Dissolvable textile package enclosing wash enabled self-unfolding textiles and corresponding methods

A kit includes a plurality of textile items arranged in a stack and a dissolvable package enclosing the plurality of textile items. The textile items can be washcloths, bath blankets, flat sheets, or other types of textile items. For larger textile items, a wash enabled self-unfolding fold can be applied to each textile item so that it automatically unfolds into wash water when the dissolvable package dissolves.

BACKGROUND

Technical Field

This disclosure relates generally to textiles, and more particularly to textiles bound in packaging.

Background Art

Textile products, examples of which include sheets, blankets, towels, and washcloths, when sold for commercial and institutional uses, are generally shipped to the industrial or commercial customer in a packaged configuration. Illustrating by example, these textiles may be folded, placed into plastic bags, and then stacked in cardboard boxes.

Industrial laundries are frequently required to launder all newly purchased textiles prior to use or shipment to others. Indeed, many healthcare facilities and industrial operations use industrial laundries to launder such textiles. Unpackaging these plastic wrapped, stacked, cardboard enclosed textiles is a time consuming and cumbersome process, as each sheet, blanket, towel, or washcloth must be manipulated by hand to be washed. This is true regardless of whether the textiles are washed in full or half batches. It would be advantageous to have improved products and processes that reduce the time and effort required to launder new textiles.

DETAILED DESCRIPTION OF THE DRAWINGS

Before describing in detail embodiments that are in accordance with the present disclosure, it should be observed that the embodiments reside primarily in combinations of method steps and apparatus components related to folding textiles so that they will self-unfold when laundered and packaging those folded textiles in a dissolvable packaging to form a kit so that the textiles can be laundered simply by placing the kit in the laundry. Alternate implementations are included, and it will be clear that functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved.

Accordingly, the apparatus components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, it is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of performing such method steps for making and using kits, packaged kits, and textile items in accordance with embodiments of the disclosure, in any order, with minimal experimentation.

Embodiments of the disclosure are now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise: the meaning of “a,” “an,” and “the” includes plural reference, the meaning of “in” includes “in” and “on.” Relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.

The terms “substantially,” “essentially,” “approximately,” “about,” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within ten percent, in another embodiment within five percent, in another embodiment within one percent and in another embodiment within one-half percent. Also, reference designators shown herein in parenthesis indicate components shown in a figure other than the one in discussion. For example, talking about a device (10) while discussing figure A would refer to an element,10, shown in figure other than figure A.

In prior art textile packaging, a textile product is typically folded in half, and perhaps half again, placed into a polyethylene bag for protection, and stacked in corrugated boxes. Since most all industrial laundries are required to launder the textiles prior to shipment to customers, a technician is required to open the boxes, remove the polyethylene bagged textiles, open the polyethylene bag, remove each textile item one by one, shake each textile item out to unfold the folds, and then loosely place the textile item in a bin (sometimes on a one-off basis) so they can be loaded into a washing machine. With prior art systems, this is the only technique available to effectively wash each textile item.

As one can imagine, this process is incredibly tedious, time consuming, cumbersome, and expensive. Moreover, it is stressful on the technician as numerous reaching, shaking, opening, lifting, and placing operations are required just to get the textile items “in the laundry.”

What's more, the process generates enormous amounts of waste. This waste accumulates as countless plastic bags are discarded when the textiles stored therein are removed. These countless single-use plastic bags ultimately get sent to the landfill once the process is completed. Studies have shown that it can take one thousand years or more for a plastic bag to degrade in a landfill. Moreover, many plastics ultimately do not completely degrade in nature. To the contrary, they frequently photodegrade into microplastics that absorb toxins and contribute to environmental pollution.

Embodiments of the disclosure provide a solution to these, and other problems associated with prior art textile products. In one or more embodiments, a method packages textile items with a unique folding method that self-releases and “self-unfolds” when being laundered. After this special “wash enabled self-unfolding” folding technique is applied to the textile items, they are placed into a dissolvable package. That the wash enabled self-unfolding textiles are placed in a dissolvable package dramatically reduces the time, effort, labor, and stress of laundering textiles due to the fact that there is no longer either a requirement to unpack or to shake out textile items. Additionally, there is no longer a need to handle textile items one by one. Instead, an entire kit comprising a dissolvable package and one or more wash enabled self-unfolding textile items can simply be placed into a laundry machine as a whole. When washed, the dissolvable package dissolves, and the wash enabled self-unfolding textile items self-unfold.

In one or more embodiments, the wash enabled self-unfolding folding method allows each textile item to “open up” in the wash to be effectively cleaned and sanitized. In effect, the wash enabled self-unfolding folding technique allows for bypassing the unfolding or “shake out” step of the prior art laundering process. Stacking the wash enabled self-unfolding textile items in the dissolvable package allows for easy management of the kits during laundering and transport. In one or more embodiments, the dissolvable packages are designed to dissolve at initial water temperatures when entering the washing machines.

In one or more embodiments, a kit includes a plurality of textile items arranged in a stack and a dissolvable package enclosing the plurality of textile items. While the textile items can take any of a number of forms, for illustrative purposes washcloths, bath blankets, and flat sheets will be discussed as explanatory examples. However, many other examples of textiles will be obvious to those of ordinary skill in the art having the benefit of this disclosure. For larger textile items, a wash enabled self-unfolding fold can be applied to each textile item so that it automatically unfolds into wash water when the dissolvable package dissolves. The kits can be arranged in a kit arrangement that is packaged as a bale.

In one or more embodiments, textile items are either stacked or folded with a wash enabled self-unfolding fold and then stacked in a dissolvable package. Illustrating by example, for smaller textile items, such as washcloths, these textile items can simply be stacked within a dissolvable package. For larger items, such as towels or “bath blankets” or sheets, a wash enabled self-unfolding fold can be applied to the textile items before stacking in the dissolvable package.

The dissolvable package can then be sealed around the textile items. In one or more embodiments, the dissolvable package is adhesively sealed around the textile items, although other sealing methods will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

When sealed, the dissolvable package enclosing the textile items, with or without the wash enabled self-unfolding folds, forms a “kit.” The kit can then be arranged into a kit arrangement, which is packaged to form a “bale” or packaged kit arrangement. When received by the laundry, the bale is simply opened, and the kits are placed into the washing machine. The dissolvable package dissolves quickly and the agitation of the washing machine causes the wash enabled self-unfolding folds to unfold.

Each textile item is then cleaned, and laundered, all without the need of any of the removal of polyethylene bagged textiles, opening of the polyethylene bags, removal of each textile item one by one, shaking each textile item out to unfold the folds, and loose placement of the textile items in a bin (sometimes on a one-off basis) for loading in a washing machine that is required by the prior art. Advantageously, embodiments of the disclosure save time, labor, wear on workers, and cost. They additionally reduce the amount of waste associated with receiving new textile items. Other advantages will be described below. Still others will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

The above summary of the embodiments of the disclosure is not intended to represent each embodiment or every aspect of the various embodiments. The detailed description and figures will describe many of the embodiments and aspects of the disclosure in further detail.

