US20070163094A1 - Fabric revitalizing method using mist - Google Patents

Abstract

A method of revitalizing a fabric comprises placing the fabric in a chamber; directing a mist into the chamber to wet the fabric with the mist; directing a flow of air into the chamber and out of the chamber; removing particulates from the flow of air out of the chamber; and removing the fluid from the fabric in the chamber to reduce fluid content to approximately 0% to 5% by weight of the fabric.

Description

CROSS-REFERENCE TO RELATED APPLICATION
• This application claims the benefit of U.S. Patent Application No. 60/755,194, filed Dec. 30, 2005.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The invention relates to a fabric revitalizing method using mist.
• 2. Description of the Related Art
• Conventional fabric cleaning methods for portable fabrics typically employ a liquid bath wash to clean clothing fabrics and other materials composed of textiles. A typical household washing machine and dryer arrangement is used for cleaning durable types of clothes that may contain water soluble stains and easily removable particulates. A dry cleaning process is used for those fabrics that are susceptible to changes, such as shrinkage or damage, during a regular wash process.
• Single wear usage of otherwise clean clothing typically results in the accumulation of small amounts of particulates, such as soils, and hairs, on the fabric surface, or the occasional relatively minor stain or odor that may become impregnated into the fabric. In this “not clean, not dirty” zone, one finds oneself confronted with the dilemma of either wearing the slightly soiled clothing article in limited situations where one's embarrassment is minimized or expending the time, cost, and energy of having the clothing article laundered or professionally treated to clean status prior to re-wear.
• Several prior art products have been developed that permit some degree of fabric cleaning removal of soils, particulates, and hairs from a worn yet not dirty (i.e., not clean, not dirty) clothing article. These products include specialty clothing brushes and adhesive-based rollers as a means to remove loosely bound particulates, soils, and hairs. Certain stain pretreatments permit removal of stain spots from clothing without having to subject the article to a complete cleaning process. Fabric deodorizing sprays facilitate masking or removal of odors from the clothing article.
• While some of these approaches do improve the overall appearance of the clothing article, they are limited typically to the treatment method employed. For example, while a clothing brush may be able to remove pet hairs from a sports coat, any odors that may derive from perfume or cigarette smoke will persist on the sports coat. Thus, there is currently a need to offer a more comprehensive approach to restoring clothing articles to their clean appearance.
SUMMARY OF THE INVENTION
• A method according to one embodiment of the invention of revitalizing a fabric comprises placing the fabric in a chamber; directing a mist into the chamber to wet the fabric with the mist; directing a flow of air into the chamber and out of the chamber; removing particulates from the flow of air out of the chamber; and removing the fluid from the fabric in the chamber to reduce fluid content to approximately 0% to 5% by weight of the fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
• In the drawings:
• FIG. 1 depicts an exemplary enclosure and user interface and control for a revitalization system according to one embodiment of the invention in which a revitalization chamber is formed by a horizontal rotatable drum.
• FIGS. 2A-2D depict alternative exemplary enclosures and revitalization chambers for the revitalization system.
• FIG. 3A depicts an exemplary enclosure for a stationary revitalization system that includes substantially horizontal support substrates for fabric.
• FIG. 3B depicts an exemplary enclosure for a stationary revitalization system that includes a cabinet having at least one horizontal drawer and substantially horizontal support substrates.
• FIG. 3C depicts an exemplary enclosure for a stationary revitalization system that includes a cabinet having a door and substantially horizontal support substrates.
• FIG. 3D depicts an exemplary enclosure for a stationary revitalization system that includes substantially vertical support substrates.
• FIG. 3E depicts an exemplary enclosure for a stationary revitalization system that includes a cabinet having at least one vertical drawer and substantially vertical support substrates.
• FIG. 3F depicts an exemplary enclosure for a stationary revitalization system that includes a cabinet having a door and substantially vertical support substrates.
• FIG. 4 depicts an exemplary revitalization chamber having a shape of a drum for a non-stationary revitalization system and heater control components of the revitalization system.
• FIG. 5A depicts exemplary textured substrate surfaces for lining a drum of a non-stationary revitalization system.
• FIG. 5B depicts alternative exemplary textured substrate surfaces for lining a drum of a non-stationary revitalization system.
• FIG. 5C depicts another alternative exemplary textured substrate surface for lining a drum of a non-stationary revitalization system, wherein the textured substrate surface is received within a recess in the drum.
• FIG. 5D depicts another alternative exemplary textured substrate surface for lining a drum of a non-stationary revitalization system, wherein the textured substrate surface can be attached to a baffle of the drum with first and second attachment means.
• FIG. 6A depicts an exemplary textured substrate surface including an inner fluid reservoir.
• FIG. 6B depicts an alternative exemplary textured substrate surface fluidly coupled to a fluid reservoir located in a baffle of the drum.
• FIGS. 7 and 8 depict exemplary air flow components of the revitalization system.
• FIG. 9A depicts a schematic view of the air flow through the revitalization system, wherein air flow through the revitalization chamber comprises recirculated air.
• FIG. 9B depicts a schematic view similar toFIG. 9A, wherein the air flow through the revitalization chamber comprises fresh, non-recirculated air.
• FIG. 10 depicts exemplary fluid removal system components of the revitalization system.
• FIGS. 11 and 12 depict exemplary particulate removal and recovery system components of the revitalization system.
• FIG. 13 depicts exemplary fluid delivery system components of the revitalization system.
• FIG. 14 depicts an exemplary nebulizer circuit and assembly for one embodiment of the fluid delivery system of the revitalization system.
• FIG. 15 depicts a perspective view the exemplary nebulizer assembly ofFIG. 14.
• FIG. 16 depicts an exploded view of the exemplary nebulizer assembly ofFIG. 14.
• FIG. 17 depicts an exploded view of the exemplary nebulizer assembly ofFIG. 14 and the revitalization chamber in the form of the drum.
• FIG. 18 depicts another exploded view of the exemplary nebulizer assembly ofFIG. 14.
• FIG. 19 depicts an exemplary nebulizer circuit and assembly for another embodiment of the fluid delivery system of the revitalization system.
• FIG. 20 depicts a schematic view of the exemplary nebulizer assembly ofFIG. 19 configured to deliver a plurality of fluids to the revitalization chamber.
• FIG. 21 depicts an exemplary embodiment of sensors of the revitalization system.
• FIG. 22 depicts an exemplary vacuum system of the revitalization system.
• FIG. 23 depicts an exemplary stain removal station of the revitalization system.
• FIG. 24 depicts another exemplary stain removal station of the revitalization system.
• FIG. 25A depicts another exemplary stain removal station of the revitalization system built into the enclosure and having a work surface shown in a retracted position.
• FIG. 25B depicts the exemplary stain removal station ofFIG. 25A with the work surface shown in an extended position.
• FIG. 25C depicts an exploded view of the exemplary stain removal station ofFIG. 25A.
• FIG. 25D depicts a rear view of the exemplary stain removal station ofFIG. 25A.
• FIGS. 26A and 26B depict an exemplary embodiment of modular construction of the revitalization system.
• FIG. 27 depicts an alternative exemplary embodiment of modular construction of the revitalization system.
• FIG. 28 depicts another alternative exemplary embodiment of modular construction of the revitalization system.
• FIG. 29 depicts a first exemplary embodiment of a dryer module for use with the revitalization system.
• FIG. 30 depicts a second exemplary embodiment of a dryer module for use with the revitalization system.
• FIG. 31 depicts a third exemplary embodiment of a dryer module for use with the revitalization system.
• FIG. 32 depicts a fourth exemplary embodiment of a dryer module for use with the revitalization system.
• FIG. 33 depicts a fifth exemplary embodiment of a dryer module for use with the revitalization system.
• FIG. 34 depicts an exemplary embodiment of an ironing module for use with the revitalization system.
• FIG. 35 depicts an exemplary embodiment of a sink module for use with the revitalization system.
• FIG. 36 depicts an exemplary embodiment of a storage module for use with the revitalization system.
• FIG. 37 depicts an exemplary embodiment of a shelf module for use with the revitalization system.
• FIG. 38 depicts an exemplary embodiment of operations and actions performed during a revitalization process.
• FIGS. 39A and 39B together depict an exemplary control flow chart for a user interface and control for the revitalization system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• Clothing refreshing is a process whereby the clothing article is restored to its clean condition without the requirement of subjecting the clothing article to a conventional full cleaning process of either washing/drying in the washer/the dryer or dry cleaning. A refreshed clothing article can have the appearance of a clean article that includes improved hand and a restored vibrant appearance. The invention of the instant disclosure provides a novel approach to clothing fabric refreshing/revitalization that can be accomplished economically and conveniently in the home setting. Additionally, a refreshed garment can have reduced wrinkles and/or minimal odors as compared to its pre-processed condition.
• By offering a refreshing process, the consumer can have reduced efforts in making their fabrics “like new again.” Additionally, by not having to place fabrics through a complete cleaning process (e.g., immersion or non-immersion wash followed by drying), fabrics will be less damaged and as a result may last longer.
• The present invention makes use of the discovery that dehydrated clothing fabrics are uniquely amenable to a fabric refreshing process that can result in many benefits, including the removal of loosely bound particulates, such as soils, stains, and odors, and wrinkles from the fabrics. In a system and method according to one embodiment of the invention, fabrics are initially dehydrated through a controlled heating process and the like, then subjected to aeration using a high flow rate air source to remove the loosened or dried particulates, such as soils and/or hairs, from the fabric, and finally subjected to a rehydration process. Fabric revitalization can leave clothing fabrics with a clean, vibrant appearance and improved hand or feel in addition to improved wrinkle and odor performance. Examples of fabric clothing articles include, but are not limited to, a hat, a scarf, a glove, a sweater, a blouse, a shirt, a pair of shorts, a dress, a sock, a pair of pants, a shoe, an undergarment, and a jacket. Furthermore, textile fabrics in other products, such as draperies, sheets, towels, pillows, and stuffed fabric articles (e.g., toys), can be revitalized with the disclosed system and method. The fabric can have any fabric composition, examples of which include, but are not limited to, cotton, polyester, wool, silk, nylon, rayon, rubber, plastic, leather, and blends thereof.
• Though the following disclosure is drawn to revitalization or refreshing of fabric materials, the system and method has broad utility for revitalizing a variety of non-fabric surfaces that contain particulates, such as stains, soils, or other foreign matter.
Components of the Fabric Revitalization System:Enclosure:
• Referring toFIG. 1, at least oneenclosure20 houses components necessary for accomplishing the fabric revitalization method on afabric load22. Though the invention contemplates the principles of modularity to achieve unification of the components necessary to carry out the disclosed process, the illustrated embodiment of the invention includes asingle enclosure20 for housing the system components as well as thefabric load22 within theenclosure20. Theenclosure20 and subassemblies thereof can be composed of suitable materials to withstand the various revitalization processes to which thefabric load22 is subjected. Anouter housing23 of theenclosure20 can be composed of aluminium, steel, or similar material. Theenclosure20 houses inner components or subassemblies that can be coated or composed of materials to withstand the various temperatures, pressures, and/or chemistries used during the method.
Chamber:
• Referring toFIGS. 2A-2D, the illustrated embodiment contains achamber26 inside theenclosure20. Thechamber26 provides an interior28 that can include asupport substrate30 for thefabric load22 during the refreshing process. Thechamber26 can include a substantiallyhorizontal support substrate30A (e.g., a shelf,FIG. 2A), a substantiallyvertical support substrate30B (e.g., a hanger,FIG. 2B), or a cylindrical support substrate, such as a cylindricalhorizontal chamber30C (e.g., an imperforate drum or perforated drum (basket),FIG. 2C) or a cylindricalvertical chamber30D (e.g., an imperforate drum or perforated drum (basket),FIG. 2D). When thesupport substrate30 comprises thehorizontal chamber30C or thevertical chamber30D, thesupport substrate30 forms thechamber26.
• For stationary refreshing systems, thesupport substrate30 can be the substantiallyhorizontal support substrate30A or substantiallyvertical support substrate30B. For non-stationary refreshing systems (e.g., dynamic or tumbling processes), thesupport substrate30 can be thecylindrical chamber30C in the shape of a drum or thecylindrical chamber30D in the shape of a basket, wherein both the drum and/or the basket have aninner surface24 defining an interior32 for placement of thefabric load22. The interior32 can be accessed through anopening31, which enables user access to the interior32, and theopening31 can be selectively closed by aclosure33, such as a hinged door.
• Referring toFIG. 3A, for the stationary refreshing systems that include the substantiallyhorizontal support substrates30A, a plurality of thehorizontal support substrates30A can be permanently mounted at designated heights in theinterior28 of thechamber26. Alternatively, a plurality of thehorizontal support substrates30A can be adjustable and installed in theinterior28 of thechamber26 at heights determined by the consumer. Each of thehorizontal support substrates30A can include pores oropenings34 to permit passage of air through thehorizontal support substrate30A. As will be explained in greater detail below, the passage of air through the pores oropenings34 permits the flow of air to contact thefabric load22 supported by thehorizontal support substrate30A. Optionally, thehorizontal support substrates30A can includefabric load restraints36A (e.g., pins, ties, clips, a secondary horizontal support substrate) to hold an article of thefabric load22 in place during the revitalization process.
