Source: https://patents.google.com/patent/US5591236?oq=6%2C970%2C917
Timestamp: 2018-02-20 18:53:36
Document Index: 417173469

Matched Legal Cases: ['art 1995', 'Application No. 08', 'Application No. 08', 'Application No. 08', 'Application No. 08', 'Application No. 08', 'Application No. 08', 'Application No. 08', 'Application No. 08', 'Application No. 08']

US5591236A - Polyacrylate emulsified water/solvent fabric cleaning compositions and methods of using same - Google Patents
Polyacrylate emulsified water/solvent fabric cleaning compositions and methods of using same
US5591236A
US5591236A US08544373 US54437395A US5591236A US 5591236 A US5591236 A US 5591236A US 08544373 US08544373 US 08544373 US 54437395 A US54437395 A US 54437395A US 5591236 A US5591236 A US 5591236A
US08544373
Timothy C. Roetker
Aqueous cleaning compositions containing solvents such as butoxy propoxy propanol (BPP) are emulsified using low levels of polyacrylate emulsifiers. Thus, an emulsion comprising BPP, a polyacrylate, optional surfactants, optional 1,2-octanediol and water is applied to fabrics in a home dry cleaning operation.
This application is a continuation-in-part of application Ser. No. 08/413,560, filed Mar. 30, 1995, now abandoned.
The present invention relates to emulsified water/solvent dry cleaning and spot removal compositions which are especially adapted for use in the home.
While various dry cleaning compositions have been suggested in the literature, the majority are designed for use in commercial immersion dry cleaning processes. Most dry cleaning compositions contain very little water. By contrast, the compositions herein employ substantial amounts of water together with organic solvents; accordingly, it is difficult to prepare stable, homogeneous mixtures therefrom. While it might be possible to use large amounts of conventional surfactants to emulsify such water/solvent mixtures, the resulting compositions would tend to leave unacceptable levels of residue on fabrics which are cleaned without a rinse step in the manner disclosed herein.
It has now been discovered that certain polyacrylate materials are excellent emulsifiers for water/solvent dry cleaning compositions. Moreover, the polyacrylates are useful at quite low levels, thereby avoiding the residue problem associated with less effective materials. The resulting polyacrylate/water/solvent compositions are smooth and lubricious, and, depending on the solvent employed, can be formulated to have a mild, inoffensive odor.
Accordingly, it is an object of the present invention to provide improved compositions for use in cleaning fabrics. It is another object herein to provide stable water/solvent compositions for use in home dry cleaning systems. These and other objects are secured herein, as will be seen from the following disclosures.
Dry cleaning processes are disclosed in: EP 429,172A1, published 29.05.91, Leigh, et al.; and in U.S. Pat. Nos. 5,238,587, issued Aug. 24, 1993, Smith, et al. Other references relating to dry cleaning compositions and processes, as well as wrinkle treatments for fabrics, include: GB 1,598,911; and U.S. Pat. Nos. 4,126,563, 3,949,137, 3,593,544, 3,647,354; 3,432,253 and 1,747,324; and German applications 2,021,561 and 2,460,239, 0,208,989 and 4,007,362. Cleaning/pre-spotting compositions and methods are also disclosed, for example, in U.S. Pat. Nos. 5,102,573; 5,041,230; 4,909,962; 4,115,061; 4,886,615; 4,139,475; 4,849,257; 5,112,358; 4,659,496; 4,806,254; 5,213,624; 4,130,392; and 4,395,261. Sheet substrates for use in a laundry dryer are disclosed in Canadian 1,005,204. U.S. Pat. Nos. 3,956,556 and 4,007,300 relate to perforated sheets for fabric conditioning in a clothes dryer. U.S. Pat. No. 4,692,277 discloses the use of 1,2-octanediol in liquid cleaners.
