Abstract:
A method of washing particulate laden material in a washer includes moving the particulate laden material from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material. A specially configured recirculation/filtration arrangement removes a majority of particulate and organic matter from the washing fluid.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Provisional Patent Application Ser. No. 61/917,158, filed 17 Dec. 2013, which is hereby incorporated herein by reference. 
         [0002]    Priority of U.S. Provisional Patent Application Ser. No. 61/917,158, filed 17 Dec. 2013, which is incorporated herein by reference, is hereby claimed. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0003]    Not applicable 
       REFERENCE TO A “MICROFICHE APPENDIX” 
       [0004]    Not applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    The present invention relates to a method and apparatus for cleaning floor mats such as when using a continuous batch washer or tunnel washer. 
         [0007]    More particularly, the present invention relates to the cleaning of particulate laden material (such as floor mats, sand laden beach towels, work uniforms laden with metal shavings, or jeans laden with pumice rock such as the pumice rocks used in garments washing such as stone washed jeans) in a multiple module washer (e.g., tunnel washer) wherein a specially configured recirculation arrangement transmits liquid from a module (e.g., first module) to an intake or hopper and wherein a pump and filter in between the module and intake effect a removal of particulate material such as sand, metal shavings, or rocks during such recirculation. 
         [0008]    2. General Background of the Invention 
         [0009]    The purpose of a floor mat is to wipe or otherwise remove sand and dirt from the feet of people. Hence, dirty floor mats can be laden with significant quantities of heavy dirt or sand. Towels can be laden with sand and thus pose a problem for a resort hotel laundry. Metal shavings from uniforms used in the metal work industry can cause problems for a laundry. Other items to be laundered can be laden with pumice rocks used in garment washing such as stone washed jeans. 
         [0010]    One of the problems with washing floor mats embedded with sand (or with organic compounds) is that once the sand is released from the mat into the washing water, the sand collects inside the shell of the washing machine such as in many of the modules of the tunnel washer. Periodically, the machine is programmed to insert a purge pocket which drains the water and hopefully most of the sand and organic compounds. If the sand and organic compounds are not removed, they build up in the machine. This causes the mats to not be cleaned. The build up of organic compounds causes the mats to have an extreme odor. 
         [0011]    Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples of such patented tunnel washers, each listed patent of the table being hereby incorporated herein by reference. 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 
               
               
                   
               
               
                   
                   
                 ISSUE DATE 
               
               
                 PAT. NO. 
                 TITLE 
                 MM-DD-YYYY 
               
               
                   
               
             
             
               
                 4,236,393 
                 Continuous tunnel batch washer 
                 12-02-1980 
               
               
                 4,485,509 
                 Continuous batch type washing machine 
                 12-04-1984 
               
               
                   
                 and method for operating same 
               
               
                 4,522,046 
                 Continuous batch laundry system 
                 06-11-1985 
               
               
                 5,211,039 
                 Continuous batch type washing machine 
                 05-18-1993 
               
               
                 5,454,237 
                 Continuous batch type washing machine 
                 10-03-1995 
               
               
                 7,971,302 
                 Integrated Continuous Batch Tunnel 
                 07-05-2011 
               
               
                   
                 Washer 
               
               
                 8,166,670 
                 Clothes Dryer Apparatus with Improved 
                 05-01-2012 
               
               
                   
                 Lint Removal System 
               
               
                 8,336,144 
                 Continuous Batch Tunnel Washer and 
                 12-25-2012 
               
               
                   
                 Method 
               
               
                 8,370,981 
                 Integrated Continuous Batch Tunnel 
                 02-12-2013 
               
               
                   
                 Washer 
               
               
                 8,365,435 
                 Laundry Press Apparatus and Method 
                 02-05-2013 
               
               
                 8,689,463 
                 Clothes Dryer Apparatus with Improved 
                 04-08-2014 
               
               
                   
                 Lint Removal System 
               
               
                   
               
             
          
         
       
     
