Cleaning apparatus and method

Abstract

The invention provides an apparatus and method for use in the cleaning of soiled substrates, the apparatus comprising housing means comprising: (a) a stationary member; (b) a rotatably mounted cylindrical cage; and (c) access means, wherein said stationary member comprises an annular planar member which is of greater internal diameter than said access means and is located adjacent said rotatably mounted cylindrical cage and said stationary member comprises a multiplicity of delivery means which are mounted thereon and a multiplicity of orifices which are respectively operably connected to said multiplicity of delivery means, wherein said multiplicity of delivery means is adapted to facilitate the delivery of materials into said rotatably mounted cylindrical cage. The method involves cleaning the soiled substrate by treatment of the moistened substrate with a formulation comprising solid particulate cleaning material and wash water, the method being carried out using the apparatus of the invention. The apparatus and method find particular application in the cleaning of textile fabrics.

1 . An apparatus for use in the cleaning of soiled substrates, said apparatus comprising housing means comprising:
 (a) a stationary member;   (b) a rotatably mounted cylindrical cage; and   (c) access means,   
       wherein said stationary member comprises an annular planar member which is of greater internal diameter than said access means and is located adjacent said rotatably mounted cylindrical cage and said stationary member comprises a multiplicity of delivery means which are mounted thereon and a multiplicity of orifices which are respectively operably connected to said multiplicity of delivery means, wherein said multiplicity of delivery means is adapted to facilitate the delivery of materials into said rotatably mounted cylindrical cage. 
     
     
         2 . An apparatus as claimed in  claim 1  wherein said stationary member is comprised in said housing means and attached thereto by attachment means incorporating fixing members. 
     
     
         3 . An apparatus as claimed in  claim 1  wherein said stationary member is intrinsically comprised as part of said housing means. 
     
     
         4 . An apparatus as claimed in  claim 1 ,  2  or  3  wherein said stationary member comprises a metallic member. 
     
     
         5 . An apparatus as claimed in  claim 4  wherein said stationary member is formed of steel. 
     
     
         6 . An apparatus as claimed in  claim 4  or  5  wherein said stationary member is formed by pressing, machining, or other suitable fabrication process. 
     
     
         7 . An apparatus as claimed in  claim 1 ,  2  or  3  wherein said stationary member comprises a plastic member. 
     
     
         8 . An apparatus as claimed in  claim 7  wherein said member is formed by moulding. 
     
     
         9 . An apparatus as claimed in any one of  claims 1  to  8  wherein the edges of said stationary member are smoothed. 
     
     
         10 . An apparatus as claimed in any preceding claim wherein the gap around the circumference between said stationary member and said rotatably mounted cylindrical cage is in the region of from 1-25 mm 
     
     
         11 . An apparatus as claimed in  claim 10  wherein said gap is in the region of from 3-5 mm. 
     
     
         12 . An apparatus as claimed in any preceding claim wherein said access means may be closed so as to provide a substantially sealed system. 
     
     
         13 . An apparatus as claimed in any preceding claim wherein said access means comprises at least one hinged door mounted in the housing means. 
     
     
         14 . An apparatus as claimed in any preceding claim wherein said rotatably mounted cylindrical cage is mounted essentially horizontally within said housing means. 
     
     
         15 . An apparatus as claimed in any preceding claim wherein no more than 50%, of the side walls of said rotatably mounted cylindrical cage comprises perforations. 
     
     
         16 . An apparatus as claimed in any preceding claim wherein said perforations have a diameter of from 2 to 25 mm. 
     
     
         17 . An apparatus as claimed in any preceding claim wherein said rotatably mounted cylindrical cage has a capacity in the region of 10 to 7000 litres. 
     
     
         18 . An apparatus as claimed in any preceding claim wherein said cage comprises a cylinder with a diameter in the region of 75 to 120 cm. 
     
     
         19 . An apparatus as claimed in any preceding claim wherein said cage has a length of between 40 and 100 cm. 
     
     
         20 . An apparatus as claimed in any preceding claim wherein rotation of said rotatably mounted cylindrical cage is effected by use of drive means. 
     
     
         21 . An apparatus as claimed in  claim 20  wherein said drive means comprises electrical drive means and said electrical drive means optionally comprises an electric motor. 
     
     
         22 . An apparatus as claimed in  claim 20  or  21  wherein operation of said drive means is effected by control means. 
     
     
         23 . An apparatus as claimed in any preceding claim which comprises circulation means. 
     
     
         24 . An apparatus as claimed in  claim 23  wherein the inner surface of the cylindrical side walls of said rotatably mounted cylindrical cage comprises circulation means comprising a multiplicity of spaced apart elongated protrusions affixed essentially perpendicularly to said inner surface. 
     
     
         25 . An apparatus as claimed in  claim 24  wherein said protrusions additionally comprise air amplifiers. 
     
     
         26 . An apparatus as claimed in  claim 25  wherein said air amplifiers are driven pneumatically and are adapted so as to promote circulation of a current of air within said cage. 
     
     
         27 . An apparatus as claimed in  claim 25  or  26  which comprises from 3 to 10 of said protrusions. 
     