The present invention encompasses a dry cleaning and spot removal composition, comprising:
(a) at least about 0.01%, by weight, of a polyacrylate emulsifier;
(b) from about 1% to about 30%, by weight, of an organic solvent;
(c) optionally, from about 0.05% to about 5%, by weight, of detersire surfactants; and
The polyacrylate emulsifier is available commercially from a variety of sources, and preferably has a molecular weight in the range from about 100,000 to about 10,000,000. The organic solvent used herein is preferably a member selected from the group consisting of butoxy propoxy propanol (BPP; preferred herein), methoxy propoxy propanol (MPP), ethoxy propoxy propanol (EPP), propoxy propoxy propanol (PPP), and mixtures and all isomers thereof, although other organic cleaning solvents may be used.
The compositions herein optionally can also comprise a detersire surfactant which is preferably a member selected from the group consisting of amine oxides, alkyl ethoxy sulfates, and mixtures thereof. The alkyl ethoxy sulfate surfactants are preferably in their magnesium salt form.
In yet another mode, the compositions herein additionally comprise at least about 0.05%, by weight, of 1,2-octanediol as a highly preferred wetting agent.
The invention also encompasses a method for cleaning fabrics, comprising applying to said fabrics a composition according to the present invention, and especially wherein said method is conducted in a hot air clothes dryer.
The dye removal attributes of the present cleaning compositions can be compared with art-disclosed cleaners using photographic or photometric measurements, or by means of a simple, but effective, visual grading test. Numerical score units can be assigned to assist in visual grading and to allow for statistical treatment of the data, if desired. Thus, in one such test, a colored garment (typically, silk, which tends to be more susceptible to dye loss than most woolen or rayon substrates) is treated by padding-on cleaner using an absorbent, white paper hand towel. Hand pressure is applied, and the amount of dye which is transferred onto the white towel is assessed visually. Numerical units ranging from: (1) "I think I see a little dye on the towel"; (2) "I know I see some dye on the towel"; (3) I see a lot of dye on the towel"; through (4) "I know I see quite a lot of dye on the towel" are assigned by panelists.
(a) Emulsifier--The compositions will comprise sufficient polyacrylate emulsifier to provide a stable, homogeneous composition comprising components (a), (b) and (d). For the emulsifiers disclosed herein, levels as low as 0.05%, preferably 0.07% to about 0.20%, by weight are effective. Levels above about 0.2% are unnecessary and are preferably not used, thereby avoiding residues on fabrics.
(b) Solvent--The compositions will comprise at least about 4%, typically from about 5% to about 25%, by weight, of the solvent. The objective is to provide at least about 0.4 g, preferably from about 0.5 g to about 2.5 g, of solvent per kg of fabrics being cleaned.
The preferred solvent herein is butoxy propoxy propanol (BPP) which is available in commercial quantities as a mixture of isomers in about equal amounts. The isomers, and mixtures thereof, are all useful herein. The isomer structures are as follows. (The MPP, EPP and PPP solvents also exist as isomers and isomer mixtures, all of which are useful herein.) ##STR1##
BPP is outstanding for cleaning, and is so effective that it allows the amount of the relatively expensive 1,2-octanediol to be minimized. Moreover, it allows for the formulation of effective cleaning compositions herein without the use of conventional surfactants. Importantly, the odor of BPP is of a degree and character that it can be relatively easily masked by conventional perfume ingredients. While BPP is not completely miscible with water and, hence, could negatively impact processing of the cleaning compositions herein, that potential problem has been successfully overcome by means of the PEMULEN-type polyacrylate emulsifiers, in the manner disclosed herein.
The BPP solvent used herein is preferably a mixture of the aforesaid isomers. In a preferred mode, the cleaning compositions comprise a mixture of the 1,2-octanediol and BPP, at a weight ratio of OD:BPP in the range of from about 1:250 to about 2:1, preferably from about 1:200 to about 1:5. Similar ratios can be used with the MPP, EPP and PPP solvents.
