METHOD AND APPARATUS FOR DISSOLVING AND ACTIVATING A SOLUBLE CLEANSING AGENT

Abstract: A method and apparatus is provided for dissolving or dispersing a predetermined quantity of granular cleansing agent into a cleansing liquor and delivering the cleansing liquor to a cleansing application, such as a clothes washing machine. A predetermined quantity of granular cleansing agent (74) is placed in an inner container (54) upon a screen (58). Water from the container is withdrawn and recirculated such that upon reentry to the container it is directed at the screen (58) and diffused to dissolve and disperse the granular cleansing agent (74) forming a solution and diffused to prevent the undissolved but wetted cleansing agent from adhering to the inner container (54). Preferably, the diffused solution operates to substantially immediately float an island of the undissolved granular cleansing agent in the center of the inner container. Also, the cleansing liquor is preferably not delivered to the cleansing application until after substantially all of the various components within the granular cleansing agent have transformed by appropriate reaction into their "active" state.

Description: METHOD AND APPARATUS FOR DISSOLVING AND ACTIVATING A SOLUBLE CLEANSING AGENT BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to methods and apparatus for dissolving soluble cleansing agents, and more particularly, to such methods and apparatus for dissolving a discrete, predetermined amount of such soluble cleansing agents. 2. DescriDtion of the Prior Art The prior art is replete with methods and apparatus (hereinafter "Prior Art Systems") for dissolving cleansing agents for a variety of applications, including dish or clothes washing machines. A substantial percentage of these Prior Art Systems operate by directing a liquid spray at a large supply of cleansing agent (i.e., an amount sufficient for multiple application cycles) which is supported by a screen. Typically the spray dissolves only a portion of the large supply of cleansing agent resting on the screen. United States Patents which disclose various examples of such Prior Art Systems include 4,790,981 which issued to Mayre et al. on December 13, 1988; 4,462,511 which issued on July 31, 1984 to Fulmer et al.; 4,020,865 which issued on May 3, 1977 to Moffat et al.; 3,850,344 which issued on November 26, 19764 to Burge et al.; and 3,595,438 which issued to Daley et al. on July 27, 1971. One principal disadvantage to these Prior Art Systems is that each cycle generally hydrates a greater amount of cleansing agent than is actually dissolved and dispensed during that cycle. Consequently, some quantity of hydrated cleansing agent remains in the supply at the end of each cycle. This hydrated detergent dries and can become caked. Caking is a significant problem since the caked cleansing agent can be extremely tenacious; in many instances becoming virtually insoluble by the apparatus. Other Prior Art Systems utilize batch dissolution processes. In other words, these Prior Art Systems dissolve a predetermined discrete quantity of soluble cleansing agent in water to form a cleansing liquor. U.S. Patent 4,489,455 issued to Spendel on December 25, 1984 and U.S. Patent 4,555,019 issued to Spendel on November 26, 1985 disclose a Prior Art System which dissolves a discrete predetermined amount of cleansing agent to form a cleansing liquor for use in a clothes washing machine. This Prior Art System mixes a predetermined quantity of cleansing agent with water until "the detergent composition is substantially dissolved or dispersed in the water." Experience has shown that these batch Prior Art Systems also have a caking disadvantage similar to the above Prior Art Systems unless water is circulating in the mixing reservoir before the cleansing agent is added thereto. Another disadvantage to such batch Prior Art Systems is they do not necessarily "activate" today's sophisticated granular cleansing agents. Current granular cleansing agents can include various distinct components which must transform from their inactive granular form to their active form to provide the desired beneficial effects. For example, a bleaching system can include a bleach (e.g., sodium perborate monohydrate) and a bleaching activator (e.g., nonanoyloxybenzene sulfonate) which must react with each other to become active. Other components react with the water itself to become active. Thus, merely dissolving the granular cleansing agent does not ensure the liquor is active; a sufficient mixing time must elapse to permit the various reactions to occur. SUMMARY OF THE INVENTION In accordance with one aspect of the present invention a method is provided for dissolving or dispersing and completely activating a discrete predetermined amount of a granular cleansing agent having an inactive ingredient. The method utilizes an apparatus which includes an outer container which has a recirculation outlet and a recirculation inlet. An inner container is