       BRIEF SUMMARY OF THE INVENTION 
       [0012]    The present invention provides an improved method and apparatus for washing floor mats in a tunnel washer. By using a filter to filter a recirculation flow of fluid in the first module, most (e.g. 90 to 95%) of the sand and organic compounds are removed. This improves the performance of the washing machine, maintains the washing quality and eliminates any build up of sand or organic material. 
         [0013]    By removing the sand in the first module, the washing machine stays clean and can be used to wash other materials such as linens. The present invention eliminates a laborious clean out of the interior of the washing machine. 
         [0014]    The present invention includes a method of washing particulate laden material in a continuous batch tunnel washer. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid. The particulate laden material can be moved from the intake to the modules and then to the discharge in sequence. A washing chemical can be added to the volume of liquid, after a selected time period, and counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material. A volume of liquid can be recirculated from the first module to the intake via a recirculation flow line. Particulate matter can be removed from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake. 
         [0015]    In one embodiment, there can be a pump in the recirculation flow line. 
         [0016]    In one embodiment, the pump can be in between the first module and the filter. 
         [0017]    In one embodiment, the pump can be in between the filter and the intake. 
         [0018]    In one embodiment, the particulate matter can include sand. 
         [0019]    In one embodiment, the filter can remove particles from the volume of fluid via centrifugal action. 
         [0020]    The present invention includes a method of washing particulate laden material in a continuous batch tunnel washer. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The particulate laden material can be moved from the intake to the discharge. A washing chemical can be added to the modules to wash the particulate laden material with a combination of water and the washing chemical, after a selected time interval, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the particulate laden material in order to effect a rinse of the particulate laden material. Liquid can be recirculated from one of the modules to the intake via a recirculation flow line. Particulate material can be removed from the recirculating liquid with a filter. 
         [0021]    In one embodiment, the present invention can further comprise boosting the flow rate in the recirculation flow line with a pump. 
         [0022]    In one embodiment, the filter can filter sand as part of the particulate matter. 
         [0023]    In one embodiment, the pump can be in between the module and the filter. 
         [0024]    The present invention includes a particulate laden material washing apparatus. The apparatus of the present invention can include a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including at least an upstream, first module that can be next to the intake and at least one downstream module next to the discharge, and a volume of liquid. The particulate laden material can move from the intake to the modules and then to the discharge in sequence. One or more counter flowing liquid flowlines can counterflow liquid along a flow path that can be from a downstream module to an upstream module. A recirculating liquid flow line can connect from the first module to the intake. A filter after the liquid leaves the first module and before the liquid reaches the intake. 
         [0025]    In one embodiment, the apparatus can further comprise a pump in the recirculating liquid flow line. 
         [0026]    In one embodiment, the pump can be in between the first module and the filter. 
         [0027]    In one embodiment, the pump can be in between the filter and the intake. 
         [0028]    In one embodiment, the filter removes particulate matter that can include sand. 
         [0029]    In one embodiment, the filter removes particulate matter that can include organic waste material. 
         [0030]    In one embodiment, the filter removes particulate material using centrifugal force. 
         [0031]    In one embodiment, the filter continuously removes particulate matter from the recirculating liquid flow line as fluid flows in said recirculating liquid flow line. 
         [0032]    The present invention includes a method of washing fabric articles that contain unwanted particulate matter. The method comprises the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules including a first module that is next to the intake, and a volume of liquid. The particulate laden material can be moved from the intake to the modules and then to the discharge in sequence. A washing chemical can be added to the volume of liquid, after a selected time period, can counter flowing a rinsing liquid along a flow path that is generally opposite the direction of travel of the material. A volume of liquid can be recirculated from the first module to the intake via a recirculation flow line. Particulate matter can be removed from the volume of liquid flowing in the recirculation flow line with a filter after the volume of liquid leaves the first module and before the volume of liquid reaches the intake. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0033]    For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