• Referring toFIG. 3B, the stationary refreshing systems that include the substantiallyhorizontal support substrates30A can optionally include acabinet38 having at least onehorizontal drawer40A with at least one of thehorizontal support substrates30A in thehorizontal drawer40A or forming a portion of thehorizontal drawer40A. Thehorizontal drawer40A can be mounted on a horizontal slidingmechanism42 to enable thehorizontal drawer40A to slide open and closed for the purposes of placing articles of thefabric load22 into the interior28 of thechamber26. Thehorizontal drawer40A can establish a locked connection with theenclosure20, such as by using asuitable locking mechanism41A commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Optionally, individualhorizontal drawers40A can establish a locked connection with theenclosure20, such as by using thesuitable locking mechanism41A commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Alternatively, all of thehorizontal drawers40A can establish a uniform, simultaneous, locked connection with theenclosure20, such as by using thesuitable locking mechanism41A commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Optionally, each of thehorizontal drawers40A can include awindow44A to enable the consumer to view the revitalization process as it proceeds (see below).
• Referring toFIG. 3C, the stationary refreshing systems that include the substantiallyhorizontal support substrates30A can optionally include acabinet38 having at least onedoor46 that the consumer can open to access theinterior28 of thechamber26. Thedoor46 can be connected to theenclosure20 through the use of a suitable connector48 (e.g., hinge), which is designed to permit the consumer to open thedoor46 to thechamber26 in any fashion commonly understood to one skilled in the art. ThoughFIG. 3C depicts thedoor46 opening rightward from theconnector48 located on a right side of thecabinet38, it will be understood that theconnector48 can be mounted in any relationship between thedoor46 and theenclosure20 so as to permit rightward, leftward, downward, and upward opening movement or any other type of movement relative to the closed position ofdoor46. Thedoor46 can establish a locked connection with theenclosure20, such as by using asuitable locking mechanism47B commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Optionally, thedoor46 can include awindow44 to enable the consumer to view the revitalization process as it proceeds (see below).
• Optionally, the stationary refreshing systems that include the substantiallyhorizontal support substrates30A can include thehorizontal support substrates30A mounted on movable or non-movable support structures50 (e.g., support pins or hinges). Alternatively, thecabinet38 can include thehorizontal support substrate30A mounted on a slidingmechanism42A to enable thehorizontal support substrate30A to slide open and closed for the purposes of placing articles of thefabric load22 into the interior28 of thechamber26. Optionally, thecabinet38 can include both thehorizontal support substrates30A mounted on the movable ornon-movable support structures50 and thehorizontal support substrates30A mounted on the slidingmechanism42A.
• Referring toFIG. 3D, for stationary refreshing systems that include the substantiallyvertical support substrates30B, a plurality of thevertical support substrates30B can be permanently mounted at designated locations in theinterior28 of thechamber26. Alternatively, a plurality of thevertical support substrates30B can be adjustable and installed in theinterior28 of thechamber26 at locations determined by the consumer. Optionally, thevertical support substrates30B can includefabric load restraints36B (e.g., pins, ties, clips, a secondary vertical support substrate, etc.) to hold an article of thefabric load22 in place during the revitalization process.
• Referring toFIG. 3E, the stationary refreshing systems that include the substantiallyvertical support substrates30B can optionally include acabinet38 having at least onevertical drawer40B with at least one of thevertical support substrates30B in thevertical drawer40B or forming a portion of thevertical drawer40B. Thevertical drawer40B can be mounted on a horizontal slidingmechanism42B to enable thevertical drawer40B to slide open and closed for the purposes of placing articles of thefabric load22 into the interior28 of thechamber26. Thevertical drawer40B can establish a locked connection with theenclosure20, such as by using asuitable locking mechanism41B commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Optionally, individualvertical drawers40B can establish a locked connection with theenclosure20, such as by using thesuitable locking mechanism41B commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Alternatively, all of thevertical drawers40B can establish a uniform, simultaneous, locked connection with theenclosure20, such as by using thesuitable locking mechanism41B commonly employed in the art, which can include a mechanical locking means, an electronic locking means, or any other suitable locking means. Optionally, each of thevertical drawers40B can include awindow44B to enable the consumer to view the revitalization process as it proceeds (see below).
• Referring toFIG. 3F, the stationary refreshing systems that include the substantiallyvertical support substrates30B can optionally include acabinet38 having at least onedoor46 that the consumer can open to access theinterior28 of thechamber26. Thedoor46 can be connected to theenclosure20 through the use of a suitable connector48 (e.g., hinge), which is designed to permit the consumer to open thedoor46 to theenclosure20 in any fashion commonly understood to one skilled in the art. ThoughFIG. 3F depicts thedoor46 opening rightward from theconnector48 located on a right side of thecabinet38, it will be understood that theconnector48 can be mounted in any relationship between thedoor46 and theenclosure20 so as to permit rightward, leftward, downward, and upward opening movement or any other type of movement relative to the closed position of thedoor46. Optionally, thedoor46 can include awindow44B to enable the consumer to view the revitalization process as it proceeds (see below).
• Optionally, the stationary refreshing systems that include the substantiallyvertical support substrates30B can include thevertical support substrates30B mounted on non-movable support structures50 (e.g., support pins). Alternatively, thecabinet38 can include thevertical support substrate30B mounted on a slidingmechanism42B to enable thevertical support substrate30B to slide open and closed for the purposes of placing articles of thefabric load22 into the interior28 of thechamber26. Optionally, thecabinet38 can include both thevertical support substrates30B mounted on thenon-movable support structures50 and thevertical support substrates30B mounted on the slidingmechanism42B. As another option, thenon-movable support structures50 and the slidingmechanism42B can be vertically adjustable within thecabinet38.
• While the following detailed description of the functional elements of the illustrated embodiment for the revitalizing system and method are in the context of a rotatable cylindrical chamber having a generally horizontal axis, it will be appreciated that the features can be readily adapted for use with any of the fabric containing structures inFIGS. 2A-2D and3A-3F and that alternative means of providing mechanical, chemical, and thermal energy to thefabric load22 can be used in accordance with the broadest concepts of the present invention. Because the following detailed description utilizes the rotatable cylindrical chamber, reference to thechamber26 can be considered a reference to thedrum30C and vice-versa.
• Referring toFIG. 4, amotor52 drives thedrum30C and thereby controls the rotational speed and rotational direction of thedrum30C. Control of the rotational speed of thedrum30C permits variation of the rotation of thedrum30C as a function of the dryness of thefabric load22. The ability to vary the rotational speed of thedrum30C improves the uniform distribution of added chemistries at different stages of the refreshing process. Optionally, themotor52 can reverse rotational direction of thedrum30C during operation. The reversible aspect of thedrum30C promotes uniformity of dehydration of thefabric load22 during the initial phase of the refreshing process and the uniformity of fluid distribution throughout thefabric load22 during the latter phase the process. Themotor52 can be considered to be a part of a fabric movement system for causing movement of thefabric load22. It is within the scope of the invention, however, to employ other systems for causing movement of thefabric load22.
• Thedrum30C can contain a plurality ofbaffles54. Thebaffles54 can be located along theinner surface24 of thedrum30C defining an interior circumference of thedrum30C. Thebaffles54 can be oriented generally parallel to a rotational axis of thedrum30C. Thebaffles54 facilitate the tumbling action of thefabric load22 within thedrum30C as thedrum30C rotates about the rotational axis. The combination of thebaffles54 and the reversible rotation of thedrum30C promotes a reduction in tangling of clothing articles; a reduction in balling of textile fabrics, such as sheets, rugs, or towels; and a reduction in wrinkles in fabrics. The surfaces of fabric articles become more open during tumbling, which greatly facilitates movement of loose particulates, such as soils, stains, and hairs, from the fabric surfaces to an air outlet of thedrum30C. The air outlet of thedrum30C will be discussed in more detail below.
Textured Substrate Surface:
• Referring toFIGS. 5A and 5B, in addition to the plurality of thebaffles54, thedrum30C can contain atextured substrate surface56. Thetextured substrate surface56 can contain a low (moisture)absorbency substrate58. Thelow absorbency substrate58 can be a non-(moisture) absorbing substrate having sound absorbing properties. The sound absorbing properties can be beneficial for absorbing at least a portion of the sound of thefabric load22 moving in thedrum30C, such as sound generated by buttons clanking against theinside surface24 of thedrum30C during rotation of thedrum30C.
• Thetextured substrate surface56 can be an integral design feature of the interior construction of thedrum30C, wherein thetextured substrate surface56 can be a machined aspect of theinside surface24 of thedrum30C, such as a textured surface machined into theinside surface24 of thedrum30C, or, optionally, a textured powder-coated treatment affixed to theinside surface24 of thedrum30C. Optionally, thetextured substrate surface56 can coat or line thebaffles54 as shown at56A. Optionally, thetextured substrate surface56 can be an independently manufactured article that is separate from thedrum30C, as shown at56B. Thetextured substrate surface56 can be provided on any surface of thedrum30C or on a surface of the door/closure33 that comes in contact with thefabric load22, including in a recess or depression formed in such surface for accepting a removable textured pad, as shown at57 inFIG. 5C, or on a protrusion formed on such surface to which a textured surface is applied, as shown at59 inFIG. 5B.
• Providing thetextured substrate surface56 on thebaffles54, as shown at56A, or on a feature or component protruding partially into the interior32 of thedrum30C, as shown at59, facilitates engagement of the textured surface with thefabric load22, thereby increasing mechanical energy and chemical transfer to thefabric load22. It further facilitates manufacture of thetextured substrate surface56 because materials that might be inappropriate for use for theentire drum30C can be used for thebaffle54 or the feature or component protruding into thedrum30C, as shown at59. Further, these materials can also be used for the removable pad or other independenttextured component56B.
• In contrast, if it is desired to use a textured surface that does not protrude significantly into the interior32 of thedrum30C due to the design of the revitalization system, the fabric to be treated, or the chemistry to be used, a textured pad or component can be mounted in a recess in the surface of thedrum30C as shown at57 inFIG. 5C so that thetextured substrate surface56 is substantially aligned with theinside surface24 of thedrum30C.
• Referring back toFIGS. 5A and 5B, the low-absorbingtextured substrate surface56 can include a removable or permanent insert or pad60 that lines at least a portion of theinside surface24 of thedrum30C. As an option, the low-absorbingtextured substrate surface56 can include one or more of thepads60 that substantially line the inside surfaces24 ofdrum30C between thebaffles54. Optionally, thetextured substrate surface56 can include one ormore pads60A that substantially line afront wall66 and/or aback wall68 of thedrum30C. In the illustrated embodiment, theback wall68 of thedrum30C is formed by an inside surface of theclosure33. Thepads60 can also be attached to a surface of thedrum30C and protrude into the interior32 of thedrum30C, as illustrated by example inFIG. 5D. Referring back toFIG. 5A, thetextured substrate surface56 can optionally becoverings70 that cover pad liners that line theinside surface24 of thedrum30C or are attached to theinside surface24 of thedrum30C and project into thedrum30C. The pad liners can be removably or permanently attached to theinside surface24 of thedrum30C.
• Thetextured substrate surface56 can comprise one or more separate elements. Thetextured substrate surface56 can be a replaceable part that fits into a holder. Thetextured substrate surface56 can be a non-continuous substrate (i.e., circular) that can have design elements that can be partially changed. Thetextured substrate surface56 can contain rollers or balls to transfer the fluid from the surface to thedrum30C or to thefabric load22. Finally, the textured substrate surface can optionally deliver chemistries and can contain an insert that fits into a pad where the chemistries can reside.
• Thetextured substrate surface56 can be permanently affixed to theinside surface24 ofdrum30C during final assembly of thedrum30C. Optionally, thetextured substrate surface56 can be removable from theinside surface24 of thedrum30C. Thetextured substrate surface56 can be coupled to a portion of thedrum30C with an attachment system, which can permanently or removably couple thetextured substrate surface56 to the portion of thedrum30C. Examples of the attachment system are illustrated inFIGS. 5C and 5D. InFIG. 5C, the attachment system comprises therecess57 that receives thetextured substrate surface56. Therecess57 and thetextured substrate surface56 can form an interference fit that retains the latter in the former. Alternatively, the attachment system can comprise a first attachment means on thetextured substrate surface56 and a second attachment means on thedrum30C, as shown inFIG. 5D. The first and second attachment means in the illustrated example are Velcro® strips67A,67B that engage one another to couple thetextured substrate surface56 in the form of thepad60 to thebaffle54 of thedrum30C. Other examples of attachment systems include, but are not limited to, mechanical fasteners, such as clips, and magnets. If thedrum30C is magnetic, then the attachment means can comprise a magnet located on thetextured substrate surface56, and thetextured substrate surface56 can be located anywhere in thedrum30C.
• Thetextured substrate surface56 can be made of any suitable materials. In addition to the examples provided above, other examples of materials for thetextured substrate surface56 include, but are not limited to, woven materials, non-woven materials, materials made of natural fibers, such as flax, cotton, wool, and felt, materials made of artificial fibers, such as rayon, acetate, nylon, polyester, triacetate, spandex, micro fibers, and lyocell. Other examples of suitable materials for thetextured substrate surface56 are provided below.
• Optimally, thetextured substrate surface56 can be substantially non-absorbing. However, a low-absorbing surface can be used to approach the benefits of a non-absorbing surface, for example, if the low-absorbing surface provides other benefits, such as cost, durability, fabric care, or sound absorption, in addition to its low absorbency. Thetextured substrate surface56 can have an open-cell structure, a closed-cell structure, or a combination thereof, depending on a desired degree of absorbency attributable to thetextured substrate surface56.
• By “non-absorbing,” it is meant that the material does not substantially absorb moisture. In relative terms, thetextured substrate surface56 that is non-absorbing will absorb less moisture than an absorbing textured open-cell substrate surface. The non-absorbing characteristics of thetextured substrate surface56 ensures that the substrate surface does not retain moisture during the initial process whereby thefabric load22 is dehydrated and during the final phase when thefabric load22 is rehydrated. Furthermore, any specialized chemistry or treatment that is added to thefabric load22 during the process will be driven either into contact with thefabric load22 or out of thedrum30C rather than being retained or trapped in the textured substrate surfaces56, such as those that line theinside surface24 of thedrum30C. Thus, use of the non-absorbing,textured substrate surface56 can improve the efficiency of the process in terms of utilization of materials and time.