Turning now toFIG.1, illustrated therein is one explanatory textile item in accordance with one or more embodiments of the disclosure. The textile item ofFIG.1is shown illustratively as a washcloth100. However, embodiments of the disclosure are not so limited. As will be described in later figures, other examples of textile items configured in accordance with embodiments of the disclosure include bath blankets and flat sheets. Still other textile items will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

As shown, the washcloth100defines a two-sided sheet of textile material115. The two-sided sheet of textile material115can be manufactured from a textile material115that is woven or knit. The textile material115can further be manufactured with natural stretch capabilities. Said differently, it can be “stretchy” with the inclusion of elastic materials in the weave. In other embodiments, the textile material115can be a standard weave without stretch capabilities.

In one or more embodiments, the textile material115is woven. For example, the textile material may include a one-ply weave, a two-ply weave, and so forth. The weave can include warps and wefts. The warps are elements of the weave that run vertically in the view ofFIG.1, while the wefts run generally horizontally (which would be a bit downward and to the right inFIG.1due to the perspective view). Note that while the terms “warps” and “wefts” are used illustratively to describe the weave, those of ordinary skill in the art having the benefit of this disclosure will note that alternate terms, such as “warp threads,” or “warp yarns” can be substituted for “warps.” Similarly, “weft fill” or “weft threads” can be substituted for “wefts.” In one or more embodiments, the weave of the textile material115is a taffeta weave. A “taffeta” weave is a style of weave where the threads forming the wefts and warps intertwine alternatively to produce the checkerboard effect.

The warps and wefts can include synthetic threads, organic threads, or combinations thereof. Illustrating by example, in one embodiment the warps and wefts comprise polyester. In another embodiment, the warps and wefts comprise cotton. In another embodiment, the warps and wefts comprise wool. Of course, combinations could be used as well. For instance, in another embodiment the warps and wefts can comprise a combination of cotton and polyester.

Elastomeric materials may be interlaced with the weave to give the item a “stretchy” characteristic. Other examples of materials for the warps and wefts will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

As shown inFIG.1, the washcloth100is substantially rectangular (and optionally square) in shape and is defined by a length116and a width117. In one embodiment, the length116is about twelve inches, while the width117is also about twelve inches. It should be noted that the width117and length116can take other dimensions as well.

A border can be placed around the perimeter of the washcloth100in one or more embodiments. Illustrating by example, the border can provide reinforcement to the washcloth100, as well as maintaining a smoothness of shape for the washcloth100. In one or more embodiments, the border (where included) is a cloth border. In other embodiments, the border is manufactured from non-cloth reinforcing materials.

Additionally, stitching101or other textile manufacturing processes can be applied to provide an ornamental appearance to the washcloth100in one or more embodiments. In the illustrative embodiment ofFIG.1, the stitching101creates one or more cross bars102,103,104,105that define a central panel106surrounded by four elongated panels107,108,109,110and four corner squares111,112,113,114.

While the cross bars102,103,104,105can be used to create an ornamental appearance, they can have functional uses as well. Illustrating by example, in one or more embodiments the cross bars102,103,104,105can comprise scrubbing materials such as loofah or plastic scrubbers. In other embodiments, the cross bars102,103,104,105can comprise small soap retaining pockets or other features that make the washcloth100more useful in personal hygiene operations.

In one or more embodiments, the central panel106, four elongated panels107,108,109,110, and four corner squares111,112,113,114have a different “hand” or feel than do the cross bars102,103,104,105. For example, in one or more embodiments the cross bars102,103,104,105have a firmer hand, while the central panel106, four elongated panels107,108,109,110, and four corner squares111,112,113,114have a softer hand.

In the illustrative embodiment ofFIG.1, the washcloth100is substantially rectangular. In this illustrative embodiment, the washcloth100is actually square. Other shapes suitable for washcloths100configured in accordance with embodiments of the disclosure will be obvious to those of ordinary skill in the art having the benefit of this disclosure. For example, in other embodiments the washcloth100is ovular. Additionally, while the washcloth100ofFIG.1is a continuous sheet, in other embodiments the washcloth100will define one or more apertures that allow a user to more securely hold the washcloth100in their hand.

Turning now toFIG.2, illustrated therein is the explanatory washcloth100ofFIG.1being placed into dissolvable package200configured in accordance with embodiments of the disclosure. Said differently,FIG.2depicts the dissolvable package200receiving multiple washcloths, each configured in the form of the washcloth100ofFIG.1.

In one or more embodiments, the dissolvable package200is manufactured from a film layer that dissolves when it contacts water. A variety of materials can be used to construct the dissolvable package200in accordance with embodiments of the disclosure. Illustrating by example, the dissolvable package200can be manufactured from a film that includes one or more of polypropylene, polyvinyl alcohol, glycerin, and/or starch.

Illustrating by example, in one or more embodiments the dissolvable package200is manufactured from a film of polyvinyl alcohol. Since polyvinyl alcohol is soluble in water, in one or more embodiments when the film defining the dissolvable package200is manufactured from polyvinyl alcohol the water will break down and dissolve the film of polyvinyl alcohol defining the sidewalls of the dissolvable package200, thereby releasing the washcloths100situated therein. When this water is within the confines of a laundering machine, this dissolution of the sidewalls of the dissolvable package200allows the washcloths100to enter the wash water for proper laundering.

The film defining the dissolvable package200can be manufactured from other dissolvable materials as well. Illustrating by example, in another embodiment the film is manufactured from polyvinylpyrrolidone. In another embodiment, the dissolvable package200is manufactured from a film of polyethylene glycol and carboxymethyl cellulose. In still other embodiments, the dissolvable package200is manufactured from polylactic-co-glycolic acid. Other examples of dissolvable materials suitable for manufacturing the dissolvable package200will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

In one or more embodiments, the film defining the sidewalls of the dissolvable package200has a minimum thickness to prevent incidental contact with moisture from destroying the dissolvable package200and releasing the washcloths100. In one or more embodiments, so as to have a texture like thick plastic, the sidewalls of the dissolvable package200are at least 0.1 millimeters in thickness to ensure that the washcloths100are retained within the dissolvable package200until the dissolvable package200contacts the water of a laundering machine.

While the sidewalls of the dissolvable package200comprise a single film layer in the illustrative embodiment ofFIG.2, in other embodiments the sidewalls of the dissolvable package200will comprise multiple layers. Each layer of a multi-layer sidewall can be constructed from a dissolvable material, and the materials of the various layers can be manufactured from the same dissolvable material or different dissolvable materials.