located within the outer container which has a screen wall portion. A recirculation pump is attached to a recirculation line so that solution in the containers may be removed at the recirculation outlet and returned through the recirculation inlet. The method includes the steps of providing water to the outer container. Initiating operation of the recirculation pump prior to substantial wetting of the cleansing agent housed in the inner container such that solution passes through the recirculation outlet and through the recirculation inlet back into the outer container toward the cleansing agent in the inner container. Diffusing the solution entering the outer container from the recirculation outlet such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and preventing the cleansing agent from attaching to the sides of either container. Delivering the solution to a cleansing application only after the cleansing agent has been dissolved or dispersed and substantially all of the ingredients in the cleansing agent have become active. In accordance with another aspect of the present invention a method is provided for dissolving or dispersing a discrete predetermined amount of a granular cleansing agent having an inactive ingredient. The method utilizes an apparatus which includes an outer container which has a recirculation outlet and a recirculation inlet. An inner container is located within the outer container which has a screen wall portion. A recirculation pump is attached to a recirculation line so that solution in the containers may be removed at the recirculation outlet and returned through the recirculation inlet. The method includes the steps of providing water to the outer container. Initiating operation of the recirculation pump prior to substantial wetting of the cleansing agent housed in the inner container such that solution passes through the recirculation outlet and through the recirculation inlet back into the outer container toward the cleansing agent in the inner container. Diffusing the solution entering the outer container from the recirculation outlet such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and preventing the cleansing agent from attaching to the sides of either container; and such that a space is substantially immediately provided between the screen wall portion of the inner container and the granular cleansing agent upon initiating operation of the recirculation pump. In accordance with another aspect of the present invention an apparatus is provided for dissolving and completely activating a granular cleansing agent prior to providing the cleansing liquor, i.e., cleansing agent in solution form, to a cleansing application. The apparatus includes an outer container having a continuous side wall sealed at its lowermost end to a bottom wall. The bottom wall has a centrally located recirculation inlet and a recirculation outlet therein. An inner container located within the outer container which has a screen wall portion and a predetermined quantity of cleansing agent housed therein. A recirculation pump is attached to the recirculation line such that the solution may be removed from the outer container at the recirculation outlet and returned through a recirculation line inlet. Means for initiating pumping of the solution prior to substantial wetting of the cleansing agent from the outer container through the recirculation outlet and through the recirculation inlet toward the cleansing agent in the inner container through the screen wall portion of the inner container. Means for diffusing the solution entering the outer container such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and substantially preventing the cleansing agent from attaching to the sides of either container, to form a cleansing liquor. Means for delivering the solution to the cleansing application only after the cleansing agent has been dissolved or dispersed and substantially all of the ingredients in the cleansing agent have become active. In accordance with another aspect of the present invention an apparatus is provided for dissolving and completely activating a granular cleansing agent prior to providing the cleansing liquor, i.e., cleansing agent in solution form, to a cleansing application. The apparatus includes an outer container having a continuous side wall sealed at its lowermost end to a bottom wall. The bottom wall has a centrally located recirculation inlet and a recirculation outlet therein. An inner container located within the outer container which has a screen wall portion and a predetermined quantity of cleansing agent housed therein. A recirculation pump is attached to the recirculation line such that the solution may be removed from the outer container at the recirculation outlet and returned through a recirculation line inlet. Means for initiating pumping of the solution prior to substantial wetting of the cleansing agent from the outer container through the recirculation outlet and through the recirculation