While the cleaning compositions herein function quite well with only the emulsifier, the 1,2-octanediol, BPP, PEMULEN and water, they may also optionally contain detersive surfactants to further enhance their cleaning performance. While a wide variety of detersive surfactants such as the C12 -C16 alkyl sulfates and alkylbenzene sulfonates, the C12 -C16 ethoxylated (EO 0.5-10 avg.) alcohols, the C12 -C14 N-methyl glucamides, and the like can be used herein, it is highly preferred to use surfactants which provide high grease/oil removal. Included among such preferred surfactants are the C12 -C16 alkyl ethoxy sulfates (ALES), especially in their magnesium salt form, and the C12 -C16 dimethyl amine oxides. An especially preferred mixture comprises MgAE1 S/MgAE6.5 S/C12 dimethyl amine oxide, at a weight ratio of about 1:1:1. If used, such surfactants will typically comprise from about 0.05% to about 2.5%, by weight, of the cleaning compositions herein.
Carrier--When used in a dry cleaning operation, the cleaning compositions are preferably used in combination with a carrier, such that the cleaning composition performs its function as the surfaces of the fabrics being cleaned come in contact with the surface of the carrier.
The lint-resistance of sheet or pad carriers used herein can be achieved by several means, including but not limited to: preparing the carrier from a single strand of fiber; employing known bonding techniques commonly used with nonwoven materials, e.g., point bonding, print bonding, adhesive/resin saturation bonding, adhesive/resin spray bonding, stitch bonding and bonding with binder fibers. In an alternate mode, a carrier can be prepared using an absorbent core, said core being made from a material which, itself, is not lint-resistant. The core is then enveloped within a sheet of porous, lint-resistant material having a pore size which allows passage of the cleaning compositions, but through which lint from the core cannot pass. An example of such a carrier comprises a cellulose or polyester fiber core enveloped in a non-woven polyester scrim.
The carrier is intended to contain a sufficient amount of the cleaning composition to be effective for its intended purpose. The capacity of the carrier for the cleaning composition will vary according to the intended usage. For example, carrier/cleaning composition pads or sheets which are intended for a single use will require less capacity than such pads or sheets which are intended for multiple uses. For a given type of carrier the capacity for the cleaning composition will vary mainly with the thickness or "caliper" (z-direction; dry basis) of the sheet or pad. For purposes of illustration, typical single-use polyester sheets used herein will have a thickness in the range from about 0.1 mm to about 0.7 mm and a basis weight in the range from about 30 g/m2 to about 100 g/m2. Typical multi-use polyester pads herein will have a thickness in the range from about 0.2 mm to about 1.0 mm and a basis weight in the range from about 40 g/m2 to about 150 g/m2. Open-cell sponge sheets will range in thickness from about 0.1 mm to about 1.0 mm. Of course, the foregoing dimensions may vary, as long as the desired quantity of the cleaning composition is effectively provided by means of the carrier.
The flexible container used herein can be provided in any number of configurations, and is conveniently in the form of a flexible pouch, or "bag", which has sufficient volume to contain the fabrics being cleaned. Suitable containers can be manufactured from any economical material, such as polyester, polypropylene, and the like, with the proviso that it must not melt if used in contact with hot dryer air. It is preferred that the walls of the container be substantially impermeable to water vapor and solvent vapor under the intended usage conditions. It is also preferred that such containers be provided with a sealing means which is sufficiently stable to remain closed during the cleaning process. Simple tie strings or wires, various snap closures such as ZIP LOK® closures, and VELCRO®-type closures, contact adhesive, adhesive tape, zipper-like closures, and the like, suffice.
