheet per towel dried. The towels were laundered using a commercial detergent and a cationic laundry conditioner. Most of the lint resulting from the drying process was imbedded in the dried polyester sheet and it was easily removed with no lint left behind in the steel trap.
One dry 5×9 non-woven polyester sheet weighing 1 gram was placed on the dryer lint trap. A towel of equal weight to the same used in Example 1 and previously laundered under the same conditions as in Example 1 was dried. Only 0.1 g of lint per sheet per towel was recovered. The rest of the lint was scattered over other surfaces of the clothes dryer, including some imbedded in the lint trap/screen. The wet sheets of Example 1 trapped three times more lint than the dried ones of Comparative Example 2.
100 g of water solution of 0.01% sodium benzoate/benzoic acid was poured into a polyolefin cylindrical container. 20 g of non-woven polyester batting was rolled and inserted into the container. The solution wet the non-woven polyester roll. The roll felt moist to the touch, however, the aqueous solution didn't drip from the individual sheets. Total weight of a dry polyethylene sheet per 5×9 inch sheet was 0.8 grams. The material retained 0.8 to 3.0 g of water per sheet with no dripping. The wet sheet was easily applied to the steel lint trap of the clothes dryer and easily adhered to it. The dryer was turned on and the wet sheet was progressively dried until the cycle was completed. The amount of lint recovered was 1.4 g per sheet per 10 lbs. load of permanent press clothing dried. The load was laundered using a commercial detergent and a cationic laundry conditioner. Most of the lint resulting from the drying process was imbedded in the dried polyethylene sheet and it was easily removed with no lint left behind in the steel trap.
A dry non-woven polyethylene sheet measuring 5×9 inches and having a weight of 0.8 gram was used to cover the steel lint trap/screen of a clothes dryer. The dry sheet was applied to the steel lint trap where it did not easily adhere. The dryer was turned on and the dry sheet was blown against the steel trap until the cycle was completed. The amount of lint recovered was 0.6g per sheet per 10 lbs. load of permanent press clothing dried. The load was laundered using a commercial detergent and a cationic laundry conditioner. Most of the lint resulting from the drying process was imbedded on the dried polyethylene sheet or in the steel trap. The lint imbedded in the steel trap was difficult to remove and had to be rinsed off for complete removal. The lint on the dried nonwoven was simply disposed with the non-woven sheet.
Using two different substrates, polyester and polyethylene, wet and dried measurements were made to determine the amount of lint trapped on the sheets. In all cases the wet substrates retained 1.4/0.8=1.75 or about 2 times the amount of lint compared to the same dried substrate.
A household clothes dryer was used to dry a load of wet laundry. The lint capturing sheet disclosed herein was not used on the lint screen during the drying cycle.
A household clothes dryer was used to dry a load of wet laundry. A lint capturing sheet comprising a non-woven polyester substrate with no aqueous solution (dry) was placed on the lint screen prior to commencing the drying cycle.
A household clothes dryer was used to dry a load of wet laundry. A lint capturing sheet comprising a non-woven polyester substrate with aqueous solution (1 gram of non-woven polyester to 3 grams of water) was placed on the lint screen prior to commencing the drying cycle.
A household clothes dryer was used to dry a load of wet laundry. A lint capturing sheet comprising a non-woven polyester substrate with no aqueous solution was placed on the lint screen prior to commencing the drying cycle.
A household clothes dryer was used to dry a load of wet laundry. A lint capturing sheet comprising a non-woven polyester substrate with aqueous solution (1 gram of non-woven polyester to 3 grams of water) was placed on the lint screen prior to commencing the drying cycle.
A household clothes dryer was used to dry a load of wet laundry.
Applicants have attempted to disclose all embodiments and applications of the disclosed subject matter that could be reasonably foreseen. However, there may be unforeseeable, insubstantial modifications that remain as equivalents. While the present invention has been described in conjunction with specific, exemplary embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is intended to embrace all such alterations, modifications, and variations of the above detailed description.
All patents, test procedures, and other documents cited herein, including priority documents, are fully incorporated by reference to the extent such disclosure is not inconsistent with this invention and for all jurisdictions in which such incorporation is permitted.
When numerical lower limits and numerical upper limits are listed herein, ranges from any lower limit to any upper limit are contemplated.
According to the present disclosure, an advantageous method of capturing lint from the lint screen during a clothes drying process includes: providing a lint capturing sheet comprising a non-woven fabric saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, placing the lint capturing sheet on a dryer lint screen prior to a clothes drying cycle, and removing the lint capturing sheet from the dryer lint screen after the clothes drying cycle to remove lint from the clothes drying process.
A further aspect of the present disclosure relates to an advantageous lint capturing sheet comprising a non-woven fabric saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30.