inlet toward the cleansing agent in the inner container through the screen wall portion of the inner container. Means for diffusing the solution entering the outer container such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and substantially preventing the cleansing agent from attaching to the sides of either container; and such that a space is substantially immediately provided between the screen wall portion of the inner container and the granular cleansing agent upon initiating operation of the recirculation pump. BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of preferred embodiments taken in conjunction with the accompanying drawings, in which like reference numerals identify identical elements and wherein: : Figure 1 is a diagrammatic perspective view of a preferred apparatus for carrying out the present dissolving process; Figure 2 is a top plan view of the apparatus illustrated in Figure 1; Figure 3 is a cross-sectional view taken along line 3-3 of Figure 2; Figure 4 is a cross-sectional view similar to Figure 3 of a second preferred embodiment of an apparatus for carrying out the present dissolving process; Figure 5 is a cross-sectional view similar to Figure 3 of a third preferred embodiment of an apparatus for carrying out the present dissolving process; Figure 6 is a cross sectional view taken along line 3-3 of Figure 2, illustrating the water and granular cleansing agent prior to initiating operation of the recirculation pump; ; Figure 7 is a cross sectional view similar to Figure 5, illustrating the water and granular cleansing agent after initiating operation of the recirculation pump; and Figure 8 is a cross sectional view similar to Figure 5, illustrating the water and granular cleansing agent just prior to complete dissolution or dispersion of the granular cleansing agent. DESCRIPTION OF PREFERRED EMBODIMENTS 1. Preferred ADDaratus Figure 1 provides a diagrammatic illustration of a preferred apparatus (generally referred to as 20) of the present invention for dissolving a soluble cleansing agent in accordance with the method of the present invention. For convenience, the term "granular" cleansing agent is used hereinafter to refer to any form of "soluble" cleansing agent, including soluble tablets. The instant method and apparatus, however, is most preferably utilized with granular cleansing agents. The apparatus 20 of this embodiment includes an open top outer container 22 which comprises a cylindrical side wall 24 and, as seen in Figure 2, a bottom wall 26. A supply line 30 is located above the outer container 22 to provide water to the outer container 22 through the open top, thereby providing a vacuum break. A pressure regulator 32 in combination with a flow control valve 34, such a needle valve, is located in the supply line 30 to ensure a constant downstream pressure (and therefore, a constant flow rate) which enables time based control of the quantity of water supplied to the outer container 22. Referring to Figure 3, the bottom wall 26 of the outer container 22 has three openings located therein; a recirculation outlet 36, a recirculation inlet 38 and an application delivery outlet 40. The recirculation inlet 38 is located in the center of the bottom wall 26. Neither the recirculation inlet 38 nor the recirculation outlet 36 have any flow restrictions such as screens or nozzles which could provide points for clogging. The recirculation outlet 36 and the recirculation inlet 38 are placed in fluid communication with each other via a closed loop recirculation line 42. Located along the recirculation line 42, intermediate the recirculation outlet 36 and the recirculation inlet 38, is a recirculation pump 44. The recirculation pump 44 is capable of passing materials typically found in granular cleansing agents and any granular clumps which may find their way to the pump 44. The application delivery outlet 40 is attached to an application delivery line 46 which includes an application delivery pump 48. The application delivery pump 48 operates to provide the cleansing liquor to the cleansing application for use through the application delivery line 46. The application delivery outlet 40 preferably has a screen 50 covering it to prevent material from entering the application delivery line 46 which might clog any downstream restrictions, such as nozzles. Utilizing two separate pumps, i.e., a recirculation pump 44 and an application delivery pump 48, eliminates the need for valves which can tend to stick when dealing with typical granular cleansing agents. As seen in Figures 1, a funnel 52 may be attached to the outer container 22 or otherwise fixed above an inner container 54 located inside the outer container 22 to channel the detergent into the inner container 54. The inner container 54 of this embodiment has a solid cylindrical side wall 56 and a wire screen bottom wall 58. The wire screen of the bottom wall 58 is selected such that it will support the granular product placed therein while permitting