• One purpose of the non-absorbing,textured substrate surface56 is to provide a friction surface for imparting mechanical energy to the tumblingfabric load22 in order to disrupt loose particulates, such as soils, hairs, and stains, from the surface of the fabric articles in thefabric load22. One of the advantages of using the texturedsubstrate surface56 is a reduction in “button clatter” during the tumbling of thefabric load22 in thedrum30C, owing to the intervening material between thefabric load22 and the front andback walls66,68 and theinside surface24 of thedrum30C. Because buttons of thefabric load22 do not directly contact the front andback walls66,68 and theinside surface24, which can be made of metal, of thedrum30C during the rotation of thedrum30C, the integrity of the buttons is also retained.
• Thetextured substrate surface56 can draw particulates, such as soils and hairs, away from thefabric load22 and trap the particulates. Theremovable pads60 or thecoverings70 are one type of thetextured substrate surface56 contemplated for use with the process, and these textured substrate surfaces can be removed from thedrum30C, such as for cleaning. Suitable cleaning procedures for these materials can include washing in conventional fabric washers and dishwashers, as well as vacuum cleaning, or mechanical agitation.
• Optionally, thetextured substrate surface56 can include directional fibers similar to those found in a conventional lint brush. For example, when the fabric articles in thefabric load22 contact the directional fibers in one orientation, lint is removed from the fabric. When the fabric articles in thefabric load22 contact the directional fibers in the opposite orientation, lint is removed from thetextured substrate surface56 as a collective particulate matter and transferred to alint filter74, which will be described in more detail below. Optionally, the textured substrate surfaces56 can be self-cleaning if the textured substrate surfaces56 contain break-away particulate surface substructures that contain the entrapped particulate matter. The break-away particulate surfaces can be suitably caught in thelint filter74 as part of the lint removed during the process. Optionally, the non-absorbing,textured substrate surface56 can be subject to limited-use or single-use applications as disposable, throw-away materials to reassure the consumer that the fabric process is optimized for a particular fabric load.
• The non-absorbing,textured substrate surface56 can also contain impregnated nanoparticles as well as a microparticulate surface structure, encapsulated liquids, and other substructures for impregnating fluids on thetextured substrate surface56. These types of substructures can function as a fluid dispensing system and can hold fragrances, perfumes, and/or specialized chemistries that aid in the process to enhance the smell, feel, and appearance of the fabrics or that impart to the fabric specific chemical attributes, such as, for example, insect repellent or flame retardant properties, as well as a variety of alternative chemistries discussed infra under the section of this disclosure entitled Delivery System. The nanoparticles and/or microparticles can be activated by a variety of mechanisms, including changes in temperature, pressure, and/or humidity, or by a mechanical means.
• The fluid dispensing system can comprise other means, examples of which are illustrated inFIGS. 6A and 6B. InFIG. 6A, thetextured substrate surface56 in the form of thepad60 comprises aninner reservoir62 inside thepad60. Theinner reservoir62 can store a supply of fluid that can be transferred to thefabric load22. Theinner reservoir62 can be a self-contained chamber that is pre-filled with the fluid and inserted into thepad60, or theinner reservoir62 can be coupled to afluid conduit63 that extends from theinner reservoir62 to the surface of thepad60. In the latter case, a user can fill theinner reservoir62 with a desired fluid through thefluid conduit63 and/or empty theinner reservoir62 through thefluid conduit63. Thefluid conduit62 can include aclosure63A, such as a screw-cap, to close thefluid conduit63 when not in use or for filling or draining theinner reservoir62. Thepad60 can further comprise a plurality offluid channels61 configured to deliver the fluid from theinner reservoir62 to the surface of thepad60. Thefluid channels61 can be designed to automatically, such as by capillary or wicking action, draw the fluid to the surface thepad60, or the fluid can be forced through thefluid channels61 as a result of mechanical interaction with thefabric load22, such as by the weight of thefabric load22 squishing thepad60. Once the fluid is located at the surface of thepad60, the fluid can be transferred to thefabric load22 when thefabric load22 contacts thepad60.
• FIG. 6B illustrates locating theinner reservoir62 in one of thebaffles54 to which thetextured substrate surface56 in the form of thepad60 is attached. Theinner reservoir62 can be accessed through afluid conduit63, which has aclosure63A, for filling and/or draining of theinner reservoir62. The fluid in theinner reservoir62 can be delivered to thepad60 through one or morefluid delivery conduits65 fluidly coupling theinner reservoir62 to thepad60. The fluid can be pumped through thefluid delivery conduit65, or the fluid can flow through thefluid delivery conduit65 as a result of gravity as thedrum30C rotates. Once the fluid reaches thepad60, the fluid can be automatically transported, such as by capillary or wicking action, to the surface of thepad60, or the fluid can be forced to the surface of thepad60 as a result of mechanical interaction with thefabric load22, such as by the weight of thefabric load22 squishing thepad60. Once the fluid is located at the surface of thepad60, the fluid can be transferred to thefabric load22 when thefabric load22 contacts thepad60.
• Thetextured substrate surface56 can also be configured to receive a solid form for delivering chemistry. In one embodiment, the chemistry itself can be the solid form.
Heater Control:
• Referring back toFIG. 4, the system can comprise aheater76 fluidly coupled to the interior32 of thedrum30C to heat air flowing through the interior32 of thedrum30C. Theheater76 illustrated inFIG. 4 having a plurality of sets ofheating elements78 is one type of heater that can be used in the system. For example, theheater76 can include at least two sets of theheating elements78. According to one embodiment, theheater76 can quickly raise the temperature of thefabric load22 from ambient temperature (about 70° F.) to a temperature substantially higher than ambient temperature, including a temperature within a temperature range from about 80° F. to about 144° F. Additionally, theheater76, according to one embodiment, can quickly raise the temperature of thefabric load22 from ambient temperature (about 70° F.) to a temperature equal to or less than an upper maximum limit ranging from about 140° F. to about 145° F. For example, the upper maximum limit can be about 144° F. This temperature maximum ensures that the stains on fabrics do not denature, yet provides for efficient dehydration of the fabrics and the elimination of odors and wrinkles without fabric damage. Both sets of theheating elements78 can be subject to independent regulation so that one set can be shut off while leaving the second set on. The remaining set ofactive heating elements78 can provide continued heating for fabric care during dehydration of thefabric load22. For example, both sets of theheating elements78 can be employed to quickly raise the temperature of thefabric load22 to or near a predetermined temperature, and after the predetermined temperature has been reached, one set of theheating elements78 can provide the continued heating during the dehydration of thefabric load22 while the other set of theheating elements78 is turned off. Operation of theheater76, including one or more sets of theheating elements78, can be governed by a heater control, which is discussed below.
• In addition to dehydrating thefabric load22, theheater76 can be employed to revitalize thefabric load22. For example, heat can be applied to thefabric load22 to minimize wrinkles and odors. However, the amount of heat applied to thefabric load22 must be controlled so as to prevent or reduce shrinkage of the fabrics in thefabric load22.
Air Flow:
• According to one embodiment of the invention, a high rate of air flow through thefabric load22 in thedrum30C occurs during the dehydration and cleaning phases of the refreshing process, while little or no air flow through thefabric load22 occurs during the rehydration. Air flow can be accomplished using a variety of means, including a fan, an air pump, an air compressor, an air source, an air tank, and the like. Referring toFIG. 7, ablower fan80 connected to aregulated motor82 is the illustrated source of air flow in the system. Because most conventional drum-based dryers contain a single motor that controls both drum rotation and fan speed, theblower fan80 can be connected to the dedicated,independent motor82. This preference is due to the fact that themotor52 that controls the speed and rotational direction of thedrum30C does not always remain on during the times that the operation of theblower fan80 is required, and the same holds true for the operation of themotor82 for theblower fan80 with respect to the operation of thedrum30C.
• The illustratedblower fan80 can operate at variable speeds, such as by variable speed operation of themotor82, and can provide a source of high throughput air movement through thedrum30C. The variable speed control of themotor82 for theblower fan80 ensures that theblower fan80 is capable of moving a constant air flow through thedrum30C despite the occurrence of air restrictions that can develop at anair outlet83, which exhausts air from thedrum30C to the atmosphere. Furthermore, high throughput air movement through thedrum30C ensures that appropriate temperature reductions of thefabric load22 are achieved and that the particulates, such as the soils and hair, are removed from thefabric load22 and blown into theair outlet83. Themotor82 for theblower fan80 can also be disengaged to stop theblower fan80 during the rehydration phase of the process.
• Referring to FIGS.8 and9A-9B, the air flow leaving thedrum30C can optionally be recirculated back to thedrum30C to promote maximal saturation of the intake air from anair inlet84 to thedrum30C with moisture before release of the air to atmosphere via theair outlet83. This can be accomplished in a variety of ways known in the art, including rerouting the outlet air back into thedrum30C through a recycle/recirculation loop86 in fluid communication with theair inlet84. Optionally, therecycle loop86 can fluidly communication withopenings90 within thedrum30C for introducing the air into thedrum30C. The fluid saturation of the recirculating air can be ascertained from sensors, such assensors92,94 located in thedrum30C or in therecirculation loop86, respectively, or from a timed or event program derived from calculations. Optionally, the degree of fluid saturation within thefabric load22 can be ascertained withsensors98 affixed or focused onto the articles of thefabric load22. Recirculation of the air flow thereby provides a means to achieve decreased saturation of the fluid in thefabric load22 during the dehydration phase of the revitalization process, or to achieve increased saturation of the fluid in thefabric load22 during the rehydration phase of the revitalization process. Thus, during the rehydration phase, the fluid, which is carried by the air, leaves thedrum30C and returns to thedrum30C through therecycle loop86 to achieve a desired saturation of the fluid in thefabric load22.
• Referring particularly toFIGS. 9A and 9B, the recirculating air passing through therecycle loop86 can be passed through thelint filter74, which is described in more detail below.Valves85 and87 in therecycle loop86 can be provided to control air flow through therecycle loop86. For example, thevalve85 can be actuated to prevent outside air from entering therecycle loop86, as shown inFIG. 9A, so that only recirculating air in therecycle loop86 enters thedrum30C, or to allow outside air to enter therecycle loop86, as illustrated inFIG. 9B. Thevalve87 can be actuated to direct air from thedrum30C to the atmosphere or to therecycle loop86. Thevalves85,87 can have operating conditions other than those illustrated inFIGS. 9A and 9B. For example, thevalve85 can be positioned to allow the recirculating air from therecycle loop86 as well as outside air to enter thedrum30C.
Fluid Removal System:
• Referring toFIG. 10, the fabric revitalization system can include a dehydration orfluid removal system100, which can be any suitable system for dehydrating or removing fluid from thefabric load22. Exemplary embodiments for the fluid removal system include air condensers, desiccants, steam-drying, electrostatic-drying, microwave-drying, conduction, convection, radiation, and the like.
• One embodiment of thefluid removal system100 is an air convection system, such as that illustrated by the exemplary arrangement shown inFIG. 10 and described herein. The exemplary air convection system includes theheater76 and theblower fan80, which function to create a heated air flow to thefabric load22 in thedrum30C. Theheater76 is disposed along the air flow system to heat the air flow generated by theblower fan80. Aheater control102 controls theheater76 to provide elevated temperature to thefabric load22 by heating the air supplied to thedrum30C that holds thefabric load22, while the speed-compensatedair blower fan80 provides the high throughput air flow to thedrum30C that holds thefabric load22. Thefluid removal system100 therefore comprises the combination of theheater control102 and theblower fan80 functionalities that provides for dehydration of moisture contained in articles of thefabric load22. As the heated air contacts thefabric load22, moisture is removed from thefabric load22 and carried out theair outlet83.
• The typical moisture content of thefabric load22 prior to subjecting clothing articles to a refreshing process is about 10% (10 grams fluid per 100 grams fabric load). An exemplary moisture content of thefabric load22 following the dehydration phase is a percentage within a range of about 0% to about 4%. For example, the moisture content offabric load22 following the dehydration phase can be about 1%, 2%, or 3%. According to one embodiment, the moisture content of thefabric load22 following the dehydration phase is about 2%. Further, the moisture content of thefabric load22 following the dehydration phase of a refreshing process, according to one embodiment, is at least 1% lower than the moisture content of an otherwise comparable fabric load that was not subjected to the process. The time required to efficiently dehydrate thefabric load22 will vary as a function of several factors, such as the humidity of the air entering the air convectionfluid removal system100, air temperature, air pressure, and the air flow rate in thedrum30C containing thefabric load22.
Particulate Removal and Recovery:
• Referring toFIG. 11, particulates, such as soils, stains, malodors, and other materials (e.g., hair), can be removed from thefabric load22 through a combination of thetextured substrate surface56 imparting mechanical energy to thefabric load22, the high air flow rate passing through thefabric load22 in thedrum30C, and the clothes in thefabric load22 opening up during reversals of thedrum30C and/or varying the rotational speed of thedrum30C. These particulates, such as the soils and other materials, are carried out of thedrum30C by passing into theair outlet83 and are trapped in theair outlet83 by a suitable filter device, such as thelint filter74.
• According to one embodiment, as shown inFIG. 11, aconduit104, which can be flexible, leading from thedrum30C to theair outlet83 is in fluid communication with alint filter housing106 for thelint filter74. Large particulates can be captured by thelint filter74 to avoid the build-up of particulates on the components, such as theblower fan80, theheater76, etc., in adrying loop108, which is a loop through which air flows and is heated prior to entering thedrum30C. Thelint filter housing106 can also include a filter lock that is adapted to lock down and seal the edges of thelint filter74 when the revitalization process is activated to avoid a breach of the closed system. In addition, when the machine is deactivated, the consumer can clean thelint filter74 as one normally would do in traditional drying machines. Thelint filter74 can also include a gasket at the interface of thelint filter74 and theouter housing23 of theenclosure20.
