Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
  • D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00 
  • D06F39/007—Arrangements of water softeners
• • C—CHEMISTRY; METALLURGY
  • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F1/00—Treatment of water, waste water, or sewage
  • C02F1/44—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis
  • C02F1/441—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis by reverse osmosis
• • C—CHEMISTRY; METALLURGY
  • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F2307/00—Location of water treatment or water treatment device
  • C02F2307/12—Location of water treatment or water treatment device as part of household appliances such as dishwashers, laundry washing machines or vacuum cleaners
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06F—LAUNDERING, DRYING, IRONING, PRESSING OR FOLDING TEXTILE ARTICLES
  • D06F39/00—Details of washing machines not specific to a single type of machines covered by groups D06F9/00 - D06F27/00 
  • D06F39/02—Devices for adding soap or other washing agents

Definitions

• the disclosure relates to cleaning machine systems and processes.
• a traditional washing machine cycle for a typical 100 pound industrial washing machine may include a wash or "suds" cycle using hot water (e.g., 40 gallons at 140° F), a bleach cycle using hot water (e.g., 20 gallons at 140° F), one or more rinse cycles using warm/cold water (e.g., 40 gallons each at 100° F), a sour/soft cycle using warm/cold water (e.g., 20 gallons at 100° F), and an extraction cycle in which excess water is removed from the textiles.
• a typical 100 pound industrial laundry machine may use up to 200 gallons / CWT
• Automated cleaning product dispenser(s) may be set up to automatically deliver cleaning products, such as detergent, bleach, rinse agent, etc., to one or more of the washing machines.
• a dispenser may be programmed to run a given "formula" for a particular type of item being washed.
• the formula for sheets may be different than the formula for towels, which may again be different than the formula for other types of linens or textiles.
• the formula may include specified amounts of one or more cleaning products, along with specified times during the washing machine cycle at which the specified amount of each chemical product is to be dispensed.
• the formula(s) may be customized for a particular location based on water hardness, pH, alkalinity, total dissolved solids, or other factor that might impact the effectiveness of the cleaning products.
• the levels of detergent, bleach, or rinse agent may be modified, and/or various water conditioning agents such as water softeners, pH neutralizers, laundry sours, etc. may be employed to counteract any inherent qualities of the water supply that may reduce the effectiveness of the cleaning products and result in stiff or dull colored linens.
• various water conditioning agents such as water softeners, pH neutralizers, laundry sours, etc. may be employed to counteract any inherent qualities of the water supply that may reduce the effectiveness of the cleaning products and result in stiff or dull colored linens.
• the disclosure is directed to laundry systems and methods using ingredient water having a defined specification.
• the disclosure is directed to a system comprising an ingredient water generator connected to receive water from a water supply, the ingredient water generator configured to treat the supply water and to output ingredient water meeting a defined specification, and a wash machine having a cavity into which articles are placed for cleaning, and configured to receive the ingredient water into the cavity at specified times during a wash cycle, the defined ingredient water specification including at least one of a Total Dissolved Solids specification and a Hardness Ion specification.
• the disclosure is directed to a system comprising an ingredient water generator connected to receive water from a water supply, the ingredient water generator configured to treat the supply water and to output ingredient water meeting a defined specification, a holding tank that receives and stores the ingredient water for subsequent delivery to the wash machine, a holding tank sensor positioned to sense whether the amount of ingredient water in the holding tank is below a threshold level, an ingredient water generator controller configured to manage generation of ingredient water based on information received from the holding tank sensor, a wash machine having a cavity into which articles are placed for cleaning, and a wash machine controller configured to manage delivery of ingredient water from the holding tank into the cavity at one or more specified times during a wash cycle, the defined ingredient water specification including at least one of a Total Dissolved Solids specification and a Hardness Ion specification.
• FIG. 1 is a block diagram illustrating an example laundry system that employs ingredient water having a defined specification in the wash process.