the flow of solution therethrough without significantly reducing the energy in the solution. (Although the term "solution" is used herein, it is understood that initially the "solution" is pure water.) Attached to and extending radially outwardly from the cylindrical side wall 56 are three equally spaced wire screen wing walls 60. These wing walls 60 axially locate the inner container 54 centrally within the outer container 22. A diffuser 62 in the shape of an inverted conical section centrally depends from the wire screen bottom wall 58. Consequently, the apex 62a of the diffuser 62 is located exactly above the center of the recirculation inlet 38. The distance between the bottom wall 26 of the outer container 22 and the bottom wall 58 of the inner container 54 is also important. A spacer pin 64 is attached to the bottom wall 58 of the inner container 54 to assure that the inner container 54 is located the correct distance from the bottom wall 26 of the outer container 22. This distance is best determined empirically to achieve the most vigorous turbulence at the surface of the solution. Furthermore, designing an apparatus for a specific application will require a certain amount of empirical analysis to determine the best dimensions for variables, including the relative diameters of the containers, 22 and 54, the shape and size of the diffuser 62, the quantity of granular cleansing agent to be activated, and the quantity and velocity of the solution exiting the recirculation inlet 38. One exemplary apparatus for dissolving up to about one (1) cup of granular cleansing agent has the following components and dimensions. The outer container 22 is made of stainless steel and has a diameter of about four and three-quarter (4 3/4) inches and an overall height of about six (6) inches. The recirculation line 42 is made of three-eighths (3/8) inch stainless steel tubing on the upstream side of the pump 44 and one-quarter (1/4) inch stainless steel tubing on the downstream side of the pump 44. The application delivery line 46 upstream of the pump 48 is made of three-eighths (3/8) inch stainless steel tubing and downstream of the pump 48 flexible tubing such as Tygon s tubing can be used. Tygon e tubing is available from Norton Performance Products, Akron, OH. The recirculation pump 44 and the application pump 48 are centrifugal pumps such as 2E-38N pumps available from the Little Giant Pump Company, Oklahoma City, OK. The inner container 54 has about a two and one-half (2 1/2) inches inner diameter, and about a three and five-eighths (3 5/8) inches overall height. The inner container 54 bottom wall 58 is made of 316-10 mesh stainless steel wire screen. The diffuser 62 is a conical section having an 828 overall angle and a maximum conical diameter of eleven-sixteenths (11/16) inch. A good starting material for the diffuser 62 is the head of a large stainless steel flat head screw. The apex 62a of the diffuser 62 is aligned vertically above the center of the recirculation inlet 38 to within about 0.010 inch. The bottom wall 58 of the inner container 64 is located about five-eighths (5/8) inch above the bottom wall 26 of the outer container 22. Referring to Figure 4, a second preferred embodiment utilizes an inner container 154 made completely of wire screen (except for the diffuser 162). Instead of having the solid cylindrical side 56 wall of Figure 3, the cylindrical side wall 156 of this inner container 154 is made of the same wire screen as the bottom wall 158 and the wing walls 160. Otherwise, the inner container 154 of this embodiment has the same general structure as the inner container 54 discussed above. The remaining components of this apparatus 120, including the outer container 22, recirculation line 42, recirculation pump 44, application delivery line 46 and application delivery pump 48, are identical. One exemplary apparatus 120 of this second embodiment for dissolving up to about two-thirds (2/3) cup of granular cleansing agent utilizes the same general components and dimensions as those discussed above except for the inner container 154. For example, the inner container 154 has a diameter of about three (3) inches and a height of about two and one-half (2 1/2) inches. Although the diffuser 162 would be of similar shape, i.e., having an 82 overall angle, the maximum conical diameter is about seven-eighths (7/8) inch. The diffuser 162 made from is the head of a large stainless steel flat head screw. The apex 162a of the diffuser 162 is aligned vertically above the center of the recirculation inlet 38 to within about 0.010 inch. The bottom wall 158 of the inner container 154 is located a distance of about five-eighths (5/8) inch from the bottom wall 26 of the outer container 22. In the embodiment illustrated in Figure 5, the inner container 254 utilizes a portion of the side wall 224 of the outer container as its side wall 256 and, like the previous embodiments, has a wire screen as its bottom wall 258. The outer container 222 is