Process--The present cleaning process can be conducted in any manner which provides mechanical agitation, such as a tumbling action, to the container with the fabrics being cleaned. If desired, the agitation may be provided manually. However, in a convenient mode a container with the carrier/cleaning composition and enveloping the soiled fabric is sealed and placed in the drum of an automatic clothes dryer. The drum is allowed to revolve, which imparts a tumbling action to the container and agitation of its contents concurrently with the tumbling. By virtue of this agitation, the fabrics come in contact with the carrier releasably containing and carrying the cleaning composition. It is preferred that heat be employed during the process. Of course, heat can easily be provided in a clothes dryer. The tumbling and optional (but preferred) heating is carried out for a period of at least about 10 minutes, typically from about 20 minutes to about 30 minutes. The process can be conducted for longer or shorter periods, depending on such factors as the degree and type of soiling of the fabrics, the nature of the soils, the nature of the fabrics, the fabric load, the amount of heat applied, and the like, according to the needs of the user. The following illustrates a typical process in more detail, but is not intended to be limiting thereof.
______________________________________Ingredient       % (wt.)______________________________________PEMULEN TR-1*    0.15BPP**            7.01,2-octanediol   0.5Surfactant Mixture*            0.50KOH              0.08Perfume          0.75Water            Balance______________________________________ *PEMULEN TR2, B. F. Goodrich, may be substituted **Isomer mixture, available from Dow Chemical Co. ***Mixture of MgAE.sub.1 S, MgAE.sub.6.5 S and C.sub.12 amine oxide, in the range of 1:1:1 to 0.5:1:1.
A non-linting carrier sheet is prepared using a non-woven, two-ply fabric stock comprising polyester fibers, caliper 0.25 mm to 0.34 ram, basis weight 84 g/m2. The fabric is cut into square carrier sheets, approximately 25 cm on a side, i.e., 625 cm2 sheets. Three or four rows of regularly-spaced 1.27 cm (0.5 in.) diameter circular holes are punched through the sheet. (The finished sheet can later be folded for packaging, and when unfolded and used in the manner disclosed herein, the holes help maintain the sheet in the desired unfolded configuration.)
23 Grams of the above-noted cleaning composition are evenly applied to the sheet by spreading onto the sheet with a roller or spatula using hand pressure. In an alternative mode, the cleaning composition can be applied by dipping or spraying the composition onto the substrate, followed by squeezing with a roller or pair of nip rollers, i.e., by "dip-squeezing" or "spray squeezing". The external surfaces of the sheet are damp but not tacky to the touch.
A dry cleaning sheet of the foregoing type is unfolded and placed flat in a plastic bag having a volume of about 25,000 cm3 together with about 2 kg of dry garments to be cleaned. The bag is closed, sealed and placed in a conventional hot-air clothes dryer. When the garments and the dry cleaning sheet are placed in the bag, the air is preferably not squeezed out of the bag before closing and sealing. This allows the bag to billow, thereby providing sufficient space for the fabrics and cleaning sheet to tumble freely together. The dryer is started and the bag is tumbled for a period of 20-30 minutes at a dryer air temperature in the range from about 50° C. to about 85° C. During this time, the dry cleaning sheet remains substantially in the desired open position, thereby providing effective contact with the fabrics. After the machine cycle is complete, the bag and its contents are removed from the dryer, and the spent dry cleaning sheet is discarded. The plastic bag is retained for re-use. The garments are cleaned and refreshed. The water present in the cleaning composition serves to minimize wrinkles in the fabrics.
______________________________________Ingredients     % (wt.)______________________________________PEMULEN         0.15BPP*            7.01,2-Octanediol  0.5Perfume         0.75Water           Balance______________________________________ *May be replaced by an equivalent amount of MPP, EPP and PPP, respectively, or mixtures thereof, and mixtures thereof with BPP.