           [0034]      FIG. 1  is a schematic diagram showing a preferred embodiment of the apparatus of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0035]      FIG. 1  shows a preferred embodiment of the apparatus of the present invention designated by the numeral 10. Washing apparatus  10  is used to wash floor mats that can contain undesirable material, particulate material such as sand, organic matter and the like. The apparatus of the present invention employs a multiple module tunnel washer  11 . Tunnel washer  11  can be as shown and described in any one of the following US patents, each of which is incorporated herein by reference: U.S. Pat. Nos. 4,236,393; 4,485,509; 4,522,046; 5,211,039; 5,454,237; 7,971,302; 8,166,670; 8,336,144; 8,370,981; 8,365,435; and 8,689,463. 
         [0036]    Tunnel washer  11  has an inlet end portion  12  with hopper  26  and an outlet end portion  13 . The tunnel washer  11  provides a plurality of modules  14 - 17 . The first module is module  14 . The second module is module  15 . The third module is module  16 . The final module is module  17 . It should be understood that more than four (4) modules can be provided. Fluid impregnated mats that exit the outlet end portion  13  of tunnel washer  11  enter an extractor or press (not shown) via a discharge  27  such as a discharge flow line or chute. The extractor removes excess water from the mats to be cleaned and transmits that excess water to water tank  29 . Water from tank  29  flows via flow line  32  in the direction of arrow  28  from tank  29  to tank  33 . A valve  18  can be provided in flow line  32 . 
         [0037]    Make up water can be added to tank  33  via flow line  22 . The flow line  22  has a valve  21 . The flow line  22  receives water from a water source  19  such as a city water supply. The flow line  22  can be provided with a back flow preventer or check valve  37 . A flow meter  20  can be provided in line  22 . The tank  33  is provided with a drain valve  23  that enables water to be discharged from tank  33  via drain valve  23  into sewer  24  as indicated by arrow  25  in  FIG. 1 . 
         [0038]      FIG. 1  shows a recirculation line that recirculates fluid from the first module  14  via flow lines  52 ,  57  to hopper  26 . Hopper  26  is at the inlet end portion  12  of tunnel washer  11 . The hopper  26  is also receptive of floor mats to be cleaned. The floor mats are added to the hopper  26 . From the hopper  26 , the mats proceed in sequence to the first module  14 , then to modules  15 ,  16 , and then to module  17 . From the module  17 , the floor mats are transferred via a discharge  27  into a water extractor, press or the like water removal device. 
         [0039]    A pump  30  can be used to transmit extracted water from tank  29  via flow line  32  to tank  33 . Tank  29  has interior  31  for holding water that is routed to the tank  29  from the water extractor or press. Such water extractors or presses are commercially available. 
         [0040]    Flow lines  34  and  35  enable water to be discharged from tank  33  to final module  17  or to any one of the modules  14 ,  15 ,  16  or to the hopper  26 . Flow line  38  enables water to flow from line  35  to hopper  26 . Flow line  39  enables water to flow from flow line  35  to module  14 . Flow line  40  enables water to flow from flow line  35  to module  15 . Flow line  41  enables water to flow from flow line  35  to module  16 . Flow line  35  terminates at module  17 . Flow line  34  also terminates at module  17 . Pumps  36  can be used to provide pressure in the flow lines  34 ,  35 . 
         [0041]    Each of the flow lines  38 ,  39 ,  40 ,  41  and  34 ,  35  are provided with valves. Flow line  38  has valve  42 . Flow line  39  has valve  43 . Flow line  40  has valve  44 . Flow line  41  has valve  45 . Flow line  34  has valve  46 . Flow line  35  has valve  47 . Flow line  38  can have flow meter  48 . Flow line  34  can have a flow meter  48 . 
         [0042]    Each of the modules  14 ,  15 ,  16 ,  17  can be provided with chemical injection such as alkaline injection  49 , detergent injection  50  or other chemical injections such as finishing liquid, starch or any other washing or finishing chemical  63 . Steam injection  51  can be provided at one or more of the modules  14 ,  15 ,  16  or  17  as indicated in  FIG. 1 . 
         [0043]    The flow lines  52 ,  57  recirculate fluid from the first module  14  to hopper  26 . The flow line  52  can be provided with a pump  53 . The flow line  57  could also be provided with a pump. Filter  54  is placed at the end of flow line  52  and at the beginning of flow line  57 . Filter  54  is preferably a centrifugal filter that removes undesirable particulate matter such as sand, organic matter or the like and deposits it in sand container  55  as indicated by arrow  56 . Filter  54  can be for example a centrifugal type filter such as is shown and described in any of the following US patents, each of which is incorporated herein by reference: U.S. Pat. Nos. 5,320,747; 5,338,341; 5,368,735; 5,425,876; 5,571,416; 5,578,203; 5,622,545; 5,653,874; 5,894,995; 6,090,276; 6,143,175; 6,167,960; 6,202,543; 7,000,782; and 7,032,760. 
         [0044]    Counter flow can be provided from one module to a previous module. Counter flow line  58  enables counter flow from module  17  to module  16 . Flow line  59  enables counter flow from module  16  to module  15 . Flow line  62  enables counter flow from module  15  to module  14 . Each of the modules  14 ,  15 ,  16 ,  17  is provided with a valved drain  23  for enabling discharge of fluid to sewer  24 . Module  14  can be provided with overflow drain line  60  which discharges fluid through valve  61  to sewer  24 . 
         [0045]    The following is a list of parts and materials suitable for use in the present invention: 
         [0000]    
       
