Abstract:
A method of washing fabric articles in a continuous batch tunnel washer, comprises providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior. Fabric articles are moved from the intake to the discharge and through the modules in sequence. One or more modules define a wash zone for washing the fabric articles. One or more of the modules are rinse modules that have a perforated scoop. Some of the modules do not have a perforated scoop. After washing fabric articles, the fabric articles can be rinsed by counter flowing liquid in the washer interior at spaced apart modules and along a flow path that is generally opposite the direction of travel of the fabric articles from the intake to the discharge. Velocity rinsing can also replace a continuous counter flow. To improve rinsing and washing, one or more modules may be dilution zone modules, which receives a flow stream from the rinsing modules via a booster pump. A dilution zone module or drum preferably has a perforated scoop to drain the free water when transferring to the next dilution zone module or drum. Drums or modules without shells (carryover modules) have scoops for fabric article (e.g., linen) transfer with no perforations. Thus, the linen and all water go to the next downstream drum at the carryover modules.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/339,457, filed 20 May 2016, which is hereby incorporated herein by reference. 
         [0002]    Priority of U.S. Provisional Patent Application Ser. No. 62/339,457, filed 20 May 2016, 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 
     1. Field of the Invention 
       [0005]    The present invention relates to washing machines. More particularly, the present invention relates to an improved washing machine and method, the washing machine having multiple modules and wherein some modules have perforated scoops, some modules have outer shells and wherein some modules do not have scoops and/or shells. 
       2. General Background 
       [0006]    Patents have issued for large commercial type washing machines typically referred to “tunnel washers” or “tunnel batch washers” or “continuous batch tunnel washers”. Examples can be seen in U.S. Pat. Nos. 4,236,393; 9,127,389 (US Patent Application Publication No. 2010/0269267); and U.S. Pat. No. 9,580,854 (US Patent Application Publication No. 2013/0291314), each of which is hereby incorporated herein by reference. Such tunnel washers have multiple modules. In U.S. Pat. No. 4,236,393, each module is a cylindrical casing having a peripheral wall with perforated areas. The &#39;393 patent provides a continuous tunnel batch washer of modular construction with the number of modules varying depending upon installational requirements. Each module includes a drum rotatably supported and driven to oscillate in a predetermined manner during the washing cycle and to rotate unidirectionally during transfer of the load from one module to a succeeding module with a chute or trough arrangement extending between the modules for transferring the wash load from one module to a next successive module. The drum in each module is roller supported and chain driven from a common shaft with a plurality of independent motors driving the shaft by a belt drive with each module including a reduction gear driven from the shaft and having an output driving the sprocket chain for the oscillatable and rotatable drum. A programmed control device provides continuous control of each batch of articles being laundered as they progress to the successive module in the machine. In the &#39;393 patent, all scoops are perforated. Perforated transfer scoops are also discussed in the above listed U.S. Pat. Nos. 9,127,389 and 9,580,854. 
         [0007]    Some prior art washing machines are based on counter flow high velocity rinsing after standing bath washing (e.g., see U.S. Pat. No. 8,336,144 (US Patent Application Publication No. 2011/0225741), incorporated herein by reference). The counter flow starts in the last module, or typically the module before the last module, and flows at high velocity sequentially through each upstream module and finally exiting upstream (e.g., at the first module). This requires that all modules have an outer shell for the water to flow in and out. Additionally, there must be a barrier in the lower part of the shell to separate the water between drums. Each module can be a dual use module. 
         [0008]    Another prior art tunnel washer type machine is a bottom transfer machine where the drum holding the fabric articles (linen) is also the drum holding the water. There is no outer shell. When the standing bath is finished, the linen (or fabric articles to be cleaned) and all the water is transferred to the next attached module or drum. In the middle of the machine, there are two or more drums that are fitted with an outer shell. The outer shell has a drain valve and water refill valve (i.e. a dilution zone). To achieve the dilution function, the drum is drained and refilled at least once. All of the fabric articles (e.g., linen) and water are transferred to the next contiguous module or drum which also has an outer shell. The water and fabric articles (e.g., linen) can be heated to between about 40 degrees and 80 degrees Celsius. Rinsing is done with counterflow in two or more downstream modules at low velocity typically about 20 to 50 gallons per minute or “GPM” (about 75.70 to 189.27 liters per minute) on a continuous basis. All modules can be single function modules. 
         [0009]    The following table lists possibly relevant patents (each hereby incorporated herein by reference) directed to other washing machines including some tunnel washing machines. 
         [0000]    
       