• WhileFIG. 11 depicts one of the lint filters74, there can be a plurality of the lint filters74 in the air flow path to collect as much particulates as possible, and the lint filters74 can be located anywhere along any air path or recycle loop (e.g.,86) that can be otherwise incorporated into the system design. Thelint filter housing106 is in fluid communication with theair blower fan80 to facilitate movement of lint particulates from thedrum30C, such as from the articles of thefabric load22 or from thetextured substrate surface56, to thelint filter74 as theair blower fan80 operates.
• Smaller particulate matter may pass through the lint filters74 described supra. To prevent release of the smaller particulate matter to the atmosphere external to the fabric revitalization system, an additional smaller particulate filter as afinal outlet filter114 can be installed in theenclosure20, such as at theouter housing23, as illustrated inFIG. 12. For example, use of a high efficiency particulate air (HEPA) filter or an ultra low penetration air (ULPA) filter as thefinal outlet filter114 would result in recovery of the smaller particulate matter.
• Other suitable filters that can be used for particulate removal and recovery include, but are not limited to a locked down sealed edge filter; a filter for a vapor, a fog, and/or a colloidal suspension; electrostatic filtering; filters impregnated with catalysts for producing species/radicals for cleaning; filters impregnated with reactants to chemically treat substances present in air; neutralizing filters to remove a previous treatment; and an air permeable matrix having a plurality of pores with a greatest pore dimension in a range from about 0.10 micron to about 1500 microns.
• The individual lint and smallerparticulate filters74,114 can be accessible to the consumer for cleaning and/or replacement as warranted following a revitalization process.
Delivery System:
• Referring toFIG. 13, the system includes ameans120 for delivering fluid (e.g., free fluid, available fluid, bound fluid, non-aqueous fluid) from a fluid storage system into thechamber26/drum30C for rehydrating thefabric load22 typically after the dehydration and aeration are completed. Each of the fluid types and varieties can be dispensed at different levels. For example, the non-aqueous fluid level can be higher than the percentages previously described. The fluid form can include any one or a combination of the following: a liquid (e.g., organized liquid, pure liquid dispensed in nanoparticulates or in encapsulated microparticles, and the like); a mist (e.g., droplets produced from a nebulizer, a sonifier, and the like); a fog; a vapor; a gas; a foam (either a wet or dry foam); a steam; a solid (e.g., powders, blocks, pouches, etc.); a semi-solid (e.g., paste, gel, viscoelastic material, etc.); capillary channels; microparticulates (e.g., nanoparticles, encapsulated microparticles, and the like); a microemulsion; an electrostatic dispersant (e.g., ionizations); multi-phase chemistries; or the like. A delivery medium comprising a fluid (e.g., a vapor, a mist, a fog, a foam, a steam, or a liquid) can use aqueous fluids, semi-aqueous fluids, non-aqueous fluids, or a mixture of these fluids. These fluids can contain a washing additive. The washing additive can be selected from the group consisting of: builders, surfactants, enzymes, bleach activators, bleach catalysts, bleach boosters, bleaches, alkalinity sources, antibacterial agents, colorants, perfumes, pro-perfumes, finishing aids, lime soap dispersants, composition malodor control and removal agents, odor neutralizers, polymeric dye transfer inhibiting agents, crystal growth inhibitors, photobleaches, heavy metal ion sequestrants, anti-tarnishing agents, anti-microbial agents, anti-oxidants, linkers, anti-redeposition agents, electrolytes, pH modifiers, thickeners, abrasives, divalent or trivalent ions, metal ion salts, enzyme stabilizers, corrosion inhibitors, diamines or polyamines and/or their alkoxylates, suds stabilizing polymers, solvents, process aids, fabric softening agents, optical brighteners, hydrotropes, suds or foam suppressors, suds or foam boosters, fabric softeners, antistatic agents, dye fixatives, dye abrasion inhibitors, anti-crocking agents, wrinkle reduction agents, wrinkle resistance agents, wrinkle release agents, soil release polymers, soil repellency agents, sunscreen agents, anti-fade agents, and mixtures thereof.
• The fluid can be activated by any suitable means, such as chemistry; changes in temperature (e.g., applying heat or a cooling medium), light (e.g., photo-oxidation, photo-activation), pressure, or humidity; or by a mechanical means.
• Where the delivery medium comprises a fluid, such medium can be delivered using a variety of chemical and mechanical processes, including temperature, pressure, pH, acoustics, friction, desolvation, dispersion, time-release, chemical activation/deactivation, flocculation, sublimation, mechanical action, and the like.
• In general, the delivery means is a fluid management system that can comprise a fluid storage system fluidly coupled to a fluid conditioning system by a fluid transport system. The fluid transport system transports fluid stored in the fluid storage system to the fluid conditioning system, where the fluid is conditioned. For example, the fluid can be conditioned by changing the physical or chemical state or a physical or chemical property of the fluid. The fluid can be conditioned in any of several ways, such as by using a thermal energy generation device, a mechanical energy generation device, an electrochemical energy generation device, an electromagnetic energy generation device, and a chemical energy generation device. After the fluid has been conditioned, a fluid delivery system delivers the conditioned fluid to thedrum30C.
• The delivery means120 can comprise, for example, an injector, a sprayer, a mister, a foamer, a steamer, a heater, a vibrator, an agitator, an atomizer, a vapor insertion system, a fluid insertion system, a multi-phase chemistry insertion system, a nebulizer, and combinations thereof. The fluid delivery means120 can also or alternatively comprise a device with capillary channels, vortex tubes, a venturi, and means for fluid displacement resulting from chemical reactions. For example, the delivery means120 illustrated inFIG. 13 can comprise a nebulizer to produce aliquid mist124 that is transmitted onto and/or into thefabric load22 in thedrum30C.
• FIGS. 14-18 illustrate anexemplary nebulizer circuit122. As shown most clearly inFIG. 17, thenebulizer circuit122 comprises anebulizer assembly126 that includes afluid tank128 that holds a fluid source, afluid level control130, afluid reservoir132, anair entry chamber134, afan136, apower source138, a mist generator in the form of apiezoelectric transducer140, alogic control142, atemperature control144, and afluid flow control146. The structure and function of each component is described in detail below.
• Thefluid tank128 holds fluid148 that is destined to become themist124. As used herein, themist124 refers to several forms of the liquid, including a vapor and a spray. In this embodiment, thefluid tank128 can be considered as part of the fluid storage system. For the purposes of rehydration of thefabric load22, the fluid148 can be sterile water. For other treatments, the fluid148 can be an aqueous system, a non-aqueous system, or mix-aqueous/non-aqueous solvent system and can include but is not limited to one or more of the following alternative chemistries: hydrating materials, dehydrating materials, hydrophilic agents, hydrophobic agents, organic and inorganic solvents, dye fixer, oxidizing agents, such as hydrogen peroxide, electrolytic water, and silver, reducing agents, fabric enhancer, color enhancer, topical ointment/medicines, antibiotics, insect repellent, sun protective agents, wrinkle resistance-imparting chemistries, chemical activators/deactivators, perfumes, deodorizers, fragrances, pheromones, aroma therapy treatments, sanitizers, disinfectants, anti-static materials, electrostatic materials, ionized fluids, phase change materials, surfactants, waxes, oils, water-repellents, flame retardants, anti-microbial agents, anti-bacterial agents, anti-fungal agents, anti-parasitic agents, anti-viral agents, sheen enhancing agents, paint, ink, and dye coloring and decoloring agents, polishing and restorative agents, metal coatings, cellulose coatings, skin coatings, softening agents, anti-static agents, pH-dependent chemistries, acids, bases, detergents, multi-phase materials, foams, anti-corrosive agents, radiation-protective agents, enzymes, nucleic acids, dust and particulate repellents, pet hair or particulate attractants, plastic coatings, leather restorative coatings, sugar-based coatings, polymerizing agents, photoprotective coating, hydrocarbon repellents, hydrocarbon attractants, and the like, as well as combinations of any of the foregoing.
• In one embodiment, thefluid tank128 can be filled with the desired amount offluid148 and substantially hermetically sealed. Any sealing means known in the art that provides a substantially hermetically sealed container can be used. As an example, a lure-lock rubber casketed sealing means can be used to provide a substantially hermetically sealed enclosure for thefluid tank128. Thefluid tank128 can be removably received within afluid tank base152 disposed above thefluid reservoir132. When thefluid tank128 is received within thefluid tank base152, thefluid tank128 fluidly communicates with thefluid reservoir132 via thefluid level control130.
• Thefluid level control130 contains a controllablefluid tank outlet154 that can be actuated upon placement of thefluid tank128 into thefluid reservoir132. The fluid148 from thefluid tank128 fills thefluid reservoir132 until the desired level of the fluid148 in thefluid reservoir132 is achieved. In the exemplary embodiment, a sensor, such as a mechanical sensor, associated with thefluid tank outlet154 can detect the desired level of the fluid148 inside thefluid reservoir132. Thefluid tank outlet154 can shut off or close when thefluid reservoir132 is filled to the desired level with thefluid148. Thefluid tank128 can optionally be vented to provide ambient pressure conditions as the fluid148 from thefluid tank128 flows to thefluid reservoir132. Thefluid reservoir132 that holds the fluid148 can also be considered as part of the fluid storage system.
• As shown inFIGS. 16-18, nebulizer controls158 can be attached to abase160 of thefluid reservoir132. Thebase160 of thefluid reservoir132 forms a well that holds the fluid148 supplied from thefluid tank128 and includes a cutout or opening to accommodate thepiezoelectric transducer140, which is supported by ametallic plate161 operatively coupled to the nebulizer controls158. Thus, thepiezoelectric transducer140 is in fluid communication with the fluid148 in thefluid reservoir132 through the cutout in thebase160. The nebulizer controls158 encompasses thenecessary power source138, thelogic control142, thetemperature control144, and thefluid flow control146 to operate thepiezoelectric transducer140 and the associated fan(s)136.
• Thepiezoelectric transducer140 is powered by a highoutput transistor circuit162. Because thetransistor circuit162 produces substantial heat output during its normal operation, aheat sink164 can be utilized to prevent overheating and destruction of thetransistor circuit162. In the illustrated embodiment, theheat sink164 is in the form of a metallic ring that surrounds thepiezoelectric transducer140, and thetransistor circuit162 is thermally coupled to theheat sink164 via themetallic plate161. As a result, thetransistor circuit162 is thermally coupled to the fluid148 in thefluid reservoir132 to provide adequate heat dissipation. The heat generated by thetransistor circuit162 conducts through themetallic plate161 and theheat sink164 to the fluid148 in thefluid reservoir132.
• In the event that thefluid reservoir132 runs low on the fluid148 or becomes depleted altogether of the fluid148, afluid level sensor166 associated with thefluid reservoir132 can be included. Thefluid level sensor166 can be coupled to thelogic control142 and thetemperature control144. Thelogic control142 can utilize feedback from thefluid level sensor166 to determine if a sufficient amount of the fluid148 is present in thefluid reservoir132 and communicate with thefluid flow control130 to provide instructions to fill thefluid reservoir132 to a desired level if there is not a sufficient amount of the fluid148 present in thefluid reservoir132. Thetemperature control144 can utilize the feedback from thefluid level sensor166 and cut off the power to thetransistor circuit162 if the amount of the fluid148 in thefluid reservoir132 is not sufficient.
• Thetemperature control144 can also optionally communicate with a temperature sensor associated with thetransistor162. Using feedback from the temperature sensor, thetemperature control144 can determine if the temperature of thetransistor162 is too high and cut off power to thetransistor162 to protect thetransistor162 from overheating. Furthermore, thetemperature control144 can optionally communicate with a temperature sensor configured to sense a temperature of the fluid148 in thefluid reservoir132 orfluid tank128 and utilize the sensed temperature to control operation of an optional heater configured to heat thefluid148. The heater can comprise any suitable heater, such as an immersion heater located in thefluid reservoir132 or thefluid tank128, a heat source embedded in thefluid reservoir132 or in thefluid tank128, or an in-line heater that heats the fluid148 as it flows from thefluid tank128 to thefluid reservoir132.
• With continued reference toFIGS. 16-18, an air flow chamber orchannel168 is situated in aninterstitial space180 formed between thefluid tank128 and thefluid reservoir132, particularly between thefluid tank base152 and thefluid reservoir132. At least one of thefans136 communicates with theinterstitial space180, which is in fluid communication with anair space186 outside thenebulizer assembly126 via theair entry chamber134. Theair entry chamber134 in the illustrated embodiment is formed in thefluid tank base152, and thefan136 is received within theair entry chamber134.
• Initiation of thenebulizer circuit122 results in activation of thepiezoelectric transducer140 and production of themist124 at the surface of the fluid148 in thefluid reservoir132. Thepiezoelectric transducer140 generates ultrasonic waves that energize through the fluid148 and result in generation of themist124 at the surface of the fluid148 when the ultrasound waves encounter the air at the surface of thefluid148. Activation of thefan136 draws air into theair flow channel168 of thenebulizer assembly126 and across surface of the fluid148 in thefluid reservoir132 that containsmist124, and carries themist124 from theair flow channel168 through a fluid transport system comprising atransition assembly188 that connects thenebulizer assembly126 to thedrum30C that contains thefabric load22. Thefluid flow control146 controls the operation of thefan136 to control the flow of themist124 to thedrum30C. In particular, thefluid flow control146 sets the speed of thefan136, which affects the speed at which themist124 is delivered to thedrum30C and the rate at which themist124 moistens thefabric load22 in thedrum30C. The set speed of thefan136 can depend on several factors, including, but not limited to, the rate of mist generation, the volume of mist generated, and the density of the fluid148 used to create themist124.