In one or more embodiments, only washcloths100are placed within the dissolvable package200. However, embodiments of the disclosure contemplate that other items can be placed within the dissolvable package200along with the washcloths100to make the laundering process more efficient. Illustrating by example, in one or more embodiments a package203of fabric softener is placed within the dissolvable package200along with the washcloths100. In another embodiment, a package204of water softener is placed within the dissolvable package200along with the washcloths100. In still another embodiment, a package205of anti-static additives is placed within the dissolvable package200along with the washcloths100. In still other embodiments, anionic surfactants (pre-detergents) that repel other parts of the textile itself so that the textiles more readily unfold can be included as well, as can be cationic sufactants that work in a similar manner to repel similar charges to assist the textiles in unfolding. Of course, these packages203,204,205could be placed in the dissolvable package200in any combination as well.

In addition to these packages203,204,205, packages of other materials could be included in the dissolvable package200along with the washcloths100as well. Examples include packages of dye neutralizers, fabric expanders, antimicrobial agents, optical brighteners, de-linters, moisture wickers, absorbency enhancers, and wrinkle reducers. These packages can be dissolvable as well and can be included in any combination in the dissolvable package200.

Where included these packages203,204,205can be constructed from dissolvable films as well. Accordingly, when the dissolvable package200dissolves in the laundry, the package(s)203,204,205can dissolve as well, thereby releasing their fabric softening, water softening, and/or anti-static materials (or combinations thereof) into the wash water with the washcloths100.

Once the washcloths100are all placed within the dissolvable package200, the side edges201of the opening202defined by the sidewalls of the dissolvable package200can be closed. The opening202of the dissolvable package200can then be sealed to form a kit. Turning now toFIG.3, illustrated therein is one explanatory kit300in accordance with one or more embodiments of the disclosure.

As shown, the opening (202) has been secured closed by a seal302. In one or more embodiments, the seal302comprises an adhesive seal. In other embodiments, the opening (202) can be closed by a seal302created by sonic welding, thermal welding, or a mechanical fastener. Other examples of seals302will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

As shown in the cutaway view301, in one or more embodiments the kit300encloses a stack of washcloths100. Illustrating by example, in one or more embodiments the kit300encloses one hundred and twenty washcloths100arranged in a single stack. Other arrangements will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now toFIG.4, once each kit300is constructed, a plurality of kits can be arranged in a kit arrangement400. In this illustrative embodiment, the kit arrangement400comprises two columns401,402of five kits. Embodiments of the disclosure contemplate that governmental and other regulations may limit the number of kits that can be placed in a single package. Accordingly, the kit arrangement400ofFIG.4is intended to meet such regulations by placing twelve or fewer kits in a single package.

Once the kit arrangement400is made, it can be packaged in a “bale” in one or more embodiments. Turning now toFIG.5, illustrated therein is a partially packaged kit arrangement500that defines the precursor step to forming a bale.

As shown, an outer packaging material501has been placed about the kit arrangement400ofFIG.4. In one or more embodiments, this packaging material is a non-dissolvable material, one example of which is a thermoplastic material. However, the outer packaging material501can take other forms as well. In one or more embodiments, the outer packaging material501comprises a corrugated box. In other embodiments, the outer packaging material501comprises a reusable box. In still other embodiments, the outer packaging material501is a dissolvable film. In still other embodiments, the outer packaging material501comprises an organic, biodegradable material. Other examples of outer packaging materials501will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now toFIG.6, once the outer packaging material501has been placed around the kit arrangement400, the outer packaging material501can be sealed with a seal601to define a packaged kit arrangement or “bale”600. In one or more embodiments, the seal601comprises an adhesive seal. However, in other embodiments the seal601is formed by a mechanical fastener, ultrasonic welding, or thermal welding. In still other embodiments, the seal601can be formed by a hood closure attached to the dissolvable package. In other embodiments, the seal601can be created by compression or vacuum sealing.

In still other embodiments, there will be no seal601. Instead, the outer packaging material501can simply be wrapped around the kit arrangement400with open ends. Alternatively, the outer packaging material501can be tied with string. The string could be manufactured from a dissolvable material. In still other embodiments, the outer packaging material501itself can be tied around the kit arrangement400. In other embodiments, the outer packaging material can be tied shut with a washable product, examples of which include sheets, pillowcases, towels, and napkins. Other examples of seals601and/or how to close the outer packaging material501will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

This bale600can then be shipped to a laundry facility for laundering. The bale600solves problems associated with prior art textile item packaging systems. Specifically, the placement of washcloths (100) in a dissolvable package (200) dramatically reduces the time, effort, labor, and stress of laundering the washcloths (100). This is true because there is no requirement to either unpack the washcloths (100) from the dissolvable package (200) or to shake them out one-by-one when placing them in the laundry machine. Instead, the seal601of the outer packaging material501is simply opened. Each kit (300) can then be retrieved and simply be placed into a laundry machine as a whole. When washed, the dissolvable package (200) dissolves and the wash with the washcloths (100) then entering the wash water. Advantageously, stacking the washcloths (100) in the dissolvable package (200) allows for easy management of the kits (300) during laundering and transport. In one or more embodiments, the dissolvable package (200) is designed to dissolve at initial water temperatures when entering the washing machines.

Turning now toFIG.7, illustrated therein is one explanatory method700summarizing the steps depicted inFIGS.1-6. Beginning at step701, a plurality of textile items is obtained. In one or more embodiments, these textile items comprise washcloths. However, the textile items could take other forms as well, as will be described below with reference toFIGS.9and18.

At step702, one or more dissolvable packages are obtained. At step703, the textile items obtained at step701are placed into the dissolvable packages obtained at step702. In one or more embodiments, this placement occurring at step703comprises placing ten dozen washcloths in each dissolvable package.

At step704, the dissolvable packages are optionally sealed around the textile items so as to completely and fully enclose the textile items situated therein. (In some embodiments, the dissolvable packages may not be sealed.) In one or more embodiments, step704comprises sealing the dissolvable packages adhesively, although other sealing techniques can be used in other embodiments as noted above.

At step705, a bale bag, one example of which is the outer packaging material (501) ofFIGS.5-6above, is obtained. At step706, the kits defined by the sealed dissolvable packages with the textile items situated therein are arranged in a kit arrangement. (In some embodiments, the dissolvable packages may not be sealed.) Where the textile items comprise square washcloths having side edge lengths of twelve inches, with those square washcloths stacked in stacks of ten dozen in each kit, step706can comprise constructing a kit arrangement having two columns of five kits, for a total of ten kits in the kit arrangement.

At step707, the bale bag is sealed. In one or more embodiments, step707comprises sealing the bale bag adhesively, although other sealing techniques can be used in other embodiments as noted above. Step708can comprise packaging and labeling the resulting bale. Step709can then comprise shipping the bale to a laundry. As noted above, to launder the washcloths, the laundry technician need only open the bale bag and deposit one or more kits in the laundry machine. The kit takes care of depositing the washcloths situated therein into the wash water by dissolution, thereby eliminating waste, saving time, and reducing the amount of labor required to wash the washcloths in each kit. One hundred and twenty washcloths can be washed as a single unit rather than requiring one hundred and twenty separate retrieval, shaking, and deposit operations.