         
               
               
               
             
           
               
                   
               
               
                 PATENT 
                   
                 ISSUE DATE 
               
               
                 NO. 
                 TITLE 
                 MM/DD/YYYY 
               
               
                   
               
             
             
               
                 9,580,854 
                 CONTINUOUS BATCH TUNNEL WASHER AND 
                 02/28/2017 
               
               
                   
                 METHOD 
                   
               
               
                 9,200,398 
                 CONTINUOUS BATCH TUNNEL WASHER AND 
                 12/01/2015 
               
               
                   
                 METHOD 
                   
               
               
                 9,127,389 
                 CONTINUOUS BATCH TUNNEL WASHER AND 
                 09/08/2015 
               
               
                   
                 METHOD 
                   
               
               
                 8,635,890 
                 PEDESTAL WASHING MACHINE 
                 01/28/2014 
               
               
                 8,370,981 
                 INTEGRATED CONTINUOUS BATCH TUNNEL 
                 02/12/2013 
               
               
                   
                 WASHER 
                   
               
               
                 8,336,144  
                 CONTINUOUS BATCH TUNNEL WASHER AND 
                 12/25/2012 
               
               
                   
                 METHOD 
                   
               
               
                 7,971,302  
                 INTEGRATED CONTINUOUS BATCH TUNNEL 
                 07/05/2011 
               
               
                   
                 WASHER 
                   
               
               
                 7,197,901 
                 WASHING MACHINE 
                 04/03/2007 
               
               
                 6,796,150  
                 INSTALLATION FOR THE WET-TREATMENT OF 
                 09/28/2004 
               
               
                   
                 LAUNDRY, AND SEAL FOR SUCH AN INSTALLATION 
                   
               
               
                 6,238,516 
                 SYSTEM AND METHOD FOR CLEANING, 
                 05/29/2001 
               
               
                   
                 PROCESSING, AND RECYCLING MATERIALS 
                   
               
               
                 5,564,595 
                 CHEMICAL DISPENSING SYSTEM 
                 10/15/1996 
               
               
                 5,564,292 
                 WASHING MACHINE 
                 10/15/1996 
               
               
                 5,454,237 
                 CONTINUOUS BATCH TYPE WASHING MACHINE 
                 10/03/1995 
               
               
                 5,392,480 
                 WASHING METHOD BY A CONTINUOUS WASHING 
                 02/28/1995 
               
               
                   
                 MACHINE 
                   
               
               
                 5,211,039  
                 CONTINUOUS BATCH TYPE WASHING MACHINE 
                 05/18/1993 
               
               
                 4,984,438  
                 PROCESSING OF DENIM GARMENTS 
                 01/15/1991 
               
               
                 4,829,792  
                 DOUBLE DRUM BATCH WASHING MACHINE 
                 05/16/1989 
               
               
                 4,522,046  
                 CONTINUOUS BATCH LAUNDRY SYSTEM 
                 06/11/1985 
               
               
                 4,485,509  
                 CONTINUOUS BATCH TYPE WASHING MACHINE 
                 12/04/1984 
               
               
                   
                 AND METHOD FOR OPERATING SAME 
                   
               
               
                 4,363,090  
                 PROCESS CONTROL METHOD AND APPARATUS 
                 12/07/1982 
               
               
                 4,236,393  
                 CONTINUOUS TUNNEL BATCH WASHER 
                 12/02/1980 
               
               
                   
               
             
          
         
       
     