• Thetransition assembly188 preferably comprises abulkhead outlet190, asump192, aconnection194 in the form of a channel between thebulkhead outlet190 and thesump192, wherein a slight elevation exists in theconnection194 from thesump192 to thebulkhead outlet190, and asump pump198. Ascreen200 associated with thebulkhead outlet190 provides enhanced dispersion of themist124 into the interior32 of thedrum30C that contains thefabric load22. Furthermore, thescreen200 can includeopenings202 of sufficient size to prevent accumulatedmist124 from covering theopenings202 and blocking thebulkhead outlet190 yet prevent lint and debris from thedrum30C from entering the transition assembly. According to one embodiment, the arrangement of theopenings202 in thescreen200 includes a geometrical configuration to promote the movement of collectedmist124/condensation to travel away from thebulkhead outlet190 to thesump192 or thefluid reservoir132. In this manner, any trappedmist124 or other condensation at thebulkhead outlet190 will be channelled to thesump192 or thefluid reservoir132. Finally, thesump pump198 facilitates moving the condensation by pumping the condensation in thesump192 to thefluid reservoir132.
• The fluid storage system can have embodiments other than the reservoir. For example, the fluid storage system could be a containment-type fluid storage system similar to a hard-sided container or a soft sides pouch. The hard-sided container can resemble a cartridge, and the fluid to be dispensed can be contained within the cartridge. The chemistry alone can be contained in the cartridge and/or the soft sides pouch and can be coupled with an in-line fluid valve that can help to dilute the chemistry prior to contact with the fabric load.
• Optionally, thenebulizer assembly126 can comprise a sanitization means to inhibit or prevent the growth of bacteria, fungi, and other unsanitary micro-organisms or microbes. For example, the sanitization means can be in the form of a material embedded into or coated onto one or more surfaces of thenebulizer assembly126. Exemplary surfaces of thenebulizer assembly126 that are especially conducive to growth of micro-organisms include surfaces of thefluid reservoir132, theair flow channel168, thefluid tank128, and thetransition assembly188. While the sanitization means can comprise any suitable material, examples of sanitization materials include materials comprising silver ions, titanium dioxide, and other oxides. Further exemplary means of sanitizing the nebulizer assembly are discussed infra in the section of this disclosure titled Sanitization Processes.
• Referring toFIG. 19, which illustrates the embodiment of thenebulizer assembly126 shown as the fluid delivery means120 inFIG. 13, adedicated pump204 can be used to pump the fluid148 from thefluid tank128 into thefluid reservoir132. In this embodiment, thepump204 can be considered to be the fluid level control. Additionally, thefluid reservoir132 of this embodiment is modified to include anenclosed air channel206 and an associatedfan208 for moving themist124 created by thepiezoelectric transducer140 to thedrum30C that contains thefabric load22. Theenclosed air channel206 incorporates thebulkhead outlet190 to thedrum30C, thereby eliminating the need for thetransition assembly188. However, thenebulizer assembly126 ofFIG. 19 can be modified to include thetransition assembly188. In the embodiment ofFIG. 19, thenebulizer circuit122 can reside inside theenclosure20, wherein thefluid tank128 is not hermetically sealed. Thefluid tank128 can be vented to provide ambient pressure conditions as thepump204 moves the fluid148 from thefluid tank128 to thefluid reservoir132.
• Thededicated pump204 permits physical and spatial decoupling of thefluid tank128 from thefluid reservoir132. As used herein, the physical and spatial decoupling/separation of thefluid tank128 and thefluid reservoir132 refers to the ability to physically locate thefluid tank128 in a location, either within or exterior to theenclosure20, that is different than the location of thefluid reservoir132. Even though thefluid tank128 and thefluid reservoir132 can be located apart from one another, thefluid tank128 and thefluid reservoir132 are fluidly coupled to one another, such as through aconduit205, so that the fluid148 in thefluid tank128 can be provided to thefluid reservoir132, such as with the assistance of thepump204. The physical separation of thefluid tank128 and thefluid reservoir132 offers advantages in the operation of thenebulizer assembly126. Such advantages include ease of servicing thenebulizer assembly126, the facile replenishment of the fluid148 into thenebulizer assembly126, and greater hygienic control of the components of thenebulizer assembly126 and the associatedfluid148, as elaborated below. By uncoupling thefluid tank128 from the remaining portion of thenebulizer assembly126, thefluid tank128 can be situated elsewhere inenclosure20 to provide greater aesthetic and/or ergonomic appeal. Furthermore, the remaining components of thenebulizer assembly126 can be isolated from external environment to promote greater protection from bacterial or fungal contamination. For example, thefluid reservoir132 can be emptied using thededicated pump204 by redirecting the fluid148 from thefluid reservoir132 back to thefluid tank148 following a refreshing process. In this case, thepump204 can be a pump, such as a peristaltic pump, capable of reversing the direction of fluid flow. Optionally, thepump204 can be used to flush thefluid reservoir132 with a bacterial disinfectant to sanitize thefluid reservoir132 between uses.
• To accommodate the use of more than one fluid with thenebulizer assembly126, the nebulizer assembly can comprise a manifold170, as illustrated in the alternative embodiment ofFIG. 20. The embodiment shown inFIG. 20 is similar to the embodiment ofFIG. 19, except that the former comprises the manifold170, a plurality of thefluid tanks128 and associated dedicated pumps204. The manifold170 fluidly couples each of thefluid tanks128 to thefluid reservoir132, and each of thefluid tanks128 has a correspondingdedicated pump204 to pump the fluid148 from therespective fluid tank128 to themanifold170.
• Thefluid tanks128 can each store a different fluid that can be used during different stages of the revitalization process or to clean or rinse thefluid reservoir132 between usage of differing fluids. For example, with the configuration shown inFIG. 20, two of thefluid tanks128, such as afirst fluid tank128A and asecond fluid tank128B, can store differing fluids, such asfirst revitalization fluid148A and asecond revitalization fluid148B, respectively, that are employed at different times during the revitalization process, while theother tank128, such as athird fluid tank128C, can store a rinse fluid148C. During the revitalization process, afirst pump204A for thefirst fluid tank128A can deliver thefirst revitalization fluid148A to the manifold170 for introduction into thefluid reservoir132. After use of the first revitalization fluid, thefirst pump204A can pump thefirst revitalization fluid148A back to thefirst fluid tank128. Next, the rinse fluid148C from thethird fluid tank128C can be pumped by athird pump204C to thefluid reservoir132 through the manifold170 to rinse thefluid reservoir132. The used rinse fluid148C can be drained from thefluid reservoir132 or pumped back to thethird fluid tank128C by thethird pump204C. Thereafter, thesecond revitalization fluid148B can be pumped by asecond pump204B to thefluid reservoir132 through themanifold170. After use of thesecond revitalization fluid148B, any excess can be pumped back to thesecond fluid tank128B by thesecond pump204B.
• Optionally, the fluids can be mixed in thefluid reservoir132 or in the manifold170 prior to entrance to thefluid reservoir132. Further, rather than each of thefluid tanks128 having adedicated pump204, it is within the scope of the invention for thefluid tanks128 to share a single pump, which can be located between the manifold170 and thefluid reservoir132. It is also within the scope of the invention to employ a single fluid tank capable of storing more than one fluid rather than using multiple separate tanks. Additionally, the manifold170 can be omitted and replaced by separate inlets for each of the fluids into the fluid reservoir. In another embodiment, each fluid can have an associatednebulizer assembly126 rather than the fluids sharing asingle nebulizer assembly126.
• The use of multiple fluids with thenebulizer assembly126 has been described with respect to the embodiment shown inFIG. 20; however, it is within the scope of the invention to modify the nebulizer assembly ofFIGS. 14-18 or any other nebulizer assembly to accommodate the use of multiple fluids.
• The fluid delivery system can further comprise an ionizer, which can be a stand alone device or can be used in conjunction with thenebulizer assembly126. The ionizer purifies fluids, including liquids and gases, with ions as the fluid passes through the ionizer. The ions function to neutralize odors and kill or remove potentially harmful micro-organisms and microbes from the fluid. As a result, the ionizer refreshes and purifies the fluid, whether fluid in the form of themist124 from thenebulizer assembly126 or other fluid, prior to entrance to thechamber26.
• To be clear, the exemplary delivery systems described hereinabove are exemplary systems for the chemistry currently contemplated by the inventors. It will be appreciated that an alternative chemistry can be selected for use in a revitalization system of the present invention, including a chemistry subsequently formulated to optimize the operation of the revitalization system. The chemistry can be deliverable in liquid, gaseous, steam, particulate, or other form. The chemistry form can be transient. For example, if the chemistry is available but is too high in viscosity for optimal use, it can be heated at the point of application to thefabric load22 as to reduce viscosity. Similarly, if available in particle form, the particles can be applied entrained in air so that they will behave more like a fluid. Furthermore, chemistries can be applied sequentially, as required, to obtain optimal results.
Sensors:
• Referring toFIGS. 18 and 21, various sensors, such as thesensors92,94, can be located along any path, including at or near theair inlet84, at or near theair outlet83, in the recirculation or recyclepath86, inside thechamber26/drum30C, attached to or in association with thefabric load22, and inside or near thenebulizer assembly126, including thefluid tank128, thefluid reservoir132, theair flow channel168, thesump192, and at thebulkhead outlet screen200.
• For example, temperature and humidity sensors can be associated with thechamber26 to monitor the temperature and moisture content of thefabric load22. Other sensors can include a single pressure sensor to monitor the pressure at a given point. Other sensors can include leak sensors to sense for fluid leaks; flow rate sensors or meters to measure the quantity of fluid or quantity of air that has moved past the flow meter point or to monitor air restrictions; a weight sensor to estimate the size of thefabric load22; sensors to indicate when the machine is deactivated so that the consumer can interact with it (e.g., ready to clean the lint and smallerparticulate filters74,114, ready to refill thefluid tank128; ready to load/unload thefabric load22, etc.).
• Other sensors that are considered within the spirit of the invention include any type of sensor that can detect a physical property of the environment in thechamber26. Such sensors include, but are not limited to, temperature, pressure, humidity, force, torque, acceleration, inertia, mass, frequency, vapor, moisture, oxygen, CO, CO₂, electrical conduction, enzyme level, aqueous and/or non-aqueous solvent vapor level, turbidity, optical spectrum, ultrasonic, shaped electromagnetic field (SEF), float sensing, laser deflection, petrotape (for petroleum and fuels) chemtape (for chemicals and petro-chemicals), electric field imaging, capacitance, resistance, pH, non-dispersive infrared, solid state, acoustic wave, oxidation-reduction potential, metal oxide semiconductor sensors, etc.
User Interface and Control:
• Referring back toFIG. 1, the revitalization system can include a user interface andcontrol210 that provides information, such as status information and safety or emergency information, representative of the fabric revitalization system. While illustrated in the front right corner of theenclosure20 inFIG. 1 for ease of illustration, it will be appreciated that the user interface andcontrol210 can be located elsewhere on theenclosure10, such as elsewhere on the front of theenclosure20, on top of theenclosure20, or on the door, as is well known in the art. The user interface andcontrol210 preferably includes acontrol panel212 to communicate the information representative of the revitalization system. For example, the information can be status information, such as time remaining, cycle step, and unbalanced load information. The information can also be different types of safety or emergency information, such as blocked conduits, valve failure, clogged filters, breach of the closed system, fluid leak, fluid level, pressure drops, temperature increase, chemical leakage, etc. After receiving the information from thecontrol panel212, the user can interact with thecontrol panel212 to send information, such as control signals, including turn-on signals, shut-off signals, and a command to delay or start of all or part of the process. Thecontrol panel212 can also store any information in amemory storage unit214 so that the information can be retrieved later. For example, the information can relate to the type of fabric in thefabric load22. Clothing articles of a particular fabric type (e.g., silk) can have specific process parameters that differ from parameters used for clothing articles composed of a different fabric material (e.g., cotton or wool). Additionally, bar code readers, RFID readers, and outer short distance communication means can be utilized to communicate information about the garment. For example, the user interface andcontrol210 or other suitable component of the machine can incorporate the reader, while garment packaging, a container holding the garment, the garment itself, or some other object associated with the garment can include a corresponding data storage medium, such as a bar code and a RFID tag, containing the information regarding the garment. Upon receiving the information, the user interface andcontrol210 can utilize the information for various purposes, such as expanding or upgrading cycles. The information can be useful for creating fabric-specific revitalization profiles. Furthermore, other types of information beneficial during servicing and machine diagnostics can be stored in the user interface andcontrol210.
• The user interface andcontrol210 can further comprise acontrol213 that can be separate from or integrated with thememory storage unit214. Thecontrol213 communicates with thecontrol panel212 and thememory storage unit214 and controls various components of the fabric revitalization system to execute the revitalization method.
Vacuum System:
• Referring toFIG. 22, the system can contain an optional vacuum system comprising avacuum source216. Reduced pressure within thechamber26/drum30C due to thevacuum source216 promotes removal of particulates, such as soils, from the articles in thefabric load22. Thevacuum source216 provides adequate levels of air suction to substantially reduce the pressure within thechamber26. Thevacuum source216 can be optionally configured as part of a separateair flow circuit218 independent of theair inlet84, theair outlet83, and the recycle/recirculation path86. In this case, theair flow circuit218 can contain thelint filter74 or other suitable filter to trap particulates, such as soils and other matter, removed from thechamber26. In one embodiment, thevacuum source216 can be configured as part of an air outlet system so that particulates, such as soils and other matter, that are removed from thechamber26 are caught in thelint filter74 or other suitable filter after or upon leaving thechamber26.