Another aspect of the present disclosure relates to an advantageous method of making a lint capturing sheet comprising: providing a non-woven fabric in roll form with perforations along the length of the roll to provide for ease of tearability of sheets from the roll, inserting the roll into a container such that the roll stands on one of its ends, placing into the container an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, and placing a openable cover onto the top of the container for sealing the container and for removal of a lint capturing sheet from the roll saturated in the aqueous solution.
Still another aspect of the present disclosure relates to an advantageous method of making a lint capturing sheet comprising: providing a non-woven fabric in sheet form, inserting a stack of the non-woven fabric in sheet form into a container such that the stack sits on the bottom of the container, placing into the container an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, and placing a openable cover onto the top of the container for sealing the container and for removal of a lint capturing sheet from the stack saturated in the aqueous solution.
Still another aspect of the present disclosure relates to an advantageous method of cleaning lint from the internal surfaces of a clothes dryer using a lint capturing sheet comprising the steps of: providing a lint capturing sheet including a non-woven fabric in sheet form saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30; placing the lint capturing sheet onto a wand to form a lint capturing cleaning device; and using the lint capturing cleaning device to wipe lint from non-readily accessible areas of the clothes dryer.
These and other features and attributes of the disclosed methods for capturing lint from the lint screen during a clothes drying process, compositions of lint capturing sheets and methods of making lint capturing sheets of the present disclosure will be apparent from the detailed description which follows.
A method of capturing lint from the lint screen during a clothes drying process is provided. The method includes providing a lint capturing sheet comprising a non-woven fabric saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, placing the lint capturing sheet on a dryer lint screen prior to a clothes drying cycle, and removing the lint capturing sheet from the dryer lint screen after the clothes drying cycle to remove lint from the clothes drying process.
In one aspect the aqueous solution is from 99 to 99.99 vol. % water and from 0.01 to 1 vol. % of water soluble ingredients. The method includes the water soluble ingredients are chosen from ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof.
In one aspect the non-ionic water soluble compounds are chosen from acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof.
In one aspect the ionic water soluble compounds are chosen from salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof.
In one aspect the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:20.
In one aspect the non-woven fabric is chosen from polyethylene, polypropylene, polyester, polyamide, polyvinylchloride, and polyvinyl acetate.
In one aspect the aqueous solution further includes a disinfecting agent at from 0.01 to 10 vol. %.
In one aspect the disinfecting agent is chosen from propylene glycol, triethylene glycol, hydrogen peroxide, triclosan, benzalkonium chloride, ethyl alcohol, propyl alcohol, ethyl alcohol, phenols, chloramines, peracids and combinations thereof.
In one aspect the aqueous solution further includes a fragrancing agent at from 0.01 to 1 vol. %.
In one aspect the fragrancing agent is chosen from esters, linear terpenes, cyclic terpenes, aromatics, alcohols, ketones, fragrant aldehydes and combinations thereof.
In one aspect the aqueous solution further includes an anticorrosive agent at from 0.01 to 1 vol %.
In one aspect the anticorrosive agent is chosen from alkali benzoates, amines, phosphates, tin salts, hydrazines and combinations thereof.
In one aspect static charge is removed from the lint screen by providing grounding of charges.
In one aspect including using a clip, a non-magnetic adhesive, a magnetic adhesive, a magnetic non-woven fabric, or combinations thereof to secure the lint capturing sheet to the dryer lint screen prior to a clothes drying cycle.
In one aspect a lint capturing sheet comprising a non-woven fabric saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30.
In one aspect lint capturing sheet wherein the aqueous solution is from 99 to 99.99 vol. % water and from 0.01 to 1 vol. % of water soluble ingredients.
In one aspect the lint capturing sheet wherein the water soluble ingredients are chosen from ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof.
In one aspect the lint capturing sheet wherein the non-ionic water soluble compounds are chosen from acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof.
In one aspect the lint capturing sheet wherein the ionic water soluble compounds are chosen from salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof.
In one aspect the lint capturing sheet wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:20.
In one aspect the lint capturing sheet wherein the non-woven fabric is chosen from polyethylene, polypropylene, polyester, polyamide, polyvinylchloride, and polyvinyl acetate.
In one aspect the lint capturing sheet wherein the non-woven fabric is polyester.
In one aspect the lint capturing sheet wherein the aqueous solution further includes a disinfecting agent at from 0.01 to 10 vol. %.
In one aspect The lint capturing sheet of claim 24, wherein the disinfecting agent is chosen from propylene glycol, triethylene glycol, hydrogen peroxide, triclosan, benzalkonium chloride, ethyl alcohol, propyl alcohol, ethyl alcohol, phenols, chloramines, peracids and combinations thereof.
In one aspect the lint capturing sheet wherein the aqueous solution further includes a fragrancing agent at from 0.01 to 1 vol. %.
In one aspect the lint capturing sheet wherein the fragrancing agent is chosen from esters, linear terpenes, cyclic terpenes, aromatics, alcohols, ketones, fragrant aldehydes and combinations thereof.
In one aspect the lint capturing sheet wherein the aqueous solution further includes an anticorrsive agent at from 0.01 to 1 vol %.
In one aspect the lint capturing sheet wherein the anticorrosive agent is chosen from alkali benzoates, amines, phosphates, tin salts, hydrazines and combinations thereof.
In one aspect the lint capturing sheet wherein the water is non-deionized water.
The method of making a lint capturing sheet providing a non-woven fabric in roll form with perforations along the length of the roll to provide for ease of tearability of sheets from the roll and inserting the roll into a container such that the roll stands on one of its ends, placing into the container an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, and placing an openable cover onto the top of the container for sealing the container and for removal of a lint capturing sheet from the roll saturated in the aqueous solution.
The method in the aqueous solution is from 99 to 99.99 vol. % water and from 0.01 to 1 vol. % of water soluble ingredients.
The method wherein the water soluble ingredients are chosen from ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof.
The method wherein the non-ionic water soluble compounds are chosen from acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof.
The method wherein the ionic water soluble compounds are chosen from salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof.
The method wherein the non-woven fabric is chosen from polyethylene, polypropylene, polyester, polyamide, polyvinylchloride, and polyvinyl acetate.
The method wherein the aqueous solution further includes a disinfecting agent at from 0.01 to 10 vol. %.
The method wherein the disinfecting agent is chosen from propylene glycol, triethylene glycol, hydrogen peroxide, triclosan, benzalkonium chloride, ethyl alcohol, propyl alcohol, ethyl alcohol, phenols, chloramines, peracids and combinations thereof.
The method wherein the aqueous solution further includes a fragrancing agent at from 0.01 to 1 vol. %.
The method wherein the fragrancing agent is chosen from esters, linear terpenes, cyclic terpenes, aromatics, alcohols, ketones, fragrant aldehydes and combinations thereof.
The method wherein the aqueous solution further includes an anticorrosive agent at from 0.01 to 1 vol %.
The method wherein the anticorrosive agent is chosen from alkali benzoates, amines, phosphates, tin salts, hydrazines and combinations thereof.
The method wherein static charge is removed from the lint screen by providing grounding of charges.
The method wherein the container and openable cover comprise plastic or glass.
The method wherein the plastic is chosen from polyethylene, polypropylene, polyvinyl chloride, and polyester.
The method of making a lint capturing sheet providing a non-woven fabric in sheet form, inserting a stack of the non-woven fabric in sheet form into a container such that the stack sits on the bottom of the container, placing into the container an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, and placing an openable cover onto the top of the container for sealing the container and for removal of a lint capturing sheet from the stack saturated in the aqueous solution.
The method wherein the water soluble ingredients are chosen from ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof.
The method wherein the non-ionic water soluble compounds are chosen from acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof.
The method wherein the ionic water soluble compounds are chosen from salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof.
The method wherein the non-woven fabric is chosen from polyethylene, polypropylene, polyester, polyamide, polyvinylchloride, and polyvinyl acetate.
The method of cleaning lint from the internal surfaces of a clothes dryer using a lint capturing sheet providing a lint capturing sheet including a non-woven fabric in sheet form saturated in an aqueous solution of from 90 to 99.999 vol. % water and from 0.001 to 10 vol. % of water soluble ingredients, wherein the non-woven fabric is negative on the Triboelectric series, wherein the water soluble ingredients increase the electrical conductivity of the water, and wherein the weight ratio of non-woven fabric to the aqueous solution in the lint capturing sheet ranges from 1:1 to 1:30, placing the lint capturing sheet onto a wand or other extensional device to form a lint capturing cleaning device using the lint capturing cleaning device to wipe lint from non-readily accessible areas of the clothes dryer.
The method wherein the water soluble ingredients are chosen from ionic water soluble compounds, non-ionic water soluble compounds and combinations thereof.
The method wherein the non-ionic water soluble compounds are chosen from acids, bases, alcohols, glycols, polyglycols, vinyl alcohols, polyvinyl alcohols, polyvinyl pyrrolidones, aldehydes, ketones, carbowaxes, ethoxylated surfactants, propoxylated surfactants and combinations thereof.
The method wherein the ionic water soluble compounds are chosen from salts of alkali halides, sulphates and phosphates; alkali metal salts of water soluble organic acids; and combinations thereof.
The method wherein the non-readily accessible areas include the opening of the lint trap and the housing between the lint trap and the exhaust vent of the clothes dryer.
It should be understood that the foregoing description is only illustrative of the aspects of the disclosed embodiment. Various alternatives and modifications can be devised by those skilled in the art without departing from the aspects of the disclosed embodiment. Accordingly, the aspects of the disclosed embodiment are intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims. Further, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be advantageously used, such a combination remaining within the scope of the aspects of the invention.
This application is a non-provisional of and claims the benefit of U.S. Provisional Patent Application No. 61/609,008 filed on Mar. 9, 2012, the disclosure of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61609008 | Mar 2012 | US |