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    The apparatus and method of the present invention improves the washing and rinsing functions of a bottom transfer type machine. The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, and a plurality of modules or drums that segment the interior. Fabric articles are moved from the intake to the discharge and through the modules in sequence. One or more modules define a wash zone for washing the fabric articles. One or more of the modules are rinse modules that have a perforated scoop, and some of the modules do not have a perforated scoop. A washing chemical may be added to one or more of the modules. After washing fabric articles, the fabric articles can be rinsed by counter flowing liquid in the washer interior at multiple locations along a flow path that is generally opposite the direction of travel of the fabric articles from the intake to the discharge. 
         [0011]    With the present invention, high velocity rinsing can replace a continuous counterflow. Because of the efficiency of the high velocity (e.g., 80 to 180 GPM (302.83 to 681.37 liters per minute)), fewer drums or modules are required for the same level of dilution. In some embodiments, there are a plurality of rinsing modules or rinsing drums. The rinsing modules or drums preferably have perforated scoops and outer shells to improve rinsing efficiency. In one embodiment of the apparatus of the present invention, only one rinsing module or drum is required. 
         [0012]    To improve rinsing and washing, one or more modules may be dilution zone modules, which receive a flow stream from rinsing modules preferably via a booster pump. This dilution zone module or drum preferably has a perforated scoop to drain the free water when transferring to the next dilution zone module or drum. Drums or modules without shells (as shown in the drawings) preferably have scoops for fabric article (e.g., linen) transfer with no perforations. These are carryover modules. Thus, the linen and all water preferably go to the next downstream module or drum. 
         [0013]    The improvements of the present invention include a much lower manufacturing cost, fewer modules or drums, and improved washing and rinsing functions. 
         [0014]    The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. The fabric articles can be moved from the intake to the modules and then to the discharge in sequence. One or more of the modules can have a perforated scoop. In one embodiment, the present invention includes not counter flowing a rinsing liquid in the washer interior for a selected time interval. In one embodiment, counter flowing a rinsing liquid can occur along a flow path that is generally opposite the direction of travel of the fabric articles. In one embodiment, boosting the pressure of the counter flowing rinsing liquid occurs with a booster pump at one or more positions spaced preferably in between the intake and the discharge. 
         [0015]    In one embodiment, multiple booster pumps can be provided, each pump boosting counter flowing rinsing liquid flow rate preferably at a different one of said modules. 
         [0016]    In one embodiment, there can be multiple said modules preferably with perforated scoops. 
         [0017]    In one embodiment, the booster pumps can be spaced apart preferably by more than one module. 
         [0018]    In one embodiment, the booster pump preferably discharges liquid into a module that has an outer shell. 
         [0019]    In one embodiment, the booster pumps preferably each discharge liquid into a module that does not have a perforated scoop. 
         [0020]    In one embodiment, flow can be substantially halted for a time period that is preferably less than about five minutes. 
         [0021]    In one embodiment, flow can be substantially halted for a time period that is preferably less than about three minutes. 
         [0022]    In one embodiment, flow can be substantially halted for a time period that is preferably less than about two minutes. 
         [0023]    In one embodiment, flow can be substantially halted for a time period that is preferably between about twenty and one hundred twenty (20-120) seconds. 
         [0024]    The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The fabric articles can be moved preferably from the intake to the discharge. Washing chemical can preferably be added to the modules. After a selected time interval, counter flowing liquid can occur in the washer interior preferably along a flow path that is generally opposite the direction of travel of the fabric articles. Counter flowing water through the modules preferably effects a rinse of the fabric articles. Some of the modules can have an outer shell and some of the modules do not have an outer shell. 