Moisture Level Control:
• A moisture level of thefabric load22 can be controlled by controlling the pressure and temperature of thechamber26. For example, thevacuum source216 can used to control the pressure inside thechamber26, and a refrigerant system can be used to control the temperature inside thechamber26 and of thefabric load22. Thevacuum source216 and the refrigerant system can be used separately or in combination with one another for a synergistic effect. Other means can be used to control the pressure and/or temperature. Examples of means for controlling the temperature include a heat pump, an air condenser, and the air flow system either alone or in combination with theheater76.
• The moisture level of the fabric can also be controlled by chemical or mechanical means. For example, thefabric load22 can be exposed to or coated with a chemistry that limits the amount of moisture that the fabric can absorb or increases the amount of moisture that the fabric can absorb. Further, thedrum30C can be rotated to tumble thefabric load22, which opens thefabric load22 to expose more surfaces of thefabric load22 to the moisture, which increases the moisture level, or to a heated or unheated air flow through thechamber26, which decreases the moisture level.
Stain Removal Station:
• Certain stains in fabrics of thefabric load22 can require pre-treatment in order to facilitate their removal. The pre-treatment can be targeted, localized, or manual by nature. Referring toFIGS. 23,24, and25A-25D, the illustrated embodiments include an integratedstain treatment station224 to facilitate stain and spot removal. Thestain treatment station224 can be fitted with different chemistries for administration to articles of thefabric load22. The chemistries administered to the fabric articles depend upon the type of stain or spot impregnated on the fabric.
• In the example illustrated inFIG. 23, thestain treatment station224 includes awork surface226 fitted into arecess225 in the top of theenclosure20 of the fabric revitalizing system. Astorage compartment228 for storing one or more pre-treatment fluids is recessed into the top and is selectively enclosed by adoor229. The fabric to be treated can be placed on thework surface226 and treated with the one or more pre-treatment fluids stored in thestorage compartment228. The one or more pre-treatment fluids can be dispensed from thestorage compartment228 in any suitable manner, such as by a wand, which is described in more detail below.
• In the example illustrated inFIG. 24, thestain treatment station224 includes awork surface226 integrated into the top of theenclosure20 of the fabric revitalizing system. Afluid reservoir227 configured to store one or more fluids is recessed into the top of theenclosure20 and is designed to selectively supply the one or more fluids via aconduit222 to adispensing device231, such as a wand, that can be movably mounted to the top of theenclosure20. The fabric to be treated can be placed on thework surface226 and treated with the one or more fluids stored in thefluid reservoir227 through thedispensing device231.
• In the example illustrated inFIG. 25A, thestain treatment station224 is located within theenclosure20 along an upper edge region of theenclosure20 and to one side of thedrum30C. Thestation treatment station224 is oriented generally parallel to a longitudinal axis A of thedrum30C. However, it is within the scope of the invention for thestain treatment station224 to be positioned in any suitable location in the enclosure and to have any orientation relative to thedrum30C.
• Thestain treatment station224 comprises afront panel234 generally flush with a front face of theenclosure20 and amovable door229 generally flush with a top face of the enclosure when thedoor229 is in a closed position, as shown inFIG. 25A. Thedoor229 of the illustrated embodiment can pivot between the closed position ofFIG. 25A to an opened position ofFIG. 25B to enable access to acompartment228 having afirst pocket240 that holds aremovable fluid reservoir227 configured to store a supply of treatment fluid or stain treatment agent and asecond pocket242 that holds a retractabletreatment fluid dispenser231 in the form of awand244 connected to aflexible hose246. Thewand244 and thehose246 can be extended from thesecond pocket242 to treat a stain on a fabric item and retracted into thesecond pocket242 for storage. Thetreatment fluid dispenser231 is fluidly coupled to thefluid reservoir227, such as through afirst supply hose248 and asecond supply hose250 located below thecompartment228, as illustrated inFIGS. 25C and 25D. Thefirst supply hose248 transports the treatment fluid from thefluid reservoir227 to apump252, which pumps the treatment fluid through thesecond supply hose250 to thetreatment fluid dispenser231. Thewand244 can be configured to dispense the treatment fluid in any suitable manner, such as by spraying, pouring, or misting the treatment fluid.
• Thestain treatment station224 further comprises awork surface226 horizontally slidable from a retracted position within theenclosure20 below thecompartment228, as shown inFIG. 25A, to an extended position forwardly of theenclosure20, as illustrated inFIG. 26B. Referring again toFIG. 25C, thework surface226 is supported by and moves along aslide238 located below thecompartment228. Thework surface226 can be in the form of shelf, drawer, or the like. Thework surface226 of the illustrated embodiment comprises an upwardly open, hollowmain body254 and aperforated surface256, which can be a mesh material, disposed above themain body254 to close themain body254. A worksurface front panel258 with an integrally formedhandle260 is attached to or formed integrally with themain body254. Thehandle260 facilitates movement of thework surface226 between the retracted and extended positions. When thework surface226 is in the retracted position, the worksurface front panel258 can be generally flush with a front surface of theenclosure20, as shown inFIG. 25A.
• Referring again toFIG. 25C, avacuum cavity262 formed between themain body254 and theperforated surface256 is fluidly coupled to avacuum source264 located below thecompartment228 via adrain conduit266. As shown inFIG. 25D, thestain treatment station224 further includes awaste conduit268 that couples thevacuum source264 to an external drain.
• To use thestain treatment station224, the user pulls thework surface226 forwardly from theenclosure20 to expose theperforated surface256. Optionally, thestain treatment station224 can be configured to automatically activate thevacuum source264 and/or thepump252 when thework surface226 is extended from theenclosure20, such as when thework surface226 is extended a predetermined distance from theenclosure20. Thestain treatment station224 can include a control system to accomplish the automatic activation of thevacuum source264 and/or thepump252. Alternatively, thevacuum source264 and/or thepump252 can be activated manually, such as by the user actuating a switch. Next, the user places the fabric item on theperforated surface256 and applies the treatment fluid to the fabric item on theperforated surface256 through thetreatment fluid dispenser231. In particular, thepump252 pumps the treatment fluid from thefluid reservoir227, through thefirst supply hose248, and through thesecond supply hose250 to theflexible hose246 and thewand244. The vacuum generated by thevacuum source264 pulls the treatment fluid applied to the fabric item through theperforated surface256. The vacuum can also draw particulates in addition to fluids from the fabric item. The treatment fluid enters thevacuum cavity262 and flows through thedrain conduit266 toward thevacuum source264. The drained treatment fluid leaves thestain treatment station224 via thewaste conduit268. When the treatment of the fabric item is complete, the user removes the fabric item from theperforated surface256 and returns thework surface226 to the retracted position in theenclosure20. Optionally, thevacuum source264 and/or thepump252 can be disabled or deactivated, such as by the control system, upon returning thework surface226 to the retracted position. Alternatively, the user can manually deactivate thevacuum source264 and/or thepump252, such as by actuating the aforementioned switch.
• Optionally, thetreatment fluid dispenser231 can be fluidly connected to both thefluid reservoir227 and a source of water in any suitable form, such as liquid, steam, or vapor. As an example, thestain treatment station224 can be plumbed into a water source for the fabric revitalizing system in theenclosure20. Thetreatment fluid dispenser231 can be configured to dispense the treatment fluid, the water in any of the forms, and a mixture of the treatment fluid and the water. Furthermore, thestain treatment station224 can be configured condition the treatment fluid and/or the water, such as by heating, cooling, mixing, and cavitating, prior to application to the fabric item.
• Thestain treatment station224 can further include a heat source and a means for applying heat to the fabric item. The heat from the heat source can facilitate removal of stains from the fabric items. Thestain treatment station224 can also be configured to include a means for applying pressure to the fabric item to facilitate removal of stains from the fabric items.
• t will be appreciated that thestain treatment station224 could alternatively or additionally include multiple fluid dispensers (including dispensers that dispense hot or cold water) as well as other fabric treatment systems to supply, for example, heat, cooling medium, moving air, steam, vapor, friction, pressure, light, or other desired inputs to thefabric load22 as part of a pre-treatment operation.
• The illustrated embodiment of the revitalizing system inFIGS. 25A and 25B further includes anoptional ironing board270. Theironing board270 can be movable relative theenclosure20, such as by being mounted on asupport272 slidably mounted within theenclosure20. Further, theironing board270 can be slidable relative to thesupport272 to extend theironing board270 after the slidably support is slid forwardly relative to theenclosure20, as shown inFIG. 25B. Thesupport272 can be coupled to afront panel274 that can pivot relative to thesupport272 to accommodate forward movement of theironing board270. It is within the scope of the invention for theironing board270 to be movable relative to theenclosure20 in other manners, such as by pivoting movement.
• Typically, an article of clothing subjected to stain pre-treatment at thestain treatment station224 can be allowed to set for a predetermined period of time prior to being subjected to a refreshing process. The predetermined period of time enables the chemistries in the treatment fluid applied to thefabric load22 by thestain treatment station224 to dissolve or disrupt the interactions between the molecules comprising the stain or spot and the fabric fibers. Once the pre-treatment predetermined period of time is complete, thefabric load22 can then be subjected to the refreshing process, whereby the debris associated with the stain or spot is removed from the article as other soils and particulates are removed.
Sanitization Processes:
• According to one embodiment, it is highly desirable to have the refreshing process render thefabric load22 sanitized, whereby thefabric load22 is rendered free of microbial content, substantially free of microbial content, or having a reduced microbial content. When thefabric load22 is to be sanitized, every component of the revitalization system in fluid communication with thechamber26 and thefabric load22 contained therein can be subject to sanitization measures that are directed at reducing or eliminating microbial content. The fluid delivery system represents one of the most critical areas for controlling microbial content, as the fluid delivery system introduces moisture into thefabric load22 during the rehydration phase of the revitalization process. The rehydration of thefabric load22 occurs as the final phase during the revitalization process and provides thefabric load22 with its final appearance prior to wearing. Thus, the sanitization status of the components of the fluid delivery system will directly contribute to whether thefabric load22 is in a sanitized condition after the rehydration phase.
• Methods of reducing the microbial content include, but are not limited to: glutaraldehyde tanning, formaldehyde tanning at acidic pH, propylene oxide or ethylene oxide treatment, gas plasma sterilization, gamma radiation, electron beam processes, ultraviolet radiation, peracetic acid sterilization, thermal (heat or cold) treatment, chemical (antibiotics, microcides, cations, quaternary amine, etc.) treatment, mechanical (acoustic energy, structural disruption, filtration, etc.) treatment, coating the components/parts with silver or silver ions, ozone treatment, microtexturing the intersurface, and combinations thereof. When the sanitizing process includes applying heat or fluids, the sanitization can be controlled by controlling the amount and rate of heat application and fluid dispersion.
• The components, such as thefluid tank128, thefluid reservoir132, theair entry chamber134, theair flow channel168/206, the fan(s)136/208, thepiezoelectric transducer140, and various fluid flow controls146, of the fluid delivery system that are accessible to air can be treated with conventional disinfectants, such as ozone (O₃).
Alternative Preferred Embodiments that Employ Principles of Component Modularity:
• Though the invention contemplates several embodiments that contain all the components necessary for fabric revitalization within a single enclosure, the present invention also contemplates a modular construction to achieve unification of the components necessary to carry out the disclosed process.
• With reference toFIGS. 26A and 26B, the present invention contemplates that the components necessary for carrying the fabric revitalization method can be located in one or more additional enclosures that comprise afunctional module230 separate from theenclosure20 that contains thefabric load22.
• Referring particularly toFIG. 26B, thefunctional module230 can be in fluid communication with theenclosure20 that contains thefabric load22 viaappropriate conduits232, such as afirst conduit232A and asecond conduit232B. The principles of modularity thereby enable a consumer to adapt a conventional fabric processing machine lacking components necessary for the fabric revitalization process with thefunctional module230 to effectively upgrade the conventional fabric processing machine to accomplish fabric revitalization process of the instant invention. In particular, for example, thefunctional module230 can contain fluid reservoirs, pumps, heaters, atomizers, coolers, and other functional components used to provide the required fluids, via theconduits232, to the revitalizing system. Thefunctional module230 can also contain appropriate controls and sensors useful in the carrying out the revitalization method.
• In one embodiment, thefunctional module230 can comprise afluid delivery system235 and afluid removal system236 similar to the fluid delivery and fluid removal systems described above. Thefluid delivery system235 can be coupled to the interior32 of thedrum30C via thefirst conduit232A, and thefluid removal system236 can be coupled to the interior32 of thedrum30C via thesecond conduit232A. In operation, thefluid delivery system235 delivers one or more fluids to thedrum30C, and thefluid removal system236 removes the one or more fluids from thedrum30C. If theenclosure20 houses a fluid removal system, then thefunctional module230 need not include thefluid removal system236. Thefunctional module230 can also include afluid recycling system237 coupled to thefluid delivery system235 and thefluid removal system236. Thefluid recycling system237 receives recovered fluid from thefluid recovery system236 and supplies the recovered fluid to thefluid delivery system235 so that that the recovered fluid can be delivered back to thedrum30C. Thefluid recycling system237 can be configured to condition the recovered fluid in addition to transporting the recovered fluid from thefluid recovery system236 to thefluid delivery system235.
• The principles of modularity and the attendant advantages of using a modular configuration for fabric processing machines in other contexts of fabric care are disclosed in U.S. patent application Ser. No. 10/971,671, filed Oct. 22, 2004, and U.S. patent application Ser. No. 10/027,160, filed Dec. 20, 2001, both entitled “Non-Aqueous Washing Apparatus and Method,” which are incorporated herein by reference in their entirety.