______________________________________Ingredient         % (wt.) Formula Range______________________________________BPP*               5-25%1,2-Octanediol     0.1-7%MgAE.sub.1 S       0.01-0.8%MgAE.sub.6.5 S     0.01-0.8%C.sub.12 Dimethyl Amine Oxide              0.01-0.8%PEMULEN**          0.05-0.20%Perfume            0.01-1.5%Water              Balance______________________________________ pH Range from about 6 to about 8. *Other cosolvents which can be used herein together with the BPP, MPP, EP and PPP primary solvents include various glycol ethers, including materials marketed under trademarks such as Carbitol, methyl Carbitol, butyl Carbitol, propyl Carbitol, hexyl Cellosolve, and the like. If desired, and having due regard for safety and odor for inhome use, variou conventional chlorinated and hydrocarbon dry cleaning solvents may also b used. Included among these are 1,2dichloroethane, trichloroethylene, isoparaffins, and mixtures thereof. **As disclosed in U.S. Pat. Nos. 4,758,641 and 5,004,557, such polyacrylates include homopolymers which may be crosslinked to varying degrees, as well as noncrosslinked. Preferred herein are homopolymers having a molecular weight in the range of from about 100,000 to about 10,000,000, preferably 200,000 to 5,000,000.
Excellent cleaning performance is secured using any of the foregoing non-immersion processes and articles to provide from about 5 g to about 50 g of the cleaning compositions per kilogram of fabric being cleaned. Use of the polyacrylate emulsifier at the indicated low levels minimizes residues on the fabrics.
______________________________________INGREDIENT        PERCENT (wt.)                          (RANGE)______________________________________Butoxypropoxy propanol (BPP)             7.000        4.0-25.0%NEODOL 23 - 6.5*  0.750        0.05-2.5%1,2-Octanediol    0.500        0.1-10.0%Perfume           0.750        0.1-2.0%Pemulen TR-1      0.125        0.05-0.2%Potassium Hydroxide (KOH)             0.060        0.024-0.10Potassium Chloride             0.075        0.02-0.20Water (distilled or deionized)             90.740       60.0-95.0%Target pH = 7.0______________________________________ *Shell; C.sub.12 C.sub.13 alcohol, ethoxylated with average EO of 6.5.
15-25 Grams of a composition of the foregoing type are placed on a carrier sheet for use in the manner disclosed herein. A preferred carrier substrate comprises a binderless (or optional low binder), hydroentangled absorbent material, especially a material which is formulated from a blend of cellulosic, rayon, polyester and optional bicomponent fibers. Such materials are available from Dexter, Non-Wovens Division, The Dexter Corporation as HYDRASPUN®, especially Grade 10244. The manufacture of such materials forms no part of this invention and is already disclosed in the literature. See, for example, U.S. Pat. Nos. 5,009,747, Viazmensky, et al., Apr. 23, 1991 and 5,292,581, Viazmensky, et al., Mar. 8, 1994, incorporated herein by reference. Preferred materials for use herein have the following physical properties.
______________________________________      Grade            Optional      10244   Targets  Range______________________________________Basis Weight gm/m.sup.2                  55       35-75Thickness    microns   355      100-1500Density      gm/cc     0.155    0.1-0.25Dry Tensile  gm/25 mmMD                     1700     400-2500CD                     650      100-500Wet Tensile  gm/25 mmMD*                    700      200-1250CD*                    300      100-500Brightness   %         80       60-90Absorption Capacity        %         735      400-900 (H.sub.2 O)Dry Mullen   gm/cm.sup.2                  1050     700-1200______________________________________ *MD -- machine direction; CD -- cross direction
A sheet of the foregoing type is placed together with the fabrics to be dry cleaned in a flexible containment bag having dimensions as noted hereinabove and sealing means. In a preferred mode, the containment bag is constructed of thermal resistant film in order to provide resistance to hot spots (350° F.-400° F.; 177° C. to 204° C.) which can develop in some dryers. This avoids internal self-sealing and external surface deformation of the bag, thereby allowing the bag to be re-used.