         [0025]    The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, and a plurality of modules that segment the interior. The fabric articles can be moved preferably from the intake to the discharge and through the modules in sequence. A washing chemical can preferably be added to the modules. The fabric articles can then be washed. The fabric articles can be rinsed preferably by counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles. One or more of the modules can be rinse modules that preferably have a perforated scoop. In one embodiment, some of the modules do not have a perforated scoop. 
         [0026]    The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising providing a continuous batch tunnel washer preferably having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. The fabric articles can be moved preferably from the intake to the modules and then to the discharge in sequence. One or more of the modules can have a perforated scoop and one or more of the modules preferably has an outer shell. In one embodiment, one or more of the modules does not have a perforated scoop. In one embodiment, counter flowing a rinsing liquid can occur along a flow path that is generally opposite the direction of travel of the fabric articles. In one embodiment, the pressure of the counter flowing rinsing liquid can be boosted preferably with a booster pump at one or more positions spaced in between the intake and the discharge. 
         [0027]    In one embodiment, there can be multiple of the modules with perforated scoops. 
         [0028]    In one embodiment, the booster pump can discharge liquid into a module that preferably has an outer shell. 
         [0029]    In one embodiment, the booster pump can discharge liquid into a module that preferably does not have a perforated scoop. 
         [0030]    In one embodiment, flow can be substantially halted for a time period. 
         [0031]    In one embodiment, flow can be substantially halted for a time period that is preferably less than about three minutes. 
         [0032]    In one embodiment, flow can be substantially halted for a time period that is preferably less than about two minutes. 
         [0033]    In one embodiment, flow can be substantially halted for a time period that is preferably between about twenty and one hundred twenty (20-120) seconds. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0034]    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: 
           [0035]      FIGS. 1A-1E  illustrate operation of a top transfer tunnel washer; 
           [0036]      FIG. 2  is a schematic diagram view of a preferred embodiment of the apparatus of the present invention showing a nine-module apparatus; 
           [0037]      FIG. 3  is a schematic diagram view of a preferred embodiment of the apparatus of the present invention showing a twelve-module apparatus; 
           [0038]      FIG. 4  is a schematic diagram view of a preferred embodiment of the apparatus of the present invention showing a seven-module apparatus; 
           [0039]      FIG. 5  is a schematic diagram view of a preferred embodiment of the apparatus of the present invention showing a twelve-module apparatus; 
           [0040]      FIG. 6  is a schematic diagram view of a preferred embodiment of the apparatus of the present invention showing a sixteen-module apparatus; 
           [0041]      FIG. 7  is a partial perspective view of a preferred embodiment of the apparatus of the present invention; and 
           [0042]      FIG. 8  is a partial perspective view of a preferred embodiment of the apparatus of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0043]      FIGS. 1A-1E  illustrate operation of a top transfer tunnel washer  111 . In  FIG. 1A , the initial step shows a module  121  before a transfer of fabric articles, linens or goods  122  to the next module Immediately before the tunnel washer  111  transfers all the batches of goods forward to the next module, the goods  122  are preferably submerged in the bath liquor  123  at the bottom of the module  121 . The tunnel washer  111  imparts mechanical action on the goods preferably by reversing the cylinder  126  through an arc of approximately ¾ of a rotation, as indicated by arrow  124 . For this phase of the cycle, the scoop  125 , which is preferably part of and rotates with the cylinder  126 , preferably does not interact with the goods  122 . 
         [0044]    After the programmed number of reversals, the tunnel washer cylinder  126  preferably makes a complete rotation counter-clockwise as seen in  FIG. 1B  and indicated by arrow  127 . When the scoop  125  crosses the bottom of the tunnel washer  111 , it preferably collects the goods  122  and bath liquor  123 . 
         [0045]    The counter-clockwise rotation preferably continues, as seen in  FIG. 1C  and indicated by arrow  128 , which preferably lifts the goods  122  off the bottom of the tunnel washer  111 . If the scoop  125  is perforated, the bath liquor  123  preferably drains back into the original module  121 ; otherwise, much of the bath liquor  123  is lifted along with the goods  122 . 