generally the same as the outer container 222 of the previous embodiments. The upper portion of the supply line 230a has a vacuum break above the top of the outer container 222 and the lower portion of the supply line 230b extends down into the outer container 222 through the wire screen bottom wall 258 of the inner container 254 to ensure that the granular cleansing agent located therein is not wetted by the initial addition of water. The quantity of water supplied to the containers, 222 and 254 is controlled by a water level sensor 270. Such sensors 270 are well known to those skilled in the art. The recirculation line 242 and delivery line 246 utilize a valve 272 and only one pump 244; i.e., the recirculation pump and the application delivery pump are one and the same. During the recirculation period the valve 272 directs the flow of solution back through the recirculation inlet 238 of the outer container 222, while during the application period the valve 272 directs the solution exiting the pump 244 to the application through the application delivery line 246. 2. Preferred Method Another aspect of this invention comprises a method of dissolving and completely activating a discrete predetermined amount of a granular cleansing agent. The process may utilize apparatus similar to those described previously. For convenience, the following description shall utilize the apparatus previously described using Figure 1 through Figure 3. Referring to Figure 6, the method operates on a discrete predetermined quantity of the granular cleansing agent 74 located in the inner container 54. Typical granular cleansing agents which may be used in the method and apparatus of the present invention could include a granular detergent prepared by mixing the following ingredients: SPRAY DRIED BASE GRANULE WEIGHT % Sodium C13 linear alklbenzene sulfonate 10.3 Sodium C14-15 linear fatty alcohol sulfate 10.3 Sodium sulfate 11.6 2.0r Sodium silicate 6.4 Polyethylene glycol (8000 M. Wt.) 0.6 Sodium tripolyphosphate 43.8 Optical brightner 0.3 C14-16 Fatty acid 3.0 Moisture and miscellaneous 7.2 Subtotal 93.5 ADMIX WEIGHT % Silicone suds supressor* 4.5 Sodium carbonate 1.2 Protease 0.8 Total 100.0 * Flakes containing ca. 10% by weight of a commercially available silicone/silica fluid (ca. 75% polydimethyl siloxane having a viscosity of 20 cs - 1500 cs at 25.0it; about 15% siloxane resin; and about 10% silica aerogel having an average ultimate particle size of about 12 millimicrons agglomerated to an average of 1.3 - 1.7 microns and having a surface area of ca. 325 m2/g) and ca. 90% by weight of polyethylene glycol having a molecular weight of about 8000 (PEG 8000) prepared as described in U.S. Paten 4,652,392. Another typical granular cleansing agent could include a bleaching component and be prepared by mixing the following ingredients: SPRAY DRIED BASE GRANULE WEIGHT % Sodium C13 linear alklbenzene sulfonate 7.3 Sodium C14-15 linear fatty alcohol sulfate 7.3 Sodium sulfate 8.2 1.6r Sodium silicate 8.2 Polyethylene glycol (8000 M. Wt.) 0.3 Sodium polyacryl ate 0.7 Sodium tripolyphosphate 29.6 Optical brightner 0.2 C14-16 Fatty acid 2.2 Moisture and miscellaneous 6.0 Subtotal 70.0 ADMIX WEIGHT % Sodium Cg alkyloxybenzene sulfonate* 7.5 Sodium perborate monohydrate 8.9 Sodium citrate 3.2 Protease 0.6 Silicone suds supressor** 3.1 Sodium carbonate 6.7 Total 100.0 * Cylindrical particles 0.9mm diameter by 1.5 - 3.0 mm long, containing 83% nonanoyloxybenzene sulfonate, 5% polyethylene glycol 8000, 5% palmitic acid and 3% C12 linear alkylbenzene sulfonate. ** Flakes containing ca. 10% by weight of a commercially available silicone/silica fluid (ca. 75% polydimethyl siloxane having a viscosity of 20 cs - 1500 cs at 25.0it; about 15% siloxane resin; and about 10% silica aerogel having an average ultimate particle size of about 12 millimicrons agglomerated to an average of 1.3 - 1.7 microns and having a surface area of ca. 325 m2/g) and ca. 90% by weight of polyethylene glycol having a molecular weight of about 8000 (PEG 8000) prepared as described in U.S. Patent 4,652,392. Water is provided to the outer container 22 through the supply line 30 prior to initiating operation of the recirculating pump 44. One function of this initial amount of water is to enable the recirculation pump 44 to purge any dry granular cleansing agent 74 which may have found its way into the pump 44. Without the water, the recirculation pump 44 may bind upon start-up. Prior to substantial wetting of the cleansing agent 74; preferably prior to the water level reaching the bottom wall 58 of the inner container 54, operation of the recirculation pump 44 is initiated. The recirculation pump 44 draws solution from the outer container 22 through the recirculation outlet 36 and returns the solution to the outer container 22 through the recirculation inlet 38. The solution returning to the outer container 22 through the recirculation inlet 38 is directed towards the diffuser 62 and the cleansing agent 74 