• FIG. 2 is a block diagram illustrating the electronic components of an example laundry system that employs ingredient water having a defined
• FIG. 3 is a graph showing example test data of soil removal for multiple staining agents for ingredient water and standard city water.
• FIG. 4 is a graph howing example test data of soil removal for multiple staining agents using water having 17 grain hardness, 5 grain hardness, soft water, and ingredient water.
• FIG. 5 is a graph showing example test data of soil removal versus temperature for multiple staining agents using water having 5 gpg hardness and ingredient water.
• FIG. 6 is a graph showing example test data of soil removal versus time for multiple staining agents using water having 5 gpg hardness and ingredient water.
• FIG. 7 is a graph showing example test data of soil removal versus detergent dose for multiple staining agents using water having 5 gpg hardness and ingredient water.
• FIG. 8 is a graph showing example test data of soil removal versus alkalinity level with blood as the staining agent using water having 5 gpg hardness and ingredient water.
• FIG. 9 is chart illustrating an example wash process that uses ingredient water having a defined specification.
• the disclosure is directed to systems and methods using ingredient water having a defined specification in cleaning machine applications.
• the cleaning application may include, for example, a laundry or dish washing application.
• the ingredient water specification may include, for example, a maximum total dissolved solids (TDS) and/or a maximum TDS from water hardness ions.
• TDS total dissolved solids
• Use of ingredient water having a defined specification may allow for more effective cleaning using less water and at lower water temperatures.
• Use of ingredient water may also allow for improved detergency at lower wash temperatures, which may further result in the potential for shorter wash cycles and less chemistry to achieve equivalent results.
• FIG. 1 is a block diagram illustrating an example cleaning system 100 that employs ingredient water having a defined specification in the wash process.
• cleaning system 100 is a laundry application. It shall be understood, however, that the present disclosure is not limited to laundry applications.
• Example laundry system 100 includes a laundry machine 102 and an ingredient water generator 106.
• Laundry machine 102 may be, for example, a commercial or industrial laundry machine having a capacity of, for example, anywhere between 20 - 900 pounds (these are example values only, and the disclosure is not limited in this respect).
• the machine may also be a tunnel-type commercial or industrial laundry machine. Smaller capacity or consumer-type laundry machines may also be used.
• Laundry machine 102 includes a door 103 through which textiles to be cleaned may be loaded into a drum/cavity 105 of machine 102.
• ingredient water generator 106 receives raw source water from a water supply 104 and outputs ingredient water meeting a defined
• a holding tank 112 may store ingredient water 114 produced by ingredient water generator 106 for later delivery to one or more laundry machines 102.
• ingredient water 114 may be generated on-demand and supplied directly from ingredient water generator 106 to one or more laundry machines 102, and it shall be understood that the disclosure is not limited in this respect.
• system 100 may not necessarily include a holding tank 112, and the ingredient water may be supplied directly from ingredient water generator 106 to laundry machine 102, or some combination of stored and on-demand ingredient water may also be used.
• the ingredient water may be supplied via a mixing valve.
• Supplying ingredient water directly to the machine from the ingredient water generator may provide one or more advantages. For example, this may help the system to provide a higher output in a smaller package. In addition, this may help to provide the ingredient water at the proper utilization temperature so that no post heating is necessary. In addition, it may help to reduce size of pumps and related equipment, resulting in a reduced footprint and reduced electrical energy costs.
• system 100 shown in FIG. 1 includes a single laundry machine 102, a single ingredient water generator 106, and a single holding tank 112
• system 100 may include one or more laundry machines 102, one or more ingredient water generators 106, and/or one or more holding tanks 112, and it shall be understood that the disclosure is not limited in this respect.
• water source 104 provides the source water supply for ingredient water generator 106.
• Water source 104 may deliver water from a local water supply, whether provided by a municipality's public water system, a private well, a dedicated water supply, or other water supply.
• a mixing valve 105 receives raw hot and raw cold water source 104 before it enters the ingredient water generator 106.