         [0046]    In  FIG. 1D , the shape of the scoop  125  preferably causes the goods  122  to slide forward, preferably toward the next module  129  in the tunnel washer  111 . If the scoop  125  is not perforated, a significant amount of bath liquor  123  is preferably also transferred forward in the tunnel washer. 
         [0047]    As the scoop  125  rotates preferably to near the top of the tunnel washer ( FIG. 1E ), the rotation preferably pauses momentarily, as indicated by circular line  120 , to let the goods  122  slide into the next module  129 . After this pause  120 , the tunnel washer  111  preferably resumes operating as shown and described in  FIG. 1A . 
         [0048]      FIGS. 2-3  show a preferred embodiment of the apparatus of the present invention, designated generally by the numeral  15 . Washing machine  15  has a plurality of modules or drums. In  FIG. 2 , the washing machine  15  has nine modules or drums  1 ,  2 ,  3 ,  4 ,  5 ,  6 ,  7 ,  8  and  9 . In  FIG. 3 , washing machine  15  has twelve modules or drums  1 ,  2 ,  3 ,  4 ,  5 ,  6 ,  7 ,  8 ,  9 ,  10 ,  11  and  12 . Machine  15  has end portions  13 ,  14 . End portion  13  is an inlet end portion or inlet  13  where dirty or soiled fabric articles (e.g., linen articles or goods) are added at hopper  16 . 
         [0049]    A fresh water source  17  enables fresh water to be added to tank  21  via flow line  18 . Flow line  18  can have flow meter  19  and valve  20 . Pump  22  enables a discharge of water from tank  21  via flow line  23 . Flow line  23  can be provided with valve  24  and flow meter  25 . Flow line  30  joins to flow line  18  at tee fitting  26 . Line  30  has tee fittings at  27 ,  28 ,  29 . Flow line  30  can have valve  31 . In  FIG. 2 , flow line  30  discharges into module or drum  9 . In  FIG. 3 , flow line  30  discharges into module  12 . 
         [0050]    Flow line  32  connects to flow line  30  at tee fitting  27 . Flow line  32  can have valve  35  and flow meter  36 . Flow line  32  discharges into hopper  16 . Flow line  33  connects to flow line  30  at tee fitting  28 . Flow line  33  can have valve  37 . Flow line  34  connects to flow line  30  at tee fitting  29 . Flow line  34  can have valve  38 . In  FIG. 2 , flow line  33  discharges into module  4 . In  FIG. 3 , flow line  33  discharges into module  5 . Each of the modules or drums  1 ,  2 ,  3 ,  4 ,  5 ,  6 ,  7 ,  8 ,  9  in  FIG. 2  and also modules  10 - 12  in  FIG. 3  can have a chemical injector  53  for adding selected chemicals such as detergent and bleach. Steam inlets can be provided at  66 . For example, in  FIG. 2  there are steam inlets  66  at modules  4 - 5  and  9 . In  FIG. 3 , there are steam inlets  66  at modules  5 - 6  and  12 . In a preferred embodiment of the present invention, there would be an outer shell  91  where there is steam inlet  66 . In  FIG. 2 , module  1  has an outer shell as do modules  4 - 5  and  8 . In  FIG. 2 , module  8  or modules  8  and  9  can have an outer shell  91 . In  FIG. 3 , there is an outer shell  91  for module  1 , modules  5 - 6  and for modules  10 ,  11 , and  12 . 
         [0051]    Extracted water tank  54  receives water that is discharged from final module  9  (for  FIG. 2 ) or module  12  (for  FIG. 3 ). Extracted water tank  54  receives extracted water from an extractor (not shown) such as a centrifuge, press or the like. Such extractors are known and commercially available. Fabric articles containing water exit final module  9  or  12  and transfer to an extractor where water is extracted. Extracted water from final module  9  or  12  is transmitted via flow line  55  to extracted water tank  54 . Line  55  can have valve  56 . Water can be transmitted from extracted water tank  54  to tank  21  via flow line  39 . Pump  57  can be provided in flow line  39 . Flow line  39  can have valve  58  which can be placed next to tank  21 . 
         [0052]    At junction or cross fitting  40 , flow can be selected to go to sewer  49  via line  47  and valve  48 . Flow can selectively go to line  43  or  44  from junction or cross fitting  40 . Line  43  has valve  41  and pump  45 . Line  43  transmits water to tank  21 . Line  44  has valve  42  and pump  46 . Line  44  also has a valve  51  and meter  52 . Line  44  transmits water from junction or cross fitting  40  to module  5  in  FIG. 2 . This water counterflows from module  5  to module  4 . 