located in the inner container 54. This solution impinging upon the diffuser 62 is diffused as it enters the inner container 54 through the wire screen bottom wall 58. As seen in Figure 7, this diffused solution preferably floats the granular cleansing agent 74 off of the bottom wall 58 of the inner container 54 substantially immediately; and/or substantially immediately dissolves or disperses the lowermost granular cleansing agent 74 so there is a space between the bottom wall 58 and the remaining granular cleansing agent 74. As it rises, some undissolved or undispersed granular cleansing agent 74 may flow over the top of the inner container 54 and into the recirculation system where the turbulence and other mechanical action of the recirculation pump 44 dissolves or disperses it. As seen in Figure 7, water preferably continues to be added to the outer container 22 even after operation of the recirculation pump 42 is initiated. As seen in Figure 8, as the additional water raises the solution level in the containers, 22 and 54, a floating island of granular cleansing agent 74 tends to form. This floating island of granular cleansing agent 74 is subjected to ever changing turbulence as the solution level rises and gradually disappears as it dissolves or disperses. The solution exiting the recirculation inlet 38 provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent 74 and preventing the cleansing agent 74 from attaching to the sides of either container, 54 or 22. In the preferred embodiment of Figure 3, this energy is somewhat confined to the space within the inner container 54 by the solid cylindrical side wall 56. In the embodiment of Figure 4, the energy is permitted to exit and return to the inner container 154. Each embodiment sets up its own patterns of turbulence in the inner container, 54 or 154. Pumping of the water through the recirculation lines 42 via the recirculation pump 44 is preferably ceased only after the cleansing agent 74 has been dissolved or dispersed and substantially all of the ingredients in the cleansing agent 74 have become active. To become active, some components are transformed by a reaction with the water itself; other components are transformed by reacting in solution with other components in the granular cleansing agent 74. During this mixing and reacting period, the amount of water in which the components of the granular cleansing agent 74 are reacting is limited. This limited amount of water speeds the rate at which the various components will find and react with their corresponding components. Furthermore, the total time period for the recirculation period utilizing typical granular cleansing agents 74 is preferably from about one (1) minute to about ten (10) minutes, more preferably from about two (2) minutes to about seven (7) minutes and most preferably from about three (3) minutes to about five (5) minutes. Once substantially all of the components within the cleansing agent 74 are transformed, an active cleansing liquor is available for use in a cleansing application. Preferably, operation of the application delivery pump 48 is not initiated until after the cleansing liquor has become active. It may be desirable to add an additional amount of water from the supply line 30 beginning simultaneously with the start-up of the application delivery pump 48. Such additional water will cause the concentration of the cleansing liquor being delivered to gradually decrease. This decrease may be desirable to reduce the amount of residue remaining on the apparatus 20 after use. The recirculation pump 44 can be turned off at any time after dissolution or dispersion of the granular cleansing agent 74. However, the recirculation pump 44 preferably operates at least until the cleansing agent 74 has become active, since the turbulence it provides aids the necessary reactions. Operation of the recirculation pump 44, however, is generally ceased prior to the water level within the outer container 22 falling to a point at which the recirculation pump 44 would begin to spray water out the top of the outer container 22. The application delivery pump 48 continues to operate until all of the liquor is delivered. It is preferable with time based apparatus, to permit the application delivery pump 48 to run a short period of time after all the active cleansing liquor is calculated to be delivered to the application. This will ensure that no liquor remains within the outer container 22 at the end of the cycle. One time based example of the instant method which may utilize either the preferred embodiment of Figure 3 or the preferred embodiment of Figure 4. Place a predetermined quantity of cleansing agent in the inner container. Beginning at time zero (hereinafter "Initiation") and continuing for thirty-eight (38) seconds add 1.4 liters of water to the outer container. Seven (7) seconds after Initiation, begin operation of the recirculation pump. Three hundred (300) seconds after Initiation, begin adding additional water