• Mixing valve 105 mixes the raw hot and raw cold water to reach a predetermined temperature (or within a predetermined temperature range).
• the predetermined temperature may be chosen such that the efficiency of ingredient water generator 106 may be increased, and that the pressure required to push the source water through the ingredient water membrane(s) goes down. This may result in reduced cost of equipment.
• the ingredient water once the ingredient water is passed through the membrane, it may be not require further heating for those applications where the ingredient water is sent directly to the end use application.
• the raw source water After passing through mixing valve 105, the raw source water enters the ingredient water generator 106, which produces ingredient water 114 by treating the source water to reduce a variety of contaminants found in the water supply to meet a defined specification.
• a drain line 108 is provided for flushing of the contaminants from ingredient water generator 106.
• the ingredient water flows from ingredient water generator 106 through an ingredient water supply line 110 into holding tank 112.
• ingredient water 114 may be drawn by a pump 116 from holding tank 112 and supplied to laundry machine 102 at the appropriate times during the wash machine cycle.
• Laundry machine 102 includes a drain line through which waste water may be delivered from laundry machine 102.
• System 100 may further include an automated chemical product dispenser 120.
• Dispenser 120 may automatically dispense appropriate amounts of various laundry chemicals (indicated generally in this example by reference numerals 122A- 122C) such as detergents, bleaches, fabric softeners, de-stainers, alkalinity agents, sour/soft agents, neutralizing agents, wetting agents, etc., at appropriate times during the wash machine cycle.
• laundry chemicals indicated generally in this example by reference numerals 122A- 122C
• Such automated chemical product dispensers 120 typically include a controller that interfaces with the laundry machine controller to provide metered amounts of the appropriate chemical products at specified times during the wash machine cycle.
• the dispensers may be programmed with a plurality of "formulas" each of which may correspond to different type of linen being laundered (e.g., sheets, towels, hospital linens, restaurant linens, etc.) and/or to different types of cycles provided by the laundry machine (e.g., light, medium, heavy, etc.).
• different type of linen being laundered e.g., sheets, towels, hospital linens, restaurant linens, etc.
• cycles provided by the laundry machine e.g., light, medium, heavy, etc.
• Ingredient water 114 may also be provided to automated chemical product dispenser 120 for use during dispensation of the chemical products.
• System 100 may include a pump 115 and ingredient water delivery line 128 for this purpose.
• Ingredient water may alternatively or in addition to be provided to the dispenser directly from ingredient water generator 106, if desired.
• Dispensing using ingredient water may be employed for, as an example, those chemical products that are manufactured and sold as solid blocks of chemical product concentrate.
• the chemical product may be dispensed by spraying or otherwise applying a diluent to the solid block of chemical concentrate. Application of the diluent erodes and/or dissolves a certain amount of the chemical product.
• the resulting use solution including the applied diluent and the eroded/dissolved amount of chemical product is then dispensed into the wash tub of the laundry machine 102 via line 124 at the appropriate time during the wash machine cycle.
• the amount of chemical product dispensed in this manner may depend upon a variety of factors such as the temperature of the diluent, the water pressure at which the diluent is applied, the amount of time the diluent is applied, the chemical and/or physical properties of the solid product concentrate, etc.
• Providing ingredient water to a chemical product dispenser may help to reduce service problems and damage due to scale buildup or corrosion on chemical dispensers and input valves and ports on wash machines.
• Ingredient water generator 106 may take any one of several forms.
• ingredient water generator 106 may implemented using a reverse osmosis (RO) system.
• RO reverse osmosis
• a typical RO system includes a semipermeable membrane designed to permit passage of water (the solvent) and prevent passage of certain contaminants (the solutes). Pressure is applied to the incoming side of the membrane. The pressure may be supplied by the incoming water pressure and/or may be further adjusted using a pressure pump or other mechanism for increasing the incoming pressure. The contaminants are retained on the incoming side of the membrane and the purified water is allowed to pass through to the output side of the membrane. The contaminants may be flushed down a drain or otherwise disposed of.