         [0053]    In  FIG. 2 , module  8  is a rinse module that receives water flow from line  23 . That rinse water then flows to junction or cross fitting  40 . In  FIG. 2 , the modules  1 ,  4 - 5  and  8  are modules with outer shells  91 . In  FIG. 2 , module  8  or modules  8  and  9  can have an outer shell  91 . In  FIG. 3 , the modules  1 ,  5 - 6  and  10 - 12  are modules with outer shells  91 . Module  9  could optionally have a shell  91  in  FIG. 2 . In  FIG. 2 , modules  2 ,  3 ,  6  and  7  do not have an outer shell  91 . In  FIG. 2 , modules  4  and  8  preferably have perforated scoops. In  FIG. 2 , modules  1 - 3 ,  5 - 7  and  9  preferably do not have perforated scoops. Modules having shells and/or perforated scoops can be seen in  FIGS. 7-8 . 
         [0054]    Recirculation flow lines  59 ,  60  transmit flow from module  1  to hopper  16 . Pump  61  receives flow from line  59  and discharges flow to line  60 . In  FIG. 2 , module  8  is preferably a rinsing drum with perforated scoop. Rinse water from line  23  receives water from tank  21  and directs that water to and through module  8 , then to junction or cross fitting  40 . Tank  21  can optionally be replenished by fresh water source  17 . Tank  21  can optionally be replenished by recirculated rinse water via flow line  43 . Tank  21  can optionally receive extracted water via flow lines  55 ,  39  and extracted water tank  54 . Line  39  can have tee fitting  64  and valve  62 . Flow line  65  with valve  63  enables discharge of line  39  to sewer  49 . Flow lines  33  and  34  enable addition of water to modules  4 ,  5  respectively in  FIG. 2  and in modules  5 ,  6  respectively in  FIG. 3 . Flow line  44  enables addition of water to module  5  in  FIG. 2  (module  6  in  FIG. 3 ). 
         [0055]    In  FIG. 3 , flow lines  33  and  34  enable addition of water to modules  5 - 6  respectively. Flow line  44  enables addition of water to module  6 . In  FIG. 3 , modules  1 ,  5 - 6  and  10 - 12  can be modules with outer shells  91 . Outer shells  91  are fixed and do not rotate. In  FIG. 3 , modules  2 - 4 , and  7 - 9  can be modules with no outer shell  91 . In  FIG. 3 , modules  1 ,  5  and  10 - 11  can be modules that each have a perforated scoop as seen in  FIG. 7 . In  FIG. 3 , modules  2 - 4  and  7 - 9  can be modules each preferably having no perforated scoop. As seen in  FIG. 3 , it is a similar arrangement to  FIG. 2  but with three additional modules  10 ,  11 , and  12 . Overflow drains  67  to sewer  49  can be provided in  FIG. 2  at modules  1  and  9  and at modules  1  and  12  for  FIG. 3 . Line  68  enables counterflow from module  5  to module  4  in  FIG. 2 . Lines  69  enable counterflow from module  6  to module  5  and from module  11  to module  10  in  FIG. 3 . Drains  72  can be provided at modules  1 ,  4  and  5  in  FIG. 2  (modules  1 ,  5 , and  6  in  FIG. 3 ). 
         [0056]      FIGS. 4, 5 and 6  show another embodiment of the apparatus of the present invention.  FIGS. 4, 5, and 6  are similar in that some modules have outer shells, some modules have perforated scoops, some modules have no outer shell (and are thus less expensive to construct), and some modules have scoops that are not perforated. 
         [0057]    In  FIGS. 4, 5, and 6 , high speed, high flow counterflow rinsing is combined with lower cost modules that do not require an outer shell to provide better dilution than prior art washers that have all modules with no shells. 
         [0058]      FIG. 4  illustrates a seven (7) module embodiment of the present invention designated by the number  80 . In  FIG. 4 , module  1  defines a pre-wash and wash zone. Module  2  is a conveyor module. Module  3  is a drain plus alkali. Module  4  is for addition of chemicals (e.g., dilution plus bleach) and for temperature elevation (e.g., using steam). Modules  3  and  4  also have an outer shell  91 . Module  5  is a carryover module. Modules  6  and  7  each have shells  91 . Modules  6 - 7  provide ph and softener. 
         [0059]    In the seven (7) module tunnel washer  80  of  FIG. 4 , the numeral  73  designates an intake end portion while the numeral  74  designates a discharge end portion. As with  FIGS. 2-3 , washer  80  has an intake chute or hopper  16 . An extractor  75  receives fabric articles or linens from module  7  at discharge end portion  74 . Tank  76  receives extracted water from extractor  75  via flow line  77 . 
         [0060]    Modules  1 ,  3 - 4  and  6 - 7  have outer shells  91 . Modules  2  and  5  do not have outer shells  91 . An outer shell  91  enables addition of water, chemicals, bleach, and steam injection. The outer shells  91  are stationary. Those modules having a shell typically have a perforated scoop. Those modules with no shell do not have a perforated scoop. 