• As illustrated inFIG. 27, it is contemplated that the functional module can be in the form of ahorizontal pedestal230A adapted to support theenclosure20 of the revitalizing system. Alternatively, the functional module in the form of thehorizontal pedestal230A could be mounted above theenclosure20 of the revitalizing system or in another configuration relative to theenclosure20 of the revitalizing system. Thefunctional module230 can be located in any suitable position relative to theenclosure20, such as adjacent to theenclosure20 or above or below theenclosure20.
• Thefunctional module230 can include additional functionality. For example, an alternativefunctional module230B illustrated inFIG. 28 includes as a stain treatment station224A similar to thestain treatment stations224 described above with respect toFIGS. 23-25D and aniron233. Alternatives for the additional functionality are disclosed in the several patent applications listed and incorporated at the end of this section.
• Other exemplary functionalities include, but are not limited to, drying, sanitizing, and alternative chemistry. The drying module can be configured to dry fabric items by forcing heated or unheated air through a chamber that holds the fabric items. The air flow can be accompanied by mechanical movement of the fabric items, such as by tumbling the fabric items in a drum. Alternatively, the fabric items can remain stationary, such as in a vertical, hanging condition or a horizontal, flat condition, during the drying process. As an alternative to or in addition to utilizing air flow to dry the fabric items, the drying module can be configured to dispense one or more chemistries, such as alcohol, onto the fabric items to facilitate evaporation of moisture from the fabric items.Exemplary drying modules230C-230G are shown inFIGS. 29-33. The dryingmodules230C,230D ofFIGS. 29 and 30 are drawer-type horizontal modules, thedrying module230E ofFIG. 31 is a drawer-type vertical module, and the dryingmodules230F,230G ofFIGS. 32 and 33 are cabinet modules. Theseexemplary drying modules230C-230G are described in more detail in the several patent applications listed and incorporated at the end of this section. The drying module can incorporate other functions, such sanitizing and refreshing.
• The sanitizing module can be capable of sanitizing fabric items or sanitizing the revitalizing system. For sanitizing the fabric items, the sanitizing module can expose the fabric item in a chamber to a sanitizing medium that disinfects the fabric item by removal of germs, microbes, and the like. The fabric items can be subjected to mechanical movement, such as tumbling, or can be stationary during the sanitization process. For sanitizing the revitalizing system, the sanitizing module can store and dispense sanitizing media that disinfect the entire revitalizing system in theenclosure20 or particular components of the revitalizing system.
• The alternative chemistry module can store one or more revitalizing chemistries for use in the revitalizing system. For example, the alternative chemistry module can have the capacity to store a larger variety of and greater volumes of revitalizing chemistries than the revitalizing system housed within theenclosure20. As a result, the alternative chemistry module can expand the capabilities of the revitalizing system. The revitalizing chemistries can be stored in the alternative chemistry module in any suitable manner, such as in individual drawers that can be easily accessed by the user by pulling the drawer from the alternative chemistry module. The alternative chemistry module can communicate with thecontrol213 for coordinating dispensing of the revitalizing chemistries from the alternative chemistry module to the revitalizing system in theenclosure20. For example, the alternative chemistry module can have the ability of resetting the revitalizing system to operate with one or more preselected revitalizing chemistries.
• Additional exemplary functional modules are illustrated inFIGS. 34-37.FIG. 34 shows anexemplary ironing module230H,FIG. 35 depicts an exemplary sink module230I,FIG. 36 illustrates anexemplary storage module230J, andFIG. 37 shows anexemplary shelf module230K. These exemplaryfunctional modules230H-230K are described in more detail in the several patent applications listed and incorporated at the end of this section.
• Several of the exemplary functional modules shown in the figures comprise common features. For example, theironing module230H and the sink module230I both includestorage drawers280. The sink module230I further includes apivotable storage compartment282, thestorage module230J provides astorage compartment284 closable by adoor286, which supports a plurality ofremovable storage bins288, and theshelf module230K has an open-top storage cavity290. Further, the dryingmodules230E,230F and theshelf module230K each include a hangingelement292 for supporting fabric items.
• Other exemplary functional modules and functionalities, including work surfaces, that can be incorporated into the functional module are disclosed in the following patent applications, which are incorporated herein by reference in their entirety: U.S. patent application Ser. No. 11/323,125, filed Dec. 30, 2005, and titled “Modular Laundry System with Horizontal Modules,” U.S. patent application Ser. No. 11/322,715, filed Dec. 30, 2005, and titled “Modular Laundry System with Horizontal Module Spanning Two Laundry Appliances,” U.S. patent application Ser. No. 11/323,221, filed Dec. 30, 2005, and titled “Modular Laundry System with Horizontally Arranged Cabinet Module,” U.S. patent application Ser. No. 11/322,739, filed Dec. 30, 2005, and titled “Modular Laundry System with Horizontal and Vertical Modules,” U.S. patent application Ser. No. 11/323,075, filed Dec. 30, 2005, and titled “Modular Laundry System with Vertical Module,” U.S. patent application Ser. No. 11/323,417, filed Dec. 30, 2005, and titled “Modular Laundry System with Cabinet Module,” U.S. patent application Ser. No. 11/322,742, filed Dec. 30, 2005, and titled “Laundry Module for Modular Laundry System,” U.S. patent application Ser. No. 11/323,220, filed Dec. 30, 2005, and titled “Modular Laundry System with Work Surface,” U.S. patent application Ser. No. 11/322,773, filed Dec. 30, 2005, and titled “Modular Laundry System with Segmented Work Surface,” U.S. patent application Ser. No. 11/322,741, filed Dec. 30, 2005, and titled “Modular Laundry System with Work Surface Having a Functional Insert,” U.S. patent application Ser. No. 11/322,740, filed Dec. 30, 2005, and titled “Modular Laundry System with Work Surface Having a Functional Element,” U.S. patent application Ser. No. 11/323,658, filed Dec. 30, 2005, and titled “Modular Laundry System with Shelf Module,” U.S. patent application Ser. No. 11/323,867, filed Dec. 30, 2005, and titled “Vertical Laundry Module,” U.S. patent application Ser. No. 11/322,943, filed Dec. 30, 2005, and titled “Vertical Laundry Module with Backsplash,” U.S. patent application Ser. No. 11/322,503, filed Dec. 30, 2005, and titled “Retractable Hanging Element,” U.S. patent application Ser. No. 11/322,502, filed Dec. 30, 2005, and titled “Non-Tumble Clothes Dryer,” U.S. patent application Ser. No. 11/323,270, filed Dec. 30, 2005, and titled “Ironing Station,” U.S. patent application Ser. No. 11/322,944, filed Dec. 30, 2005, and titled “Sink Station with Cover.”
Automated Fabric Processing System:
• Various components and systems of the revitalizing system have been described above. The revitalizing system can comprise other components and systems such that the revitalizing system can be operated in any suitable manner. The components and system form an automated fabric processing system that provides at least one of mechanical energy, thermal energy, and chemical energy to thefabric load22 in thechamber26 to perform a fabric treatment process. For example, the automatic fabric processing system can comprise the fabric movement system and the heated air supply system whereby the fabric treatment process comprises drying thefabric load22 much like in a conventional clothes dryer. Alternatively, the automatic fabric processing system can comprise the fabric movement system, a water supply system, and a water removal system whereby the fabric treatment process comprises washing thefabric load22 much like in a conventional clothes washing machine. As another example, the automatic fabric processing system can comprise the fabric movement system, the heated air supply system, the water supply system, and the water removal system whereby the fabric treatment process comprises drying thefabric load22 and washing thefabric load22 much like in a conventional combination fabric washing and drying machine. The automatic fabric processing system can comprise, among other systems, the treatment fluid dispensing system whereby the fabric treatment process comprises revitalizing thefabric load22.
Revitalization Method:
• Referring toFIG. 38, the present invention contemplates use of an assortment of operations and methods (herein termed “Actions”) for using the revitalization system disclosed herein to achieve article refreshing for thefabric load22. After the user inputs thefabric load22 into therevitalization chamber26 of theenclosure20, the user inputs or enters a specific set of parameters into thecontrol panel212 of the user interface andcontrol210 for communication with thecontrol213. Thecontrol213 can also receive inputs or information from other sources, including internal sources, such as the sensors associated with the revitalization system, and external sources. The parameters determine the set of operations and Actions to be performed on thefabric load22 during the revitalization process. Alternatively, the user can manually select the operations and Actions from a menu on thecontrol panel212. After thecontrol panel212 receives input or engages an initiation entry, thecontrol213 commences with an initial action corresponding to a selected operation. One skilled in the art will understand that a plurality of operations can be performed simultaneously or sequentially on thefabric load22, and, for any given operation, a plurality of Actions may be performed simultaneously or sequentially on thefabric load22 during the course of the revitalization process.
• Basic operations associated with fabric revitalization includeFluid Extraction300,Relative Motion310,Fabric Air Flow320,Cooling330,Fluid Insertion340,Fabric Fluid Absorption350, andResidual Fluid Extraction300A. An exemplary order of the operations performed on thefabric load22 begins with theFluid Extraction300, theRelative Motion310, and theFabric Air Flow320. Because each of these three initial operations is independently controllable (e.g., theFluid Extraction300 is governed by theheater76, theblower fan80, and themotor82; theRelative Motion310 is governed by themotor52; and theFabric Air Flow320 is governed by theblower fan80 and themotor82, and optionally the recycle/recirculation loop86), it will be understood that the precise order of these three initial operations can be selectable by the user and can vary according to the type of thefabric load22 present in thechamber26. It will be understood to those skilled in the art that the user can select to use only a subset of these three initial operations to effect the desired treatment on thefabric load22. It will also be understood to those skilled in the art that a plurality of operations can be performed sequentially or simultaneously and in varied order throughout the revitalization process. For example, thefabric load22 can be subjected to multiple of theRelative Motion310 operations during performance of theFluid Extraction300 and theFabric Air Flow320 operations.
• Each of theFluid Extraction300, theRelative Motion310, and theFabric Air Flow320 operations is associated with a set of specific Actions that can be selected by the user engaging thecontrol panel212 of the user interface andcontrol210. If the user selects theFluid Extraction300 as part of the revitalization program, then thecontrol panel212 of the user interface andcontrol210 prompts the user with a menu of the Actions associated with theFluid Extraction300 operation. The Actions associated with theFluid Extraction300 operation include Dehydration/Heating301,Vacuum302, High Speed Spin303, and Chemical Extraction (e.g. desiccant)304. If the user selects theRelative Motion310 as part of the revitalization program, then thecontrol panel212 of the user interface andcontrol210 prompts the user with a menu of the Actions associated with theRelative Motion310 operation. The Actions associated with theRelative Motion310 operation includeTumble311,Shake312,Oscillate313,Nutate314, Vibrate315,Chemistry Distribution316,Wrinkle Prevention317, and Fabric Surface Brushing318. If the user selects theFabric Air Flow320 as part of the revitalization program, then thecontrol panel212 of the user interface andcontrol210 prompts the user with a menu of the Actions associated with theFabric Air Flow320 operation. The Actions associated with theFabric Air Flow320 operation includeRecirculated Air321,Ambient Air322,Heated Air323, andBlower Air324.
• If theFluid Extraction300 is selected as one of the operations, then the various sensors, such as thesensors92,94,98 can become active to sense fluid content and temperature of thefabric load22 as theFluid Extraction300 operation proceeds. Optionally, the user can specify in theFluid Extraction300 operation the extent of the fluid extraction from thefabric load22, which can be prompted by selection of the type of fabric included in the fabric load22 (e.g., linen, silk, polyester blend, cotton, wool, etc.) at thecontrol panel212 of the user interface andcontrol210. Other operations associated with theFluid Extraction300 include theCooling330. The Actions associated with the Cooling330 include CirculateAmbient Air331,Refrigerant332, and Thermal-Elastic Transducer333. In a manner similar to selection of theFluid Extraction300, election of theCooling330 operation can result in temperature sensors becoming activated to sense the temperature of thefabric load22. The Cooling330 operation returns thefabric load22 to ambient temperature. Because theRelative Motion310 and theFabric Air Flow320, when not performed with theHeated Air323 Action or other Action including heating thefabric load22, are not associated with Actions that result in heat being imparted to thefabric load22, the Cooling330 will not be an option typically available to the user through operation of thecontrol panel212 of the user interface andcontrol210 absent the selection of theFluid Extraction300. However, theRelative Motion310 and theFabric Air Flow320 are user selectable options available at thecontrol panel212 of the user interface andcontrol210 following completion of theCooling330.
• Following the completion of the selected operations, which can include any combination of theFluid Extraction300, theRelative Motion310, theFabric Air Flow320, and theCooling330, thefabric load22 can be subjected to rehydration, which is performed by theFluid Insertion340 operation. The Actions associated with theFluid Insertion340 operation includeNebulize341, Injection342, Spray343, Fan344, Fluid Level Detection345, Pumping346, Power347, Time348, and Temperature349. Sensors, such as those included in the system and on thefabric load22, can be activated to sense moisture content or temperatures within thechamber26 and thefabric load22 during theFluid Insertion340. Thefabric load22 can be subjected to any of the Actions311-318 of theRelative Motion310 during or after theFluid Insertion340 operation.
• The rehydration is further promoted by subjecting thefabric load22 to theFabric Fluid Absorption350 operation. The Actions associated with theFabric Fluid Absorption350 operation includeAdsorption351,Absorption352,Tumbling353,Humidified Air354,Condensation355,Electrostatic356, and Cooling/Heating357. Sensors, such as those included in the system and on thefabric load22, can be activated to sense moisture content or temperature within thechamber26 and thefabric load22 during theFabric Fluid Absorption350 operation.