     
         28 . An apparatus as claimed in any preceding claim which comprises additional agitating means, and wherein said additional agitating means optionally comprises an air jet. 
     
     
         29 . An apparatus as claimed in any preceding claim wherein said rotatably mounted cylindrical cage is mounted in a first upper chamber of said housing means and said apparatus additionally comprises a second lower chamber located beneath said cylindrical cage. 
     
     
         30 . An apparatus as claimed in any preceding claim which comprises at least one recirculation means and/or pumping means. 
     
     
         31 . An apparatus as claimed in any preceding claim which comprises housing means comprising:
 (a) a first upper chamber having mounted therein a rotatably mounted cylindrical cage and a stationary member;   (b) a second lower chamber located beneath said cylindrical cage;   (c) at least one recirculation means;   (d) access means;   (e) pumping means; and   (f) a multiplicity of delivery means,   
       wherein said stationary member is located adjacent said rotatably mounted cylindrical cage wherein said stationary member comprises an annular planar member which is of greater internal diameter than said access means and is located adjacent said rotatably mounted cylindrical cage and said stationary member comprises a multiplicity of delivery means which are mounted thereon and a multiplicity of orifices which are respectively operably connected to said multiplicity of delivery means, wherein said multiplicity of delivery means is adapted to facilitate the delivery of materials into said rotatably mounted cylindrical cage. 
     
     
         32 . An apparatus as claimed in  claim 31  wherein said second lower chamber functions as a collection chamber for cleaning media and comprises an enlarged sump. 
     
     
         33 . An apparatus as claimed in  claim 31  or  32  wherein said at least one recirculation means facilitates recirculation of said solid particulate material from said lower chamber to said rotatably mounted cylindrical cage, for re-use in cleaning operations and comprises ducting connecting said second chamber and said rotatably mounted cylindrical cage. 
     
     
         34 . An apparatus as claimed in  claim 33  wherein said ducting comprises separating means for separating said solid particulate material from water. 
     
     
         35 . An apparatus as claimed in  claim 34  wherein said separating means comprises a vessel located above said cylindrical cage. 
     
     
         36 . An apparatus as claimed in  claim 35  wherein said vessel comprises a filter material, and said filter material optionally comprises a wire mesh. 
     
     
         37 . An apparatus as claimed in any one of  claims 31  to  36  wherein at least one recirculation means comprises first recirculation means which comprises pumping means. 
     
     
         38 . An apparatus as claimed in any one of  claims 31  to  37  which includes a second recirculation means. 
     
     
         39 . An apparatus as claimed in  claim 38  wherein said second recirculation means allows for the return of water separated by said separating means to said lower chamber. 
     
     
         40 . An apparatus as claimed in any one of  claims 15  to  39  wherein said lower chamber comprises additional pumping means to promote circulation and mixing of the contents thereof. 
     
     
         41 . A method for cleaning a soiled substrate, said method comprising the treatment of the substrate with a formulation comprising solid particulate cleaning material and wash water, wherein said method is carried out in an apparatus according to any one of  claims 1  to  40 . 
     
     
         42 . A method for cleaning a soiled substrate, said method comprising the steps of:
 (a) introducing a solid particulate cleaning material and water into the second chamber of an apparatus as claimed in any one of  claims 1  to  40 ;   (b) agitating and heating said solid particulate cleaning material and water;   (c) loading at least one soiled substrate into said rotatably mounted cylindrical cage via access means;   (d) closing the access means so as to provide a substantially sealed system;   (e) causing the rotatably mounted cylindrical cage to rotate whilst introducing said wash water and any required additional cleaning agent to uniformly wet out the substrate;   (f) introducing said solid particulate cleaning material into said rotatably mounted cylindrical cage and operating the apparatus for a wash cycle, wherein said rotatably mounted cylindrical cage continues to rotate, and wherein fluids and solid particulate cleaning material are caused to fall through perforations in said rotatably mounted cylindrical cage into said second chamber in a controlled manner;   (g) operating pumping means so as to transfer fresh solid particulate cleaning material and recycle used solid particulate cleaning material to separating means;   (h) adding said fresh and recycled solid particulate cleaning material to said rotatably mounted cylindrical cage in a controlled manner; and   (i) continuing with steps (f), (g) and (h) as required to effect cleaning of the soiled substrate.   
     
     
         43 . A method as claimed in  claim 41  or  42  which additionally comprises a rinsing operation wherein additional water is added to said rotatably mounted cylindrical cage. 
     
     
         44 . A method as claimed in  claim 43  wherein the rotation speed of said rotatably mounted cylindrical cage is increased during said rinsing operation. 
     
     
         45 . A method as claimed in  claim 43  or  44  wherein substrate treatment agents are added to the rinse water during said rinsing operation. 
     
     
         46 . A method as claimed in  claim 45  wherein said substrate treatment agents are selected from anti-redeposition additives, optical brighteners, perfumes, softeners and starch. 
     
     
         47 . A method as claimed in any one of  claims 41  to  46  wherein at least one additional cleaning agent is added to said apparatus. 
     