• the contaminated water may be used as a prewash to remove bulk solids soils before actual wash cycle, may be reclaimed and treated for future use.
• the heat from the contaminated water may be reclaimed heat for reducing energy costs on reuse water or infeed streams.
• the resulting ingredient water may then be stored in some type of storage container, such as tank 112 or provided directly to the end use application.
• a typical RO generator may include one or more pre-filters, the RO membrane, and one or more post filters.
• the pre-filters remove particles such as sand, dirt, rust, and other sediment.
• the pre-filters may also include filters to remove chlorine, which may damage certain types of RO membranes.
• the RO membrane itself may include, for example, a TFC/TFM (thin film
• One or more post- filter ⁇ may be included to capture other chemicals not removed by the RO membrane.
• Ingredient water generator 106 may further include an automatic shut-off valve.
• the automatic shut-off valve may stop any further supply water from entering ingredient water generator 106 and stop production of further ingredient water. Conversely, the shut- off valve may open when ingredient water 114 is drawn from the holding tank 112, allowing additional supply water to flow through ingredient water generator 106 and additional ingredient water to be produced.
• Ingredient water generator may also include a check valve that prevents the backward flow of ingredient water from holding tank 112 into ingredient water generator 106.
• Ingredient water generator 106 may also include a flow control device that maintains a flow rate required to obtain the ingredient water having the defined specifications.
• ingredient water generator 106 may also include a pressure pump to increase the pressure to the RO membrane. This may help to increase the performance and production efficiency of the RO system, and/or to provide an optimum operating pressure to the RO membrane.
• ingredient water generator 106 of system 100 may have a production efficiency in the range of 50-90%.
• the production rate of the ingredient water generator 106 may be at least 1.0 - 10.0 gallons/minute.
• ingredient water generator has been described with respect to an RO system, those of skill in the art will readily understand that any system capable of producing ingredient water meeting the predefined specifications may be substituted for the RO system described herein, and that the disclosure is not limited in this respect.
• mixed resin bed deionizers, distillation, or electrolytic deionization, or other technologies may also be used.
• ingredient water generator 106 may produce ingredient water meeting one or more of the following example ingredient water specifications:
• the ingredient water must include between 0-400 parts per million (ppm) total dissolved solids with not more than 60 ppm solids contribution coming from water hardness ions such as, but not limited to, calcium and magnesium.
• the ingredient water must include between 0-200 parts per million (ppm) total dissolved solids with not more than 20 ppm solids contribution coming from water hardness ions.
• the ingredient water must include between 0-100 parts per million (ppm) total dissolved solids with not more than 10 ppm solids contribution coming from water hardness ions.
• ppm parts per million
• other ingredient water specifications may also be defined, that the above ingredient water specification are for example purposes only, and that the disclosure is not limited in this respect.
• FIG. 2 is a block diagram illustrating the electronic components 200 of an example laundry system that employs ingredient water having a defined
• a laundry machine controller governs operation of laundry machine 102, including how long each part of a laundry cycle lasts, the temperature and amount of water to be used during each part of the laundry cycle, the speed of the motor, and other facets of a laundry machine cycle.
• Laundry machine controller 206 may communicate with ingredient water controller 202, an ingredient water pump 212, and a dispenser controller 208.
• Ingredient water controller 202 governs operation of ingredient water generator 106.
• Ingredient water generator controller 202 may communicate with a level sensor 204 associated with a holding tank, such as holding tank 112 in FIG. 1.
• Level sensor 204 may indicate when the amount of ingredient water stored in holding tank is below a predefined level. When the predefined level is reached, ingredient water generator controller 202 may cause additional ingredient water to be generated until a desired level is reached.
• Laundry machine controller 206 may communicate with ingredient water pump 212 to cause appropriate amounts of ingredient water to be drawn from a holding tank into the laundry machine at various times during the laundry machine cycle. If the ingredient water for the laundry machine is being generated on demand, laundry machine controller 206 may communicate with ingredient water generator controller to cause appropriate amounts of ingredient water to be delivered from ingredient water generator to the laundry machine at various times during the laundry machine cycle. [0035] Laundry machine controller 206 may further communicate with dispenser controller 208 to cause specified amounts of one or more chemical products to be dispensed at specified times during the laundry machine cycle. Dispenser controller 208 governs operation of chemical product dispensers 210 to dispense the chemical into the laundry machine.
• Dispenser controller may communicate with an ingredient water pump 214 so that one or more of chemical product dispensers 210 may use the ingredient water during dispensation of the associated chemical product. If the ingredient water for the chemical product dispenser is being generated on demand, dispenser controller 208 may communicate with ingredient water generator controller 206to cause appropriate amounts of ingredient water to be delivered directly from ingredient water generator to one or more chemical product dispensers 210 at the appropriate times during the laundry machine cycle.
• FIG. 3 is a graph 302 showing example test data of soil removal for multiple staining agents for ingredient water (in this example, RO water having
• TDS approximately 10 TDS
• solids e.g., other suspended or dissolved materials in solution that are not typical hardness ions.
• the tests were performed in the field using equivalent product dose, wash formula, speed of agitation and water temperature.
• the tests were performed using several staining agents including coffee, curry, body soils, olive oil, lipstick, makeup and tea.
• the example data shows enhanced soil removal for each type of staining agent when using ingredient water as compared to the standard city water.
• FIG. 4 is a graph 304 showing example test data of soil removal for multiple staining agents using water having 17 grain hardness, 5 grain hardness, soft water (insert measurement here) and ingredient water (in this example, RO water having approximately 10 TDS).
• the tests were performed with a tergotometer using equivalent product dose, wash formula, speed of agitation, and water temperature.
• the tests were performed using several staining agents including dust sebum, lipstick, makeup, olive oil (cotton fabric) and olive oil (poly cotton fabric).
• the example data shows increased detergency for each type of staining agent when using ingredient water as compared to any of the other types of water.
• 5 is a graph 306 showing example test data of soil removal versus temperature for multiple staining agents using water having 5 gpg hardness and ingredient water (in this example, RO water having approximately 10 TDS).
• the tests were performed with a tergotometer using equivalent product dose, wash formula, speed of agitation. Each test were performed at water temperatures of 70° F, 80° F, 100° F, and 120° F.
• the tests were performed using several staining agents including dust sebum, lipstick, makeup, olive oil (cotton fabric) and olive oil (poly/cotton fabric).
• the example data shows increased soil removal for each type of staining agent at each temperature when using ingredient water as compared to the 5 gpg hardness water.
• FIG. 6 is a graph 308 showing example test data of soil removal versus time for multiple staining agents using water having 5 gpg hardness and ingredient water (in this example, RO water having approximately 10 TDS).
• the tests were performed with a tergotometer using equivalent product dose, wash formula, speed of agitation, and water temperature. Each test were performed at wash times of 4 minutes, 6 minutes, 8 minutes, 10 minutes, 15 minutes, and 20 minutes. The tests were performed using several staining agents including dust sebum, lipstick, makeup, olive oil (cotton) and olive oil (poly/cotton).
• the example data shows increased soil removal for each type of staining agent for each wash time when using ingredient water as compared to the 5 gpg hardness water.
• FIG. 7 is a graph 310 showing example test data of soil removal versus detergent dose for multiple staining agents using water having 5 gpg hardness and ingredient water (in this example, RO water having approximately 10 TDS).
• the tests were performed with a tergotometer using equivalent wash formula, speed of agitation, and water temperature. Each test were performed with detergent doses of 25%, 40%, 60 % and 100% of the total formula dose.
• the tests were performed using several staining agents including BMI (blood, milk, ink), dust sebum, lipstick, makeup, olive oil (cotton), olive oil (poly/cotton) and tea.
• BMI blood, milk, ink
• dust sebum dust sebum
• lipstick makeup
• olive oil cotton
• olive oil poly/cotton
• FIG. 8 is a graph 312 showing example test data of soil removal versus alkalinity level with blood as the staining agent using water having 5 gpg hardness and ingredient water (in this example, RO water having approximately 10 TDS).
• the tests were performed with a tergotometer using equivalent product dose, wash formula, speed of agitation and water temperature. Each test was performed at 93 ppm sodium oxide (Na 2 0), 186 ppm sodium oxide, and 279 ppm sodium oxide. The tests were performed using two different chemistries to obtain the desired alkalinity levels; soda ash (sodium carbonate, Na 2 C0 3 ) and sodium hydroxide ("caustic," NaOH). The example data shows increased soil removal for each alkalinity level when using ingredient water as compared to the 5 gpg hardness water.
• FIGS. 3-8 illustrate, for example, improved soil removal in all tests of ingredient water as compared to water having 5 ppg hardness. This is surprising as 5 ppg hardness water is often considered to be "good" water for laundry purposes.
• FIG. 9 is chart illustrating an example wash process 350 that uses ingredient water having a defined specification.
• Example wash process 350 for a typical 100 pound industrial washing machine may include a wash or "suds" cycle 352 using warm/cold water (e.g., 40 gallons at 100° F).
• the water temperature may be accomplished, for example, by mixing an appropriate volume of cold water (e.g., 65-85° F) water with an appropriate amount of hot water (e.g., 120-140° F).
• cycle 352 the appropriate volume of ingredient water is delivered to laundry machine 102.
• an appropriate amount of detergent and/or other laundry chemicals may also be dispensed into laundry machine 102.
• the laundry tub is drained and wash cycle proceeds to a bleach cycle 354.
• Example bleach cycle 354 may use warm/cold water (e.g., 20 gallons at 100° F).
• An intermediate extraction cycle 356 removes excess water, along with any laundry chemicals and removed soils, from the textiles via spinning or other extraction method.
• a rinse/finish cycle 358 may use warm/cold water (e.g., 52 gallons at 100° F).
• the appropriate volume of ingredient water is delivered to laundry machine 102 and an appropriate amount of laundry chemicals relevant to each cycle may also be dispensed into laundry machine 102.
• a final extraction cycle 360 may remove excess water from the textiles before the end of the wash machine cycle to speed drying.
• one laundry machine cycle uses approximately 112 gallons / CWT (hundredweight), approximately 56 gallons of which is hot (e.g., 120-140° F) water and approximately 56 gallons of which is cold (e.g., 65-85° F) water.
• CWT high-140° F
• cold e.g., 65-85° F
• the cycles may be performed in a different order, one or more cycles may be removed, or one or more additional cycles may be added, and the disclosure is not limited in this respect.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Detergent Compositions (AREA)
• Separation Using Semi-Permeable Membranes (AREA)
• Detail Structures Of Washing Machines And Dryers (AREA)

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• 2012
  • 2012-08-22 US US13/591,411 patent/US20140053611A1/en not_active Abandoned
• 2013
  • 2013-08-21 JP JP2015528621A patent/JP2015529517A/ja active Pending
  • 2013-08-21 CA CA2881196A patent/CA2881196A1/fr not_active Abandoned
  • 2013-08-21 EP EP13831067.7A patent/EP2888396A4/fr not_active Withdrawn
  • 2013-08-21 CN CN201380043675.8A patent/CN104937158A/zh active Pending
  • 2013-08-21 AU AU2013305818A patent/AU2013305818B2/en active Active
  • 2013-08-21 BR BR112015003664-3A patent/BR112015003664B1/pt active IP Right Grant
  • 2013-08-21 WO PCT/US2013/055996 patent/WO2014031753A1/fr not_active Ceased

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