Turning now toFIG.8, illustrated therein is another method800configured in accordance with one or more embodiments of the disclosure. Beginning at step801, a plurality of textile items is obtained. While a washcloth is shown illustratively at step801, the textile items could take other forms as well. Illustrating by example, in other embodiments the textile items could be bath blankets or flat sheets.

At step802, the textile items obtained at step801are arranged in a stack. As will be described in more detail below, in some embodiments a wash enabled self-unfolding fold is applied to each textile item prior to arranging the same in a stack. The wash enabled self-unfolding fold can comprise an accordion fold followed by a book fold. At step802, a dissolvable package is sealed around the stack of textile items to form a kit.

At step803, the kit is arranged with at least one other kit to form a kit arrangement. At step803, the kit arrangement is positioned within a bale bag. At step804, the bale bag is sealed.

Turning now toFIG.9, illustrated therein is another textile item configured in accordance with one or more embodiments of the disclosure. The textile item ofFIG.9is shown illustratively as a towel or “bath blanket”900. As shown, the bath blanket900defines a two-sided sheet of textile material915. The two-sided sheet of textile material915can be manufactured from a textile material915that is woven or knit. The textile material915can further be manufactured with natural stretch capabilities. In other embodiments, the textile material915can be a standard weave without stretch capabilities.

In one or more embodiments, the textile material915is woven. For example, the textile material may include a one-ply weave, a two-ply weave, and so forth. The weave can include warps and wefts. In one or more embodiments, the weave of the textile material915is a taffeta weave.

The warps and wefts can include synthetic threads, organic threads, or combinations thereof. Illustrating by example, in one embodiment the warps and wefts comprise polyester. In another embodiment, the warps and wefts comprise cotton. In another embodiment, the warps and wefts comprise wool. Of course, combinations could be used as well. For instance, in another embodiment the warps and wefts can comprise a combination of cotton and polyester. Elastomeric materials may be interlaced with the weave to give the item a “stretchy” characteristic. Other examples of materials for the warps and wefts will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

In the illustrative embodiment ofFIG.9, the bath blanket900is substantially rectangular in shape and is defined by a length917and a width916. In one or more embodiments, the length917is about ninety inches, while the width916is about seventy inches. It should be noted that the width916and length917can take other dimensions as well.

Since the bath blanket900is quite large, it is folded before being positioned within a disposable package in one or more embodiments. In one or more embodiments, so as to unfold automatically in a washing machine once the dissolvable package dissolves, a wash enabled self-unfolding fold is applied to the bath blanket900.

In one or more embodiments, the wash enabled self-unfolding fold comprises an accordion fold. As such, explanatory embodiments of the disclosure will be directed to using variations of an accordion fold to generate a wash enabled self-unfolding fold because testing has shown that this type of fold unfolds quickly and easily in a washing machine once a disposable package situated around the textiles has dissolved.

However, it should be noted that those of ordinary skill in the art having the benefit of this disclosure will find it obvious to try other folds, or non-folds, with embodiments of the disclosure as well. Illustrating by example, as will be described below with reference toFIG.27, in other embodiments “jumble” packaging can be used where the textiles are jumbled together in a haphazard fashion and placed into a dissolvable package. In other embodiments, such as the one described below with reference toFIG.28, interlocking folds can be substituted for the accordion-based folds described with reference toFIGS.10-12and18-20.

Other types of folds that will be obvious to those of ordinary skill in the art having the benefit of this disclosure include balled up folds, twisted folds, rolled folds, and coiled folds. Embodiments of the disclosure contemplate that any technique that reduces an overall packaged size of a textile item from its original size that also self-unfolds through a traditional wash process can be used in accordance with embodiments of the disclosure. Additionally, while most disposable packaging described below is adhesively sealed, other techniques including vacuum sealing, compression prior to, or in addition to, sealing, and other tyles of sealing techniques can be used as well.

Moreover, while washcloths, bath blankets, and flat sheets will be discussed as explanatory textile examples to which an accordion-based wash enabled self-unfolding fold or other type of fold may be applied prior to placing the textiles in the disposable package, it will be obvious to those of ordinary skill in the art having the benefit of this disclosure that the techniques, kits, systems, and methods described herein can be used with other types of textiles as well. These textiles include towels, blankets, gowns, pillow cases, fitted sheets, “scrubs” and other medical apparel, and other non-medical apparel.

Turning now toFIG.10, illustrated therein is a first portion of such a wash enabled self-unfolding fold. The folding method introduced inFIG.10facilitates quick, easy, and accurate loading and laundering of the bath blanket900when a kit comprising a plurality of the bath blankets positioned within a dissolvable package is placed into a laundering machine. Moreover, the folding method introduced inFIG.10can allow a single person to put multiple bath blankets in a laundering machine with a single motion, all the while having the confidence that each bath blanket will automatically unfold while being washed.

As shown inFIG.10, to create the wash enabled self-unfolding fold an accordion fold1000is first applied to the bath blanket900. The accordion fold1000ofFIG.10is a “quad” accordion fold due to the fact that three folds1001,1002,1003have been introduced to create four panels1004,1005,1006,1007that are adjacently situated between the ends1008,1009of the bath blanket900. In one or more embodiments where the bath blanket900has dimensions of about seventy inches by about ninety inches, the length of each panel1004,1005,1006,1007is about twenty-two and a half inches.

Turning now toFIG.11, illustrated therein is the bath blanket900once the accordion fold1000has been applied to create a partially folded bath blanket1100. The wash enabled self-unfolding fold is then completed by applying a book fold1101where a first half1102of the partially folded bath blanket1100is folded about a medial line1103such that its upper surface1104abuts the upper surface1105of the second half1106of the partially folded bath blanket1100. In one or more embodiments, the first half1102of the partially folded bath blanket1100and the second half1106of the partially folded bath blanket1100each have a length measured from the ends of the partially folded bath blanket1100to the medial line1103of about thirty-five inches.

The resulting folded bath blanket1200with the wash enabled self-unfolding fold1201is shown inFIG.12. It should be noted that the wash enabled self-unfolding fold1201ofFIG.12is but one example of how a wash enabled self-unfolding fold can be configured in accordance with embodiments of the disclosure. In other embodiments, a folded bath blanket1200is formed using multiple accordion folds arranged in two different directions across the bath blanket (900). These multiple accordion folds can be trifolds, quad-folds, or other types of folds.

In still other embodiments, the wash enabled self-unfolding fold1201is created by folding multiple bath blankets (900) together, with an accordion fold or otherwise. Illustrating by example, multiple bath blankets (900) can be folded together with interlocking folds in one or more embodiments. In still other embodiments, the wash enabled self-unfolding fold1201is formed from a rolled fold. Other examples of wash enabled self-unfolding folds1201will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now toFIG.13, illustrated therein is the folded bath blanket1200ofFIG.12being placed into dissolvable package1300configured in accordance with embodiments of the disclosure. As shown inFIG.13, a plurality of folded bath blankets is being positioned within the dissolvable package1300in a stack. The dissolvable package1300ofFIG.13can be constructed in a manner similar to that described above with reference toFIG.2. In one or more embodiments, the dissolvable package1300ofFIG.13will have different dimensions than the dissolvable package (200) ofFIG.2due to the fact that the folded bath blanket1200has different dimensions than the washcloth (100) ofFIG.2.