In addition to thermally stable "nylon-only" bags, the containment bags herein can also be prepared using sheets of co-extruded nylon and/or polyester or nylon and/or polyester outer and/or inner layers surrounding a less thermally suitable inner core such as polypropylene. In an alternate mode, a bag is constructed using a nonwoven outer "shell" comprising a heat-resistant material such as nylon or polyethylene terephthalate and an inner sheet of a polymer which provides a vapor barrier. The non-woven outer shell protects the bag from melting and provides an improved tactile impression to the user. Whatever the construction, the objective is to protect the bag's integrity under conditions of thermal stress at temperatures up to at least about 400°-500° F. (204° C. to 260° C.). Nylon VELCRO®-type, ZIP-LOK®-type and/or zipper-type closures can be used to seal the bag, in-use.
Besides the optional nonionic surfactants used in the cleaning compositions herein, which are preferably C8 -C18 ethoxylated (E01-15) alcohols or the corresponding ethoxylated alkyl phenols, the compositions contain enzymes to further enhance cleaning performance. Lipases, amylases and protease enzymes, or mixtures thereof, can be used. If used, such enzymes will typically comprise from about 0.001% to about 5%, preferably from about 0.01% to about 1%, by weight, of the composition. Commercial detersive enzymes such as LIPOLASE, ESPERASE, ALCALASE, SAVINASE and TERMAMYL (all ex. NOVO) and MAXATASE and RAPIDASE (ex. International Bio-Synthesis, Inc.) can be used.
1. A method for cleaning fabrics, comprising applying to said fabrics a dry cleaning and spot removal composition, comprising:
(a) from about 0.01%, to about 0.20%, by weight, of a polyacrylate emulsifier;
(b) from about 1% to about 30%, by weight, of an organic cleaning solvent selected from the group consisting of the monomethyl-, monoethyl-, monopropyl-, and monobutyl-ethers of propoxylated propanol, and mixtures thereof;
(c) optionally, from about 0.05% to about 5%, by weight, of detersive surfactant selected from the group consisting of amine oxides, alkyl ethoxy sulfates, ethoxylated alcohols, and mixtures thereof surfactants; and
(d) at least about 60%, by weight water.
2. A method according to claim 1 wherein the polyacrylate emulsifier has a molecular weight in the range from about 100,000 to about 10,000,000.
3. A method according to claim 1 wherein the alkyl ethoxy sulfate surfactant is in its magnesium salt form.
4. A method according to claim 1 wherein said composition additionally comprises at least about 0.05%, by weight, of 1,2-octanediol.
US08544373 1995-03-30 1995-10-17 Polyacrylate emulsified water/solvent fabric cleaning compositions and methods of using same Expired - Fee Related US5591236A (en)
US41356095 true 1995-03-30 1995-03-30
US08544373 US5591236A (en) 1995-03-30 1995-10-17 Polyacrylate emulsified water/solvent fabric cleaning compositions and methods of using same
EP19960907171 EP0817882A1 (en) 1995-03-30 1996-03-04 Emulsified water/solvent cleaning compositions
CA 2216850 CA2216850A1 (en) 1995-03-30 1996-03-04 Emulsified water/solvent cleaning compositions
PCT/US1996/002902 WO1996030583A1 (en) 1995-03-30 1996-03-04 Emulsified water/solvent cleaning compositions
JP52941196A JPH11502888A (en) 1995-03-30 1996-03-04 Emulsified water / solvent cleaning composition
US41356095 Continuation-In-Part 1995-03-30 1995-03-30
US5591236A true US5591236A (en) 1997-01-07
ID=27022227
US08544373 Expired - Fee Related US5591236A (en) 1995-03-30 1995-10-17 Polyacrylate emulsified water/solvent fabric cleaning compositions and methods of using same
US (1) US5591236A (en)
JP (1) JPH11502888A (en)
CA (1) CA2216850A1 (en)
EP (1) EP0817882A1 (en)
WO (1) WO1996030583A1 (en)
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