         [0061]    Pump  78  transmits fluid/water via flow line  79  from tank  81  to module  6 . Fluid/water in module  6  discharges via flow line  82  to module  4  and then counterflows to module  3  via counterflow line  83 . Flow line  82  can have a pump  84 . From module  3 , fluid/water flows via flow line  85  to module  1 . Flow line  85  can have pump  88 . Modules  1  and  2  can have drains or drain lines  87  to sewer. Module  1  is a prewash and wash module. Module  2  is a carryover module. A flow line  89  can be provided for transmitting water/fluid from module  1  to hopper  16 . Flow line  89  can be provided with a pump  92 . 
         [0062]      FIG. 5  is a diagram of a twelve (12) module tunnel washer (e.g., top transfer tunnel washer), designated generally by the numeral  200 .  FIG. 5  is similar to  FIG. 4  but adds modules without outside shells downstream of module  1 . In  FIG. 5 , modules  2 ,  3  and  4  are modules without outside shells and without a perforated scoop. In  FIG. 5 , module  1  is a pre-wash module. Modules  2 ,  3 , and  4  are carryover modules. Module  5  is a dilution (drain) plus alkali (or other chemical) addition modules. Module  6  is a dilution plus bleach (or other chemical) addition module. Modules  1 ,  5  and  6  have outer shells  91 . Modules  7 ,  8  and  9  are carryover modules. Modules  10  and  11  are rinse modules having outer shells  91 . Module  12  is a ph adjustment and softener (or other chemical) addition module. 
         [0063]    In  FIG. 5 , tanks are provided at  76 ,  81 . Tank  76  is an extracted water tank. Tank  81  is a tank using fluid/water for counterflow at a high flow rate (e.g., 400 cubic feet per minute (11.33 cubic meters per minute)). In  FIG. 5 , counterflow is from module  11  to module  10  to module  6  to module  5  to module  1  using flow lines  83 ,  82  and  85 . Flow line  79  can have a pump  78 . Flow line  82  can have a pump  84 . Flow line  85  can have a pump  88 . Counterflow lines  83  are provided between modules  6  and  5  (for counterflow from module  6  to module  5 ) for counterflow from module  4  to module  3  and from module  3  to module  2 . A flow line  89  can be provided for transmitting water/fluid from module  1  to hopper  16 . Flow line  89  can be provided with a pump  92 . 
         [0064]      FIG. 6  shows a sixteen (16) module apparatus, designated generally by the numeral  300 .  FIG. 6  is similar to  FIG. 5  but with additional modules  96 ,  97 ,  98 ,  99 . Module  1  is a prewash module. Module  2  is a wash module. Modules  1  and  2  have outer shells  91 . Modules  3 ,  4 , and  5  are carry over modules. 
         [0065]    Module  6  is a dilution (drain) plus chemical addition (e.g., alkali) module. Module  7  is a rinse module. Module  8  is a dilution plus chemical addition (e.g., bleach) module. Modules  6 ,  7  and  8  have outer shells  91  and perforated scoops. Modules  9 ,  10 ,  11 ,  12  are carry over modules with no perforated scoops. Modules  96 - 98  are rinse modules. Module  99  is a ph adjustment and chemical addition (e.g., softener) module. Otherwise,  FIG. 6  operates as  FIGS. 4 and 5  with counterflow flow lines  82 ,  83 ,  85  and fluid holding tanks  76 ,  81  as shown in  FIG. 6 . 
         [0066]    The present invention improves washing and rinsing functions as pulse flow velocity rinsing (e.g., flow lines  79 ,  82  and  85 ) replaces continuous counterflow. Because of the efficiency of the high velocity (e.g., about 80 to 180 GPM (about 302.83 to 681.37 liters per minute) in a preferred embodiment of the present invention), fewer modules or drums are required for the same level of dilution. The rinsing modules or drums  90  (see  FIG. 7 , i.e., modules  4 ,  5  and  8  in  FIG. 2  and modules  1 ,  5 - 6 ,  10 - 12  in  FIG. 3 ) preferably have scoops  94  with perforations  95  and an outer shell  91  to improve rinsing efficiency. Inner shell  93  and scoop  94  rotate together. In most applications, preferably only one rinsing drum or module  90  is required. Each module or drum  90  preferably has a scoop  94  with perforations at  95  and a perforated inner wall at  93  to drain the free water when transferring to the next module or drum. 
         [0067]    Drums or modules without shells are carryover modules  101  (see  FIG. 8 ) and preferably have scoops (for linen transfer) with no perforations  103 . Thus, the linen (fabric articles) and all water preferably goes to the next downstream drum or module; carryover modules  101  have no outer shell  91  but have inner shell/inner wall  102  with no perforations and scoop  103  that rotate together. The present invention has much lower manufacturing cost. Fewer drums results in lower cost with improved washing and rinsing. 
         [0068]    The following is a list of parts and materials suitable for use in the present invention: 
       PARTS LIST 
       [0069]      
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 Parts Number 
                 Description 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 1 
                 module/drum 
               