In one or more embodiments, the dissolvable package1300is manufactured from a film layer that dissolves when it contacts water. Illustrating by example, in one or more embodiments the dissolvable package1300is manufactured from a film of polyvinyl alcohol. Since polyvinyl alcohol is soluble in water, in one or more embodiments when the film defining the dissolvable package1300is manufactured from polyvinyl alcohol the water will break down and dissolve the film of polyvinyl alcohol defining the sidewalls of the dissolvable package1300, thereby releasing the folded bath blankets1200situated therein. When this water is within the confines of a laundering machine, this dissolution of the sidewalls of the dissolvable package1300allows the folded bath blanket1200to enter the wash water for proper laundering.

The fact that each folded bath blanket1200is folded with a wash enabled self-unfolding fold1201ensures that when each folded bath blanket1200enters the wash water it will self-release and “self-unfold” while being laundered. In one or more embodiments, the wash enabled self-unfolding allows each folded bath blanket1200to “open up” in the wash to be effectively cleaned and sanitized. Advantageously, the wash enabled self-unfolding fold1201eliminates the need for a technician to unfolding and/or “shake out” each folded bath blanket1200during the laundering process.

As with the embodiment ofFIG.2, inFIG.13only folded bath blankets1200are placed within the dissolvable package1300in one or more embodiments. However, in other embodiments additional items can be placed within the dissolvable package1300along with the folded bath blankets1200to make the laundering process more efficient. Illustrating by example, in one or more embodiments a package (203) of fabric softener is placed within the dissolvable package1300along with the folded bath blankets1200. In another embodiment, a package (204) of water softener is placed within the dissolvable package1300along with the folded bath blankets1200. In still another embodiment, a package (205) of anti-static additives is placed within the dissolvable package1300along with the folded bath blankets1200. In still other embodiments, anionic surfactants (pre-detergents) that repel other parts of the textile itself so that the textiles more readily unfold can be included as well, as can be cationic sufactants that work in a similar manner to repel similar charges to assist the textiles in unfolding. Of course, these packages (203,204,205) could be placed in the dissolvable package1300in any combination as well.

In addition to these packages (203,204,205), packages of other materials could be included in the dissolvable package1300along with the folded bath blankets1200as well. Examples include packages of dye neutralizers, fabric expanders, antimicrobial agents, optical brighteners, de-linters, moisture wickers, absorbency enhancers, and wrinkle reducers. These packages can be dissolvable as well and can be included in any combination in the dissolvable package1300.

Where included these packages (203,204,205) can be constructed from dissolvable films as well. Accordingly, when the dissolvable package1300dissolves in the laundry, the package(s) (203,204,205) can dissolve as well, thereby releasing their fabric softening, water softening, and/or anti-static materials (or combinations thereof) into the wash water with the folded bath blankets1200.

Once the folded bath blankets1200are all placed within the dissolvable package1300, the side edges1301of the opening1302defined by the sidewalls of the dissolvable package1300can be closed. In one or more embodiments, the dissolvable package1300contains six folded bath blankets1200. The opening1302of the dissolvable package1300can then be sealed to form a kit. Turning now toFIG.14, illustrated therein is one explanatory kit1400in accordance with one or more embodiments of the disclosure.

As shown, the opening (1302) has been secured closed by a seal1402. In one or more embodiments, the seal1402comprises an adhesive seal. In other embodiments, the opening (202) can be closed by a seal1402created by sonic welding, thermal welding, or a mechanical fastener. Other examples of seals1402will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now toFIG.15, once each kit1400is constructed, a plurality of kits can be arranged in a kit arrangement1500. In this illustrative embodiment, the kit arrangement1500comprises four columns1501,1502,1503,1504of twelve kits, for a total of forty-eight kits. Embodiments of the disclosure contemplate that governmental and other regulations may limit the number of kits that can be placed in a single package. Accordingly, the kit arrangement1500ofFIG.15is intended to meet such regulations by placing less than fifty kits in a single package.

Once the kit arrangement1500is made, it can be packaged in a “bale” in one or more embodiments. Turning now toFIG.16, once the outer packaging material1601has been placed around the kit arrangement (1500), the outer packaging material1601can be sealed with a seal1602to define a packaged kit arrangement or “bale”1600. In one or more embodiments, the seal1602comprises an adhesive seal. However, in other embodiments the seal1602is formed by a mechanical fastener, ultrasonic welding, or thermal welding. In still other embodiments, the seal1602can be formed by a hood closure attached to the dissolvable package. In other embodiments, the seal1602can be created by compression or vacuum sealing.

In still other embodiments, there will be no seal1602. Instead, the outer packaging material1601can simply be wrapped around the kit arrangement (1500) with open ends. Alternatively, the outer packaging material1601can be tied with string. The string could be manufactured from a dissolvable material. In still other embodiments, the outer packaging material1601itself can be tied around the kit arrangement (1500). In other embodiments, the outer packaging material can be tied shut with a washable product, examples of which include sheets, pillowcases, towels, and napkins. Other examples of seals1602and/or how to close the outer packaging material1601will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

This bale1600can then be shipped to a laundry facility for laundering. The bale1600solves problems associated with prior art textile item packaging systems. Specifically, the placement of folded bath blankets (1200) that are configured with a wash enabled self-unfolding fold (1201) in a dissolvable package (1300) dramatically reduces the time, effort, labor, and stress of laundering the bath blankets (900). This is true because there is no requirement to either unpack the folded bath blanket (1200) from the dissolvable package (1300), unfold them, or to shake them out one-by-one when placing them in the laundry machine. Instead, the seal1602of the outer packaging material1601is simply opened. Each kit (1400) can then be retrieved and simply be placed into a laundry machine as a whole.

When washed, the dissolvable package (1300) dissolves and the wash with the folded bath blankets (1200) then entering the wash water. Since they are folded with a wash enabled self-unfolding fold (1201), they automatically unfold in the wash water. Said differently, once the dissolvable package (1300) dissolves, each folded bath blanket (1200) self-releases and “self-unfolds” when being laundered. That the wash enabled self-unfolding folded bath blankets (1200) are placed in a dissolvable package (1300) dramatically reduces the time, effort, labor, and stress of laundering the same due to the fact that there is no longer either a requirement to unpack or to shake out folded bath blankets (1200). Additionally, there is no longer a need to handle each folded bath blanket (1200) one by one. Instead, an entire kit (1400) can simply be placed into a laundry machine as a whole. When washed, the dissolvable package (1300) dissolves and the wash enabled self-unfolding folded bath blankets (1200) self-unfold.