to the outer container at the same rate as before for between about thirty (30) seconds and about one-hundred thirty-five (135) seconds. Forty (40) seconds after the conclusion of the addition of this additional water the recirculation pump ceases operating. The application delivery pump is timed to cease operating about thirty (30) seconds after all the water is dispensed to ensure the container is completely drained. The instant method and apparatus can dissolve or disperse a discrete predetermined quantity of cleansing agent without caking problems. This method and apparatus can also deliver a fully active cleansing liquor to any cleansing application, thereby ensuring full cleansing action immediately. Further advantages are achieved when this method and apparatus is used in conjunction with a cleansing application which utilizes a minimum amount of water. In such minimum water cleansing applications sufficient water is not available, e.g. in a reservoir, to permit the various reactions necessary to activate the cleansing agent. Consequently, very little additional activation will take place in the cleansing application itself. Therefore, it is particularly important in these minimum water applications to deliver a completely active liquor to the cleansing application. Such a minimum water cleansing application is disclosed in U.S. Patent 4,489,455 issued to Spendel on December 25, 1984 and U.S. Patent 4,555,019 issued to Spendel on November 26, 1985, the disclosure of each is hereby incorporated herein by reference. This cleansing application basically involves spraying a relatively small amount of cleansing liquor onto clothes while agitating the clothes. Heat energy is preferably supplied to the clothes during the spraying and agitation process by recirculating moist humid air through a heater. Although particular embodiments of the present invention have been shown and described, modifications may be made to the invention without departing from the teachings of the present invention. Accordingly, the present invention comprises all embodiments within the scope of the appended claims.

Claims: 1. A method, utilizing an apparatus including an outer container having a recirculation outlet and a recirculation inlet, an inner container located within the outer container and having a screen wall portion, a recirculation pump attached to a recirculation line such that liquid in the containers may be removed at the recirculation outlet and returned through the recirculation inlet, for dissolving and completely activating a discrete predetermined amount of a cleansing agent having an inactive ingredient housed in the inner container, the method characterized by the steps of: : (a) providing water to the outer container; (b) initiating operation of the recirculation pump prior to substantial wetting of the cleansing agent housed in the inner container such that solution passes through the recirculation outlet and through the recirculation inlet back into the outer container toward the cleansing agent in the inner container; (c) diffusing the solution entering the outer container from the recirculation outlet such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and for preventing the cleansing agent from attaching to either container; and (d) delivering the solution to a cleansing application only after the cleansing agent has been dissolved or dispersed and substantially all of the ingredients in the cleansing agent have become active. 2. A method, utilizing an apparatus including an outer container having a recirculation outlet and a recirculation inlet, an inner container located within the outer container and having a screen wall portion, a recirculation pump attached to a recirculation line such that solution in the containers may be removed at the recirculation outlet and returned through the recirculation inlet, for dissolving or dispersing a discrete predetermined amount of a cleansing agent housed in the inner container, the method characterized by the steps of: : (a) providing water to the outer container; (b) initiating operation of the recirculation pump prior to substantial wetting of the cleansing agent housed in the inner container such that the solution passes through the recirculation outlet and through the recirculation inlet back into the outer container toward the cleansing agent in the inner container; and (c) diffusing the solution entering the outer container from the recirculation outlet such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and for preventing the cleansing agent from attaching to the sides of either container; and such that a space is substantially immediately provided between the screen wall portion of the inner container and the cleansing agent upon initiating operation of the recirculation pump. 3. A method for dissolving and activating a discrete predetermined amount of a cleansing agent according to Claim 1 or Claim 2 wherein water is provided to the outer container prior to initiation of operation of the recirculation pump. 4. A method for dissolving and activating a discrete predetermined amount of a cleansing agent according to any one of the preceding Claims further characterized by the step of providing water to the outer container after initiating operation of the recirculating pump. 5. A method for dissolving and activating a discrete predetermined amount of a cleansing agent according to any one of the preceding Claims further characterized by the step of ceasing operation of the recirculation pump after substantially all of the ingredients in the cleansing agent have become active. 