• Following completion of theFabric Fluid Absorption350 operation, thefabric load22 can be subjected to theResidual Fluid Extraction300A operation to remove extraneous fluid from thefabric load22 or within thechamber26. The Actions associated with theResidual Fluid Extraction300A include the Actions301-304 associated with theFluid Extraction300 operation. Optionally, thefabric load22 can be subjected to theRelative Motion310 and theFabric Air Flow320 operations and their respective Actions during theResidual Fluid Extraction300A. Sensors, such as those included in the system and on thefabric load22, can be activated to sense moisture content and temperature in thechamber26 and thefabric load22 during theResidual Fluid Extraction300A.
• Following completion of theResidual Fluid Extraction300A, the temperature of thefabric load22 can be returned to ambient temperature through the Cooling330 operation and its attendant Actions331-333. Optionally, thefabric load22 can be subjected to theRelative Motion310 and theFabric Air Flow320 operations and their respective Actions311-318,321-324 during theCooling330 operation. Sensors, such as those included in the system and on thefabric load22, can be activated to sense temperature in thechamber26 and thefabric load22 during theCooling330 operation.
• After completion of a final Action of an operation of the selected program, the user interface andcontrol210 communicates, such as via an audio or visual signal, to the user that the revitalization process is completed, and the system powers off. Thereafter, the user effects ClothesRemoval370 by removing therefreshed fabric load22 from thechamber26.
• Optionally, the fabric revitalization can proceed without the steps associated with rehydration, such as theFluid Insertion340 operation and theFluid Fabric Absorption350 operation, whereby the process corresponds to a dry operation similar to that of a conventional clothes dryer.
Cadence and Evolutionary Development of Embodiments:
• It will be apparent to those skilled in the art that the revitalization system and method disclosed herein for fabric materials can be configured in a variety of formats for fabric care systems, including an independent revitalization system in a sealed, stand-alone enclosure, a combination dryer-revitalization system, and a combination washer-dryer-revitalization system that employs a combination of aqueous and non-aqueous processes.
• Furthermore, it will be evident to those skilled in the art that features, components, and processes of the revitalization system and method disclosed herein for fabric materials have broad applications to removing particulates, such as stains, soils, and other foreign matter, from any number of different surfaces, including: human hair and skin; pet hair and skin; metallic materials associated with precious metals and coins, jewellery, flatware; cars, boats, bicycles, and the like; as well as ceramic materials associated with jewellery, flatware, and dishware, such as china.
• Exemplary enclosures20 for exemplary embodiments of the revitalization systems for various applications include tanning or spa booths (to remove debris and dead cells from the skin and hair of humans and pets), automated car washes or stand alone garage enclosures (to remove debris from automobile, bikes, boats), enclosures for a combination dishwasher/revitalization system (to remove debris and stains from flatware and dishware, such as china), and table top enclosure systems (to remove debris and stains from jewellery and precious metals and coins). Each of these exemplary enclosures, though already well established in the art for particular applications, can be modified, upon reading the present detailed description and understanding the system disclosed herein, to include components of the revitalization system and method for revitalization of fabric materials.
Exemplary Control Process:
• Acontrol chart400 illustrating a user interface and control process as well as alternative cycles for the revitalization system and method is provided inFIGS. 39A and 39B, which include multiple alternative operations for treating fabric. In contrast toFIG. 38, which illustrates a wide variety of alternative Actions possible for each operation in a revitalization process, the control process ofFIGS. 39A and 39B is described in the context of an exemplary production control for a specific configuration of the revitalization system. More particularly,FIGS. 39A and 39B are directed to a control process for a revitalization system incorporated into a horizontal axis clothes dryer or a horizontal axis combination washer/dryer, such as that illustrated by example inFIG. 1, which offers the user a small number of pre-programmed alternative cycles as well as a small number of specific variable parameters for each of these cycles. It will be appreciated by those skilled in the art that principles behind the control process chart ofFIGS. 39A and 39B can be applied to other configurations of the revitalization systems, such as those illustrated inFIGS. 2A-2D and3A-3F.
• The control process illustrated on thecontrol chart400 is divided into two primary cycles, adehydration cycle402 and a finishingcycle404. Thedehydration cycle402 is shown in detail inFIG. 39A, while the finishingcycle404 is illustrated in detail inFIG. 39B.
• Referring now toFIG. 39A, the control process begins, prior to running thedehydration cycle402 and the finishingcycle404, with loading thefabric load22 into the chamber atstep406 and determining which cycle is to be run atsteps408,410, and412, as described in more detail below.
• After thefabric load22 is loaded into the chamber, the operator provides information to and receives information from thecontrol213 via thecontrol panel212 of the user interface andcontrol210 atstep408. The information input by the user can include load type, load size, soil level of the load, the presence of stains, the presence of odors, cycle selection, special operations, details of the operation of the motor (e.g., speed, direction of movement, duration of operation), the type of fluid to use or to be dispensed, details of the operation of the fluid delivery system, and details of operation of the fluid removal system. Alternatively, the user might chose to directly select a cycle of operation from a list of pre-programmed cycles. The information received by the user from thecontrol panel212 of the user interface andcontrol210 could include status information, safety information, emergency information, time remaining, cycle step status, unbalanced load, blocked conduit, valve failure, clogged filter, breach of close system, fluid leak, fluid level, pressure drops, temperature increase, and chemical leakage.
• Thecontrol213 retrieves additional information atstep410. This can include information delivered from sensors that can be built into the revitalizing system. Such sensors can include sensors that detect aspects of the internal environment of the revitalization system, the condition of the system, or the ambient environment of the room in which the system resides. The sensors can specifically include sensors detecting temperature, pressure, humidity, vapor, moisture, oxygen, carbon monoxide, carbon dioxide, electrical condition, enzyme, aqueous vapor, non-aqueous vapor, turbidity, optical spectrum, ultrasonic, sharp electronic field, float, laser deflection, petrotape (for petroleum and fuels), chemtape (for chemicals and petro-chemicals), electric field imaging, capacitance, resistance, pH, non-disperse infrared, acoustic wave, and oxidation reduction potential sensors. The information provided to thecontrol213 at thestep410 can also include information received from other data sources available to thecontrol213. Examples of such information include online look up tables, data from the fluids added to the revitalization system or from the fluid packaging, data integrated into thefabric load22, or data from a washing machine or other pre-treatment machine relating to thefabric load22.
• Thecontrol213 uses both the information provided by the user and the additional information to select cycles and set parameters atstep412, unless more information is needed from the user, as determined atstep411 prior to step412. More information is needed, for example, if thecontrol213 finds that there is any inconsistency between the cycle or fluid selected by the user and the type of thefabric load22 detected. Exemplary parameters that can be set for a cycle are the type of fluid and the amount of fluid used during the cycle, such as to obtain a desired rehydration, which will be explained in more detail below.
• Next, thedehydration cycle402 begins by tumbling thefabric load22 atstep414. If the revitalization system is capable of different types of tumbling motion, the tumbling is determined by the cycle selected. The type of motion can be, for example, unidirectional, bi-directional, random, and/or cradle, and the motion can vary in speed and duration, depending upon the cycle and cycle parameters set atstep412. The drum rotation can be controlled to minimize damage to thefabric load22.
• If thedrum30C has the texturedsubstrate surface56, then thefabric load22 will contact, at least intermittently, thetextured substrate surface56 as thedrum30C rotates. During the rotation of thedrum30C, thefabric load22 moves, such as by tumbling, thereby causing relative movement between thefabric load22 and thetextured substrate surface56. During the relative motion, thetextured substrate surface56 can draw particulates away from thefabric load22 and trap the particulates. Further, if thetextured substrate surface56 includes fluid dispensing means, the fluid can be dispensed onto thefabric load22.
• A process aid can optionally be provided atstep416 of the process depending upon the cycle selected atstep412 and as determined atstep415. The process aids introduced atstep416 can be aqueous fluids, semi-aqueous fluids, non-aqueous fluids, or a mixture of these fluids. The fluids can contain a washing additive, such as a washing additive selected from builders, surfactants, enzymes, bleach activators, bleach catalysts, bleach boosters, bleaches, alkalinity sources, antibacterial agents, colorants, perfumes, pro-perfumes, finishing aids, lime soap dispersants, composition malodor control and removal agents, odor neutralizers, polymeric dye transfer inhibiting agents, softening agents, anti-static agents, crystal growth inhibitors, photobleaches, heavy metal ion sequestrants, anti-tarnishing agents, anti-microbial agents, anti-oxidants, linkers, anti-redeposition agents, electrolytes, pH modifiers, thickeners, abrasives, divalent or trivalent ions, metal ion salts, enzyme stabilizers, corrosion inhibitors, diamines or polyamines and/or their alkoxylates, suds stabilizing polymers, solvents, process aids, fabric softening agents, optical brighteners, hydrotropes, suds or foam suppressors, suds or foam boosters, fabric softeners, antistatic agents, dye fixatives, dye abrasion inhibitors, anti-crocking agents, wrinkle reduction agents, wrinkle resistance agents, wrinkle release agents, soil release polymers, soil repellency agents, sunscreen agents, anti-fade agents, and mixtures thereof. The process aid can optionally be added to thefabric load22 uniformly by using the fluid delivery system of the present invention as described above.
• A dehydration process of thedehydration cycle402 is formally initiated atstep418. A variety of dehydration cycles and cycle parameters are possible based on both the information input by the operator and the additional information received from external sources, such as sensors. In particular, thedehydration cycle402 can vary depending on whether thefabric load22 has been placed in the chamber atstep406 at near ambient humidity or is damp, such as from being washed in an automatic washer or being pretreated. Thedehydration cycle402 can also vary depending on the type offabric load22. Thedehydration cycle402 can typically employ a combination of the heater control, the air flow, the fluid removal system, and the particle removal and recovery system. Thedehydration cycle402 can terminate atstep420 based on a period of time set atstep412 or, alternatively, when a sensor detects directly or permits an inference that thefabric load22 has reached a predetermined level of dryness. The predetermined level of dryness for washable fabrics can be, for example, 0% to 10% by weight.
• A process aid can be optionally added atstep422 as determined bystep421 and can be selected from the list provided above and in tone of the manners described above for process aid that can be added instep416. In one embodiment, the process aid added instep416 can be a different process aid added atstep422. The process aids can be, for example, two different fluids. A first fluid added atstep416 can provide a revitalizing function on the fabric, while a second fluid can be released at the time of use of the fabric for the benefit of the user. Alternatively, the second fluid can activate the first fluid. During the dehydration cycle run atstep418, the first fluid can be at least partially extracted from the fabric before the second fluid is added atstep421. Alternatively, the two fluids can be added to the fabric during the finishingcycle404.
• Referring now toFIG. 30B, the finishingcycle404, which can bet set instep412, is initiated atstep424. Options offered for the finishing cycles in the illustrated embodiment include “Refresh,” “Refinish,” “Light Clean,” and “Dry.” The primary differences in the operation of the revitalizing system between the exemplary finishing cycles are the level of rehydration, as shown bysteps426,428, and430, and whether there is a step of tumbling without heat atstep432 followed by adehydration step434.
• The four exemplary finishing cycles shown inFIG. 30B are provided as examples and do not represent all of the possible contemplated finishing cycles. Each of the exemplary finishing cycles performs a different function for thefabric load22. In the “Refresh” cycle, which can also be referred to as a “Revitalize” cycle, thefabric load22 is only rehydrated atstep426 to about 2-5% moisture by weight of the fabric for dewrinkling, rinsing mild odors, and delivery of functional chemistry, if desired. In the “Refinish” cycle, which can also be referred to as a “Reshape” cycle, the fabric is rehydrated atstep428 to about 10-20% moisture by weight of the fabric and tumbled without heat for a predetermined period of time atstep432 to provide significantly more wrinkle removal and reshaping of thefabric load22 than would occur at the lower moisture level of the “Refresh” cycle. In the exemplary “Light Clean” cycle, thefabric load22 is rehydrated atstep430 to an intermediate level of about 5-10% moisture by weight of the fabric and tumbled without heat for a predetermined period of time atstep432 for the removal of soils. The soil removal is obtained at least in part from the mechanical action of tumbling and rubbing against thetextured surface substrate56 in thedrum30C. Chemistry can be added for additional soil removal. Both the “Refinish” and the “Light Clean” cycles can include thedehydration step434 following the tumblingstep432 to dehydrate thefabric load22 to a predetermined level, such as about 2-5% moisture by weight of the fabric. In the exemplary “Dry” cycle, the revitalization system stops after the completion of thedehydration cycle402, and, thus, the revitalization system functions similar to a conventional clothes dryer. It follows that the revitalization system can dry awet fabric load22 and then revitalize thefabric load22, such as by using the “Dry” cycle followed by another cycle, or revitalize an initiallydry fabric load22.
• In the finishing cycle, thefabric load22 can be hydrated to or near an equilibrium moisture level to provide a predetermined amount of free moisture that can participate in background soil removal. By hydrating thefabric load22 in such a manner, thefabric load22 becomes saturated or slightly saturated, and any additional fluid added will be the free moisture that can facilitate soil removal from the saturated or slightly saturatedfabric load22.
• As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.

Claims (25)

1. A method of revitalizing a fabric, the method comprising:

placing the fabric in a chamber;

directing a mist into the chamber to wet the fabric with the mist;

directing a flow of air into the chamber and out of the chamber;

removing particulates from the flow of air out of the chamber; and

removing the fluid from the fabric in the chamber to reduce fluid content to approximately 0% to 5% by weight of the fabric.

2. The method ofclaim 1 wherein the step of directing the mist into the chamber comprises wetting the fabric until the fabric contains approximately a predetermined amount of fluid.