In effect, the wash enabled self-unfolding fold (1201) allows each folded bath blanket (1200) to “open up” in the wash to be effectively cleaned and sanitized. The wash enabled self-unfolding folding technique allows for bypassing the unfolding or “shake out” step of the prior art laundering process. Stacking the wash enabled self-unfolding folded bath blanket (1200) in the dissolvable package (1300) also allows for easy management of the kits (1400) during laundering and transport.

Turning now toFIG.17, illustrated therein is one explanatory method1700summarizing the steps depicted inFIGS.9-16. Beginning at step1701, a plurality of textile items is obtained. In one or more embodiments, these textile items comprise bath blankets. However, the textile items could take other forms as well, as noted above and as will be described below with reference toFIG.18.

At step1702, one or more dissolvable packages are obtained. At step1703, the bath blankets obtained at step1701are folded with a wash enabled self-unfolding fold. In one or more embodiments, the wash enabled self-unfolding fold comprises an accordion fold that is first applied to the bath blanket, followed by a book fold. In one or more embodiments, the accordion fold is a “quad” accordion fold creating four panels separated by three folds. In one or more embodiments, the book fold folds a first half of a partially folded bath blanket about a medial line such that a surface of the first half abuts a surface of a second half of the partially folded bath blanket.

In other embodiments, the wash enabled self-unfolding fold applied at step1703is formed using multiple accordion folds arranged in two different directions across the bath blanket. These multiple accordion folds can be trifolds, quad-folds, or other types of folds.

In still other embodiments, the wash enabled self-unfolding fold applied at step1703is formed by folding multiple bath blankets together, with an accordion fold, an interlocking fold, or otherwise. In still other embodiments, the wash enabled self-unfolding fold formed at step1703is a rolled fold. Other examples of wash enabled self-unfolding folds suitable for application at step1703will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

At step1704, folded bath blankets are placed into the dissolvable packages obtained at step1702. In one or more embodiments, this placement occurring at step1704comprises placing six folded bath blankets in each dissolvable package.

At step1705, the dissolvable packages are sealed around the textile items so as to completely and fully enclose the textile items situated therein. In one or more embodiments, step1705comprises sealing the dissolvable packages adhesively, although other sealing techniques can be used in other embodiments as noted above.

At step1706, a bale bag is obtained. At step1707, the kits defined by the sealed dissolvable packages with the textile items situated therein are arranged in a kit arrangement. Where the textile items comprise folded bath blankets such as that shown inFIG.12, with those folded bath blankets stacked in stacks of six in each kit, step1707can comprise constructing a kit arrangement having four columns of twelve kits, for a total of forty-eight kits in the kit arrangement.

The bale bag can then be sealed at step1708. In one or more embodiments, step1708comprises sealing the bale bag adhesively, although other sealing techniques can be used in other embodiments as noted above. Step1709can comprise packaging and labeling the resulting bale. Step1709can also comprise shipping the bale to a laundry. As noted above, to launder the folded bath blankets, the laundry technician need only open the bale bag and deposit one or more kits in the laundry machine. The kit takes care of depositing the folded bath blanket situated therein into the wash water by dissolution. This also causes each folded bath blanket to automatically unfold. The use of the dissolvable package eliminates waste, saves time, and reduces the amount of labor required to wash the bath blankets in each kit. Six folded bath blankets can be washed as a single unit rather than requiring six separate retrieval, shaking, and deposit operations.

Turning now toFIG.18, illustrated therein is another textile item configured in accordance with one or more embodiments of the disclosure. The textile item ofFIG.18is shown illustratively as a flat sheet1800. As shown, the flat sheet1800defines a two-sided sheet of textile material1815. The two-sided sheet of textile material1815can be manufactured from a textile material1815that is woven or knit. The textile material1815can further be manufactured with natural stretch capabilities. In other embodiments, the textile material1815can be a standard weave without stretch capabilities.

As shown inFIG.18, the flat sheet1800is substantially rectangular in shape and is defined by a length1817and a width1816. In one embodiment, the length1817is about one hundred and twelve inches, while the width1816is about sixty-six inches. It should be noted that the width1816and length1817can change depending upon the size mattress the flat sheet1800is designed to fit. Generally speaking, the width1816will substantially equal in width to the width of a mattress that will be covered by the flat sheet1800, plus about two times the depth of the mattress. Meanwhile, length1817of the flat sheet1800may be substantially equal to the length of the selected mattress, plus about one to two times the depth of the mattress.

In one or more embodiments, the textile material1815is woven. For example, the textile material may include a one-ply weave, a two-ply weave, and so forth. The weave can include warps and wefts. In one or more embodiments, the weave of the textile material1815is a taffeta weave. The warps and wefts can include synthetic threads, organic threads, or combinations thereof. Elastomeric materials may be interlaced with the weave to give the item a “stretchy” characteristic.

Since the flat sheet1800is quite large, it is folded before being positioned within a disposable package in one or more embodiments. In one or more embodiments, so as to unfold automatically in a washing machine once the dissolvable package dissolves, a wash enabled self-unfolding fold is applied to the flat sheet1800.

As shown inFIG.18, the first portion of such a wash enabled self-unfolding comprises an accordion fold1801to the flat sheet1800. In one or more embodiments, the accordion fold1801is a “sept” accordion fold due to the fact that six folds1802,1803,1804,1805,1806,1807are introduced to define seven panels1808,1809,1810,1811,1812,1813,1814that are adjacently situated between the ends of the flat sheet1800. In one or more embodiments where the flat sheet1800has dimensions of about one hundred and twelve by about sixty-six inches, the length of each panel1808,1809,1810,1811,1812,1813,1814is about sixteen inches. This “sept” accordion fold1801is shown in more detail inFIG.19.

Turning now toFIG.20, once the accordion fold (1801) has been applied to create a partially folded flat sheet, the wash enabled self-unfolding fold of this illustrative embodiment is then completed by applying a book fold2001where a first half2002of the partially folded flat sheet ofFIG.19is folded about a medial line such that a major surface abuts a major surface of the second half2003of the partially folded flat sheet. In one or more embodiments, the first half2002of the partially folded flat sheet and the second half2003of the partially folded flat sheet each have a length measured from the ends of the partially folded flat sheet to the medial line of about thirty-three inches.

Turning now toFIG.21, illustrated therein is the resulting folded flat sheet2101being placed into dissolvable package2100configured in accordance with embodiments of the disclosure. In one or more embodiments, a plurality of folded flat sheets is being positioned within the dissolvable package2100in a stack. The dissolvable package2100ofFIG.21can be constructed in a manner similar to that described above with reference toFIG.2. In one or more embodiments, the dissolvable package2100ofFIG.21will have different dimensions than the dissolvable package (200) ofFIG.2or the dissolvable package (1300) ofFIG.13due to the fact that the folded flat sheet2101has different dimensions than the washcloth (100) ofFIG.2or the folded bath blanket (1200) ofFIG.12.