6. An apparatus for dissolving or dispersing and completely activating a cleansing agent in a solution to form an active cleansing liquor prior to providing the dissolved cleansing agent to a cleansing application, the apparatus characterized by: (a) an outer container having a continuous side wall sealed at its lower end to a bottom wall, the bottom wall having a centrally located recirculation inlet and a recirculation outlet therein; (b) an inner container having a screen wall portion and a predetermined quantity of the cleansing agent housed therein and being located within the outer container; (c) a recirculation pump attached to a recirculation line such that the solution may be removed from the outer container at the recirculation outlet and returned to the outer container through the recirculation inlet; ; (d) means for initiating pumping of said solution prior to substantial wetting of the cleansing agent from the outer container through the recirculation outlet and through the recirculation inlet toward the cleansing agent in the inner container through the screen wall portion of said inner container; (e) means for diffusing the solution entering the outer container such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and substantially preventing the cleansing agent from attaching to the sides of either container to form a cleaning liquor; and (f) means for delivering the solution to the cleansing application only after the cleansing agent has been dissolved or dispersed and substantially all of the ingredients in the cleansing agent have become active. 7. An apparatus for dissolving or dispersing a predetermined amount of a granular cleansing agent in a solution to form a cleansing liquor prior to providing the cleansing agent to a cleansing application, the apparatus characterized by:, (a) an outer container having a continuous side wall sealed at its lower end to a bottom wall, the bottom wall having a centrally located recirculation inlet and a recirculation outlet therein; (b) an inner container having a screen wall portion and a predetermined quantity of the cleansing agent housed therein and being located within the outer container; (c) a recirculation pump attached to a recirculation line such that the solution may be removed from the outer container at the recirculation inlet and returned to the outer container through the recirculation outlet; ; (d) means for initiating pumping of said solution prior to substantial wetting of the cleansing agent from the outer container through the recirculation outlet and through the recirculation inlet toward the cleansing agent in the inner container through the screen wall portion of said inner container forming a solution; (e) means for diffusing the solution entering the outer container from the recirculation outlet such that the solution provides energy for dissolving or dispersing the entire predetermined quantity of cleansing agent and for preventing the cleansing agent from attaching to the sides of the inner container; and such that a space is substantially immediately provided between the screen wall portion of the inner container and the granular cleansing agent upon initiating operation of the recirculation pump. 8. An apparatus for dissolving or dispersing and completely activating a discrete predetermined quantity of cleansing agent according to Claims 6 or 7 wherein the inner container has a continuous side wall and the screen wall portion is a bottom wall attached at the lower end of the continuous side wall. 9. An apparatus for dissolving or dispersing and completely activating a discrete predetermined quantity of cleansing agent according to any one of Claims 6-8 wherein the continuous side wall is made of a wire screen. 10. An apparatus for dissolving or dispersing and completely activating a discrete predetermined quantity of cleansing agent according to any one of Claims 6-9 wherein the means for diffusing is an inverted conical shaped diffuser depending from the bottom wall of the inner container and wherein the apex of the diffuser is located directly above the center of the recirculation inlet.

Inventors: MARKLAND THOMAS ARTHUR, WIERENGA THOMAS JAMES, MARKLAND, THOMAS, ARTHUR, WIERENGA, THOMAS, JAMES
Applicants: PROCTER & GAMBLE, THE PROCTER & GAMBLE COMPANY
Application year: 1992
Main classification: D06F39
IPC codes: A47L15, B01F1, B08B3, D06F39