               
                   
                 2 
                 module/drum 
               
               
                   
                 3 
                 module/drum 
               
               
                   
                 4 
                 module/drum 
               
               
                   
                 5 
                 module/drum 
               
               
                   
                 6 
                 module/drum 
               
               
                   
                 7 
                 module/drum 
               
               
                   
                 8 
                 module/drum 
               
               
                   
                 9 
                 module/drum 
               
               
                   
                 10 
                 module/drum 
               
               
                   
                 11 
                 module/drum 
               
               
                   
                 12 
                 module/drum 
               
               
                   
                 13 
                 inlet/inlet end portion 
               
               
                   
                 14 
                 outlet/outlet end portion 
               
               
                   
                 15 
                 washing machine apparatus/tunnel washer 
               
               
                   
                 16 
                 hopper 
               
               
                   
                 17 
                 fresh water source 
               
               
                   
                 18 
                 flow line 
               
               
                   
                 19 
                 flow meter 
               
               
                   
                 20 
                 valve 
               
               
                   
                 21 
                 tank 
               
               
                   
                 22 
                 pump 
               
               
                   
                 23 
                 flow line 
               
               
                   
                 24 
                 valve 
               
               
                   
                 25 
                 flow meter 
               
               
                   
                 26 
                 tee fitting 
               
               
                   
                 27 
                 tee fitting 
               
               
                   
                 28 
                 tee fitting 
               
               
                   
                 29 
                 tee fitting 
               
               
                   
                 30 
                 flow line 
               
               
                   
                 31 
                 valve 
               
               
                   
                 32 
                 flow line 
               
               
                   
                 33 
                 flow line 
               
               
                   
                 34 
                 flow line 
               
               
                   
                 35 
                 valve 
               
               
                   
                 36 
                 flow meter 
               
               
                   
                 37 
                 valve 
               
               
                   
                 38 
                 valve 
               
               
                   
                 39 
                 flow line 
               
               
                   
                 40 
                 junction/cross fitting 
               
               
                   
                 41 
                 valve 
               
               
                   
                 42 
                 valve 
               
               
                   
                 43 
                 flow line 
               
               
                   
                 44 
                 flow line 
               
               
                   
                 45 
                 pump 
               
               
                   
                 46 
                 pump 
               
               
                   
                 47 
                 flow line 
               
               
                   
                 48 
                 valve 
               
               
                   
                 49 
                 sewer 
               
               
                   
                 51 
                 valve 
               
               
                   
                 52 
                 meter 
               
               
                   
                 53 
                 chemical injector 
               
               
                   
                 54 
                 extracted water tank 
               
               
                   
                 55 
                 flow line 
               
               
                   
                 56 
                 valve 
               
               
                   
                 57 
                 pump 
               
               
                   
                 58 
                 valve 
               
               
                   
                 59 
                 flow line 
               
               
                   
                 60 
                 flow line 
               
               
                   
                 61 
                 pump 
               
               
                   
                 62 
                 valve 
               
               
                   
                 63 
                 valve 
               
               
                   
                 64 
                 tee fitting 
               
               
                   
                 65 
                 flow line 
               
               
                   
                 66 
                 steam inlet 
               
               
                   
                 67 
                 overflow drain 
               
               
                   
                 68 
                 flow line 
               
               
                   
                 69 
                 flow line 
               
               
                   
                 70 
                 flow line 
               
               
                   
                 71 
                 booster pump 
               
               
                   
                 72 
                 drain/drain valve 
               
               
                   
                 73 
                 intake end portion 
               
               
                   
                 74 
                 discharge end portion 
               
               
                   
                 75 
                 extractor 
               
               
                   
                 76 
                 extracted water tank 
               
               
                   
                 77 
                 flow line 
               
               
                   
                 78 
                 pump 
               
               
                   
                 79 
                 flow line 
               
               
                   
                 80 
                 washing machine apparatus/tunnel washer 
               
               
                   
                 81 
                 tank 
               
               
                   
                 82 
                 flow line 
               
               
                   
                 83 
                 flow line 
               
               
                   
                 84 
                 pump 
               
               
                   
                 85 
                 flow line 
               
               
                   
                 87 
                 drain/drain line 
               
               
                   
                 88 
                 pump 
               
               
                   
                 89 
                 flow line 
               
               
                   
                 90 
                 module/drum 
               
               
                   
                 91 
                 outer shell 
               
               
                   
                 92 
                 pump 
               
               
                   
                 93 
                 perforated inner shell/inner wall 
               
               
                   
                 94 
                 scoop 
               
               
                   
                 95 
                 perforation 
               
               
                   
                 96 
                 module 
               
               
                   
                 97 
                 module 
               
               
                   
                 98 
                 module 
               
               
                   
                 99 
                 module 
               
               
                   
                 101 
                 carry over module 
               
               
                   
                 102 
                 inner shell/inner wall with no perforations 
               
               
                   
                 103 
                 scoop without perforation 
               
               
                   
                 111 
                 top transfer tunnel washer 
               
               
                   
                 120 
                 arrow 
               
               
                   
                 121 
                 module 
               
               
                   
                 122 
                 fabric articles/linens/goods 
               
               
                   
                 123 
                 bath liquor 
               
               
                   
                 124 
                 arrow 
               
               
                   
                 125 
                 scoop 
               
               
                   
                 126 
                 cylinder 
               
               
                   
                 127 
                 arrow 
               
               
                   
                 128 
                 arrow 
               
               
                   
                 129 
                 module 
               
               
                   
                 200 
                 washing machine apparatus/tunnel washer 
               
               
                   
                 300 
                 washing machine apparatus/tunnel washer 
               
               
                   
                   
               
             
          
         
       
     
         [0070]    All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
         [0071]    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.