         
               
             
               
               
             
           
               
                   
               
               
                 PARTS LIST 
               
             
          
           
               
                 Part Number 
                 Description 
               
               
                   
               
               
                 10 
                 washing apparatus 
               
               
                 11 
                 tunnel washer 
               
               
                 12 
                 inlet end portion 
               
               
                 13 
                 outlet end portion 
               
               
                 14 
                 module 
               
               
                 15 
                 module 
               
               
                 16 
                 module 
               
               
                 17 
                 module 
               
               
                 18 
                 valve 
               
               
                 19 
                 water source/flow line/city water supply 
               
               
                 20 
                 flow meter 
               
               
                 21 
                 valve 
               
               
                 22 
                 make up water line/flow line 
               
               
                 23 
                 drain valve/valved drain 
               
               
                 24 
                 sewer 
               
               
                 25 
                 arrow 
               
               
                 26 
                 hopper 
               
               
                 27 
                 discharge 
               
               
                 28 
                 arrow 
               
               
                 29 
                 water tank 
               
               
                 30 
                 pump 
               
               
                 31 
                 interior 
               
               
                 32 
                 flow line 
               
               
                 33 
                 tank 
               
               
                 34 
                 flow line 
               
               
                 35 
                 flow line 
               
               
                 36 
                 pump 
               
               
                 37 
                 back flow preventer/check valve 
               
               
                 38 
                 flow line 
               
               
                 39 
                 flow line 
               
               
                 40 
                 flow line 
               
               
                 41 
                 flow line 
               
               
                 42 
                 valve 
               
               
                 43 
                 valve 
               
               
                 44 
                 valve 
               
               
                 45 
                 valve 
               
               
                 46 
                 valve 
               
               
                 47 
                 valve 
               
               
                 48 
                 flow meter 
               
               
                 49 
                 alkaline injection 
               
               
                 50 
                 detergent injection 
               
               
                 51 
                 steam/steam injection 
               
               
                 52 
                 flow line 
               
               
                 53 
                 pump 
               
               
                 54 
                 filter 
               
               
                 55 
                 sand container 
               
               
                 56 
                 arrow 
               
               
                 57 
                 flow line 
               
               
                 58 
                 counter flow line 
               
               
                 59 
                 counter flow line 
               
               
                 60 
                 overflow drain 
               
               
                 61 
                 valve 
               
               
                 62 
                 counter flow line 
               
               
                 63 
                 other chemical injections/finishing liquid/starch 
               
               
                   
               
             
          
         
       
     
         [0046]    All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. 
         [0047]    The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.