     
         48 . A method as claimed in  claim 47  wherein said at least one additional cleaning agent is added to the lower chamber of said apparatus with said solid particulate cleaning material, heated to the desired temperature therein, and the introduced, via said first recirculation means, into said cylindrical cage via said multiplicity of delivery means and said stationary member. 
     
     
         49 . A method as claimed in  claim 47  wherein said at least one additional cleaning agent is pre-mixed with water and added to said cylindrical cage via said multiplicity of delivery means attached to said stationary member. 
     
     
         50 . A method as claimed in  claim 47 ,  48  or  49  wherein said at least one additional cleaning agent comprises at least one detergent composition. 
     
     
         51 . A method as claimed in  claim 50  wherein said at least one detergent composition comprises cleaning components and post-treatment components. 
     
     
         52 . A method as claimed in  claim 51  wherein said cleaning components comprise surfactants, enzymes and bleach. 
     
     
         53 . A method as claimed in  claim 51  or  52  wherein said post-treatment components comprise anti-redeposition additives, perfumes and optical brighteners. 
     
     
         54 . A method as claimed in any one of  claims 50  to  53  which additionally comprises at least one other additive selected from builders, chelating agents, dye transfer inhibiting agents, dispersants, enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal agents, suds suppressors, dyes, structure elasticizing agents, fabric softeners, starches, carriers, hydrotropes, processing aids and pigments. 
     
     
         55 . A method as claimed in any one of  claims 41  to  54  wherein, during the wash cycle, rotation of said rotatably mounted cylindrical cage is caused to occur at a G force of less than 1. 
     
     
         56 . A method as claimed in any one of  claims 41  to  55  wherein, on completion of the wash cycle, feeding of solid particulate cleaning material into said rotatably mounted cylindrical cage ceases and the G force on the cage is increased in order to effect a measure of drying of the cleaned substrate. 
     
     
         57 . A method as claimed in  claim 56  wherein said G force is between 10 and 1000. 
     
     
         58 . A method as claimed in  claim 56  or  57  wherein G force is subsequently reduced to below 1 so as to allow for removal of the solid particulate cleaning material. 
     
     
         59 . A method as claimed in any one of  claims 41  to  58  wherein said solid particulate cleaning material is subjected to a cleaning operation in said lower chamber by sluicing said chamber with clean water. 
     
     
         60 . A method as claimed in any one of  claims 48  to  58  wherein said solid particulate cleaning material is subjected to a cleaning operation in said rotatably mounted cylindrical cage. 
     
     
         61 . A method as claimed in  claim 59  or  60  wherein said cleaning operation is carried out in the presence of a cleaning agent. 
     
     
         62 . A method as claimed in any one of  claims 41  to  61  wherein said at least one soiled substrate comprises at least one textile fibre garment. 
     
     
         63 . A method as claimed in any one of  claims 41  to  62  wherein said solid particulate cleaning material comprises a multiplicity of polymeric particles and said polymeric particles optionally comprise particles of polyamides, polyesters, polyalkenes or polyurethanes or their copolymers. 
     
     
         64 . A method as claimed in  claim 63  wherein said polyamide particles comprise nylon beads. 
     
     
         65 . A method as claimed in  claim 63  wherein said polyester particles comprise polyethylene terephthalate or polybutylene terephthalate beads. 
     
     
         66 . A method as claimed in  claim 63  wherein said polyalkene particles comprise polyethylene or polypropylene beads. 
     
     
         67 . A method as claimed in  claim 63  wherein said polyurethane particles comprise beads of foamed or unfoamed polyurethane. 
     
     
         68 . A method as claimed in any one of  claims 63  to  67  wherein said polymeric particles comprise crosslinked or uncrosslinked polymers. 
     
     
         69 . A method as claimed in any one of  claims 41  to  68  wherein said washing treatment is carried out so as to achieve a wash water to substrate ratio of between 2.5:1 to 0.1:1 w/w. 
     
     
         70 . A method as claimed in any one of  claims 41  to  69  wherein the ratio of solid particulate cleaning material to substrate is in the range of from 0.1:1 to 10:1 w/w. 
     
     
         71 . A method as claimed in any one of  claims 41  to  70  wherein the wash cycle is performed at temperatures of between 5 and 95° C. 
     
     
         72 . A method as claimed in any one of  claims 41  to  71  wherein the wash cycle is performed for a duration of between 5 and 120 minutes. 
     
     
         73 . A method as claimed in any one of  claims 41  to  72  wherein the cycle for removal of solid particulate material is performed at room temperature. 
     
     
         74 . A method as claimed in any one of  claims 41  to  73  wherein the cycle for removal of solid particulate material is performed for cycle times of between 2 and 30 minutes. 
     
     
         75 . A method as claimed in any one of  claims 41  to  74  which additionally comprises separation and recovery of said solid particulate cleaning material and its re-use in subsequent washes. 
     
     
         76 . An apparatus as claimed in any one of  claims 1  to  40  for use in small or large scale batchwise processes. 
     
     
         77 . A method as claimed in any one of  claims 41  to  75  for use in small or large scale batchwise processes.