In one or more embodiments, the dissolvable package2100is manufactured from a film layer that dissolves when it contacts water. Illustrating by example, in one or more embodiments the dissolvable package2100is manufactured from a film of polyvinyl alcohol. Since polyvinyl alcohol is soluble in water, in one or more embodiments when the film defining the dissolvable package2100is manufactured from polyvinyl alcohol the water will break down and dissolve the film of polyvinyl alcohol defining the sidewalls of the dissolvable package2100, thereby releasing the folded flat sheets2101situated therein. When this water is within the confines of a laundering machine, this dissolution of the sidewalls of the dissolvable package1300allows the folded bath blanket1200to enter the wash water for proper laundering.

The fact that each folded flat sheet2101is folded with a wash enabled self-unfolding created by the method shown inFIGS.18-20, or by other methods described herein, ensures that when each folded flat sheet2101enters the wash water it will self-release and “self-unfold” while being laundered. In one or more embodiments, the wash enabled self-unfolding allows each folded flat sheet2101to “open up” in the wash to be effectively cleaned and sanitized. Advantageously, the wash enabled self-unfolding fold eliminates the need for a technician to unfolding and/or “shake out” each folded flat sheet2101during the laundering process.

As with previous embodiments, additional items can optionally be placed within the dissolvable package2100along with the folded flat sheets2101to make the laundering process more efficient. Illustrating by example, in one or more embodiments a package (203) of fabric softener is placed within the dissolvable package2100along with the folded flat sheets2101. In another embodiment, a package (204) of water softener is placed within the dissolvable package2100along with the folded flat sheets2101. In still another embodiment, a package (205) of anti-static additives is placed within the dissolvable package2100along with the folded flat sheets2101. In still other embodiments, anionic surfactants (pre-detergents) that repel other parts of the textile itself so that the textiles more readily unfold can be included as well, as can be cationic sufactants that work in a similar manner to repel similar charges to assist the textiles in unfolding. Of course, these packages (203,204,205) could be placed in the dissolvable package2100in any combination as well.

In addition to these packages (203,204,205), packages of other materials could be included in the dissolvable package2100along with the folded flat sheets2101as well. Examples include packages of dye neutralizers, fabric expanders, antimicrobial agents, optical brighteners, de-linters, moisture wickers, absorbency enhancers, and wrinkle reducers. These packages can be dissolvable as well and can be included in any combination in the dissolvable package2100.

Where included these packages (203,204,205) can be constructed from dissolvable films as well. Accordingly, when the dissolvable package2100dissolves in the laundry, the package(s) (203,204,205) can dissolve as well, thereby releasing their fabric softening, water softening, and/or anti-static materials (or combinations thereof) into the wash water with the folded flat sheets2101.

Once the folded flat sheets2101are all placed within the dissolvable package2100, the side edges of the opening defined by the sidewalls of the dissolvable package2100can be closed. In one or more embodiments, the dissolvable package2100contains twelve folded flat sheets2101. The opening of the dissolvable package2100can then be sealed to form a kit. Turning now toFIG.22, illustrated therein is one explanatory kit2200in accordance with one or more embodiments of the disclosure.

As shown, the opening has been secured closed by a seal2202. In one or more embodiments, the seal2202comprises an adhesive seal. In other embodiments, the opening can be closed by a seal2202created by sonic welding, thermal welding, or a mechanical fastener. Other examples of seals2202will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Turning now toFIG.23, once each kit2200is constructed, a plurality of kits can be arranged in a kit arrangement2300. In this illustrative embodiment, the kit arrangement1500comprises one column of five kits. Embodiments of the disclosure contemplate that governmental and other regulations may limit the number of kits that can be placed in a single package. Accordingly, the kit arrangement2300ofFIG.23is intended to meet such regulations by placing five or fewer in a single package.

Once the kit arrangement2300is made, it can be packaged in a “bale” in one or more embodiments. Turning now toFIG.24, once the outer packaging material2401has been placed around the kit arrangement (2300), the outer packaging material2401can be sealed with a seal2402to define a packaged kit arrangement or “bale”2400. In one or more embodiments, the seal1602comprises an adhesive seal. However, in other embodiments the seal2402is formed by a mechanical fastener, ultrasonic welding, or thermal welding. In still other embodiments, the seal2402can be formed by a hood closure attached to the dissolvable package. In other embodiments, the seal2402can be created by compression or vacuum sealing.

In still other embodiments, there will be no seal2402. Instead, the outer packaging material2401can simply be wrapped around the kit arrangement (2300) with open ends. Alternatively, the outer packaging material2401can be tied with string. The string could be manufactured from a dissolvable material. In still other embodiments, the outer packaging material2401itself can be tied around the kit arrangement (2300). In other embodiments, the outer packaging material can be tied shut with a washable product, examples of which include sheets, pillowcases, towels, and napkins. Other examples of seals2402and/or how to close the outer packaging material2401will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

This bale2400can then be shipped to a laundry facility for laundering. The bale2400solves problems associated with prior art textile item packaging systems. Specifically, the placement of folded flat sheets (2101) that are configured with a wash enabled self-unfolding fold in a dissolvable package (2100) dramatically reduces the time, effort, labor, and stress of laundering the flat sheets (1800). This is true because there is no requirement to either unpack the folded flat sheets (2101) from the dissolvable package (2100), unfold them, or to shake them out one-by-one when placing them in the laundry machine. Instead, the seal2402of the outer packaging material2401is simply opened. Each kit (2200) can then be retrieved and simply be placed into a laundry machine as a whole.

When washed, the dissolvable package (2100) dissolves and the wash with the folded flat sheets (2101) then entering the wash water. Since they are folded with a wash enabled self-unfolding fold, they automatically unfold in the wash water. Said differently, once the dissolvable package (2100) dissolves, each folded flat sheet (2101) self-releases and “self-unfolds” when being laundered. That the wash enabled self-unfolding folded flat sheets are placed in a dissolvable package (2100) dramatically reduces the time, effort, labor, and stress of laundering the same due to the fact that there is no longer either a requirement to unpack or to shake out folded flat sheets (2101). Additionally, there is no longer a need to handle each folded flat sheet (2101) one by one. Instead, an entire kit (2200) can simply be placed into a laundry machine as a whole. When washed, the dissolvable package (2100) dissolves and the wash enabled self-unfolding folded flat sheets (2101) self-unfold.

To this point, the explanatory wash enabled self-unfolding folds have been accordion based. While this type of wash enabled self-unfolding fold is advantageous in that it works really well, embodiments of the disclosure contemplate that disposable packaging can be used with textiles that are manipulated in other ways prior to packaging as well. Turning now toFIGS.27-28, illustrated therein are two such examples. Others will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

Beginning withFIG.27, illustrated therein is what is known as a “jumble package”2700where textiles2701,2702,2703jumbled together in a haphazard fashion and placed into a dissolvable package2704. This type of packaging is quick and simple, and is especially useful when the textiles2701,2702,2703are soiled. However, this type of packaging can be used by a textile manufacturer as well, in that placement of the textiles2701,2702,2703into the dissolvable package2704is quick and easy. In some embodiments the dissolvable package2704will be sealed when the jumble package2700is complete. By contrast, in other embodiments the dissolvable package2704will be left unsealed. In the illustrative embodiment ofFIG.27, the dissolvable package is unsealed.

Turning now toFIG.28, illustrated therein are textiles2801,2802that are arranged in an interlocking fold2800. While two textiles2801,2802are shown inFIG.28, it will be clear to those of ordinary skill in the art having the benefit of this disclosure that three, four, five or more textiles could be placed into the dissolvable package2803. Using the interlocking fold2800, portions of each textile2801,2802wrap around a portion of at least one other textile. Illustrating by example, inFIG.28two portions of textile2801wrap around one portion of textile2802, while two portions of textile2802wrap around one portion of textile2801. If a third textile were included, the two portions of textile2802would wrap around a portion of the textile2801and a portion of the third textile, and so forth. The dissolvable package2803can then be sealed or left unsealed, arranged in rows and stacks, baled, and otherwise used as described above with previous embodiments.

Turning now toFIG.25, illustrated therein is one explanatory method2500summarizing the steps depicted inFIGS.18-24. Beginning at step2501, a plurality of textile items is obtained. In one or more embodiments, these textile items comprise flat sheets. However, the textile items could take other forms as well, as noted above.

At step2502, one or more dissolvable packages are obtained. At step2503, the flat sheets obtained at step2501are folded with a wash enabled self-unfolding fold. In one or more embodiments, the wash enabled self-unfolding fold comprises an accordion fold that is first applied to the flat sheet, followed by a book fold. In one or more embodiments, the accordion fold is a “sept” accordion fold creating seven panels separated by sixe folds. In one or more embodiments, the book fold folds a first half of a partially folded flat sheet about a medial line such that a surface of the first half abuts a surface of a second half of the partially folded flat sheet.

In other embodiments, the wash enabled self-unfolding fold applied at step2503is formed using multiple accordion folds arranged in two different directions across the bath blanket. These multiple accordion folds can be trifolds, quad-folds, or other types of folds.

In still other embodiments, the wash enabled self-unfolding fold applied at step2503is formed by folding multiple bath blankets together, with an accordion fold, an interlocking fold, or otherwise. In still other embodiments, the wash enabled self-unfolding fold formed at step2503is a rolled fold. Other examples of wash enabled self-unfolding folds suitable for application at step2503will be obvious to those of ordinary skill in the art having the benefit of this disclosure.

At step2504, folded flat sheets are placed into the dissolvable packages obtained at step2502. In one or more embodiments, this placement occurring at step2504comprises placing twelve folded flat sheets in each dissolvable package.

At step2505, the dissolvable packages are sealed around the textile items so as to completely and fully enclose the textile items situated therein. In one or more embodiments, step2505comprises sealing the dissolvable packages adhesively, although other sealing techniques can be used in other embodiments as noted above.

At step2506, a bale bag is obtained. At step2507, the kits defined by the sealed dissolvable packages with the textile items situated therein are arranged in a kit arrangement. Where the textile items comprise folded flat sheets such as that shown inFIG.21, with those folded flat sheets stacked in stacks of twelve in each kit, step2507can comprise constructing a kit arrangement having one column of five kits in the kit arrangement.

The bale bag can then be sealed at step2508. In one or more embodiments, step2508comprises sealing the bale bag adhesively, although other sealing techniques can be used in other embodiments as noted above. Step1709can comprise packaging and labeling the resulting bale. Step2509can also comprise shipping the bale to a laundry. As noted above, to launder the folded flat sheets, the laundry technician need only open the bale bag and deposit one or more kits in the laundry machine. The kit takes care of depositing the folded flat sheets situated therein into the wash water by dissolution. This also causes each folded flat sheet to automatically unfold. The use of the dissolvable package eliminates waste, saves time, and reduces the amount of labor required to wash the bath blankets in each kit. Twelve folded flat sheets can be washed as a single unit rather than requiring twelve separate retrieval, shaking, and deposit operations.

Turning now toFIG.26, illustrated therein are various embodiments of the disclosure. The embodiments ofFIG.26are shown as labeled boxes inFIG.26due to the fact that the individual components of these embodiments have been illustrated in detail inFIGS.1-25, which precedeFIG.26. Accordingly, since these items have previously been illustrated and described, their repeated illustration is no longer essential for a proper understanding of these embodiments. Thus, the embodiments are shown as labeled.

At2601, a kit comprises a plurality of textile items arranged in a stack. At2601, the kit comprises a dissolvable package enclosing the plurality of textile items.

At2602, the plurality of textile items of2601is folded with a wash enabled self-unfolding fold. At2603, the wash enabled self-unfolding fold of2602comprises an accordion fold.

At2604, the accordion fold of2603comprises a quad accordion fold. At2605, the accordion fold of2603comprises a sept accordion fold.

At2606, the wash enabled self-unfolding fold of2603comprises a book fold. At2607, the accordion fold of2606is applied to each textile item of the plurality of textile items prior to the book fold.

At2608, the dissolvable package of2607is adhesively sealed about the plurality of textile items. At2609, the plurality of textile items of2608comprises a plurality of bath blankets. At2610, the plurality of textile items of2608comprises a plurality of washcloths. At2611, the plurality of textile items of2608comprises a plurality of flat sheets.

At2612, a method comprises stacking a plurality of textile items in a dissolvable package. At2612, the method comprises sealing the dissolvable package around the plurality of textile items to form a kit.

At2613, the method of2612further comprises applying a wash enabled self-unfolding fold to each textile item of the plurality of textile items prior to stacking the plurality of textile items in the dissolvable package. At2614, the applying the wash enabled self-unfolding fold of2613comprises first applying an accordion fold to the textile items to create partially folded textile items. At2614, the applying the wash enabled self-unfolding fold of2613comprises then applying a book fold to the textile items to create folded textile items.

At2615, the method of2613further comprises arranging the kit with at least one other kit to define a kit arrangement. At2616, the method of2615further comprises positioning the kit arrangement in a bale bag and sealing the bale bag. At2617, the textile items of2612are soiled.

At2618, a kit arrangement comprises a kit comprising a plurality of textile items folded with a wash enabled self-unfolding fold and arranged in a stack within a sealed dissolvable package. At2618, the kit arrangement comprises at least one other kit comprising at least one other plurality of textile items folded with at least one other wash enabled self-unfolding fold and arranged in at least one other stack within at least one sealed dissolvable package.

At2619, the at least one other kit of2618comprises four kits arranged in a single column with the kit. At2620, the kit arrangement of2619further comprises a sealed bale bag enclosing the kit arrangement.

In the foregoing specification, specific embodiments of the present disclosure have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present disclosure as set forth in the claims below. Thus, while preferred embodiments of the disclosure have been illustrated and described, it is clear that the disclosure is not so limited. Numerous modifications, changes, variations, substitutions, and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present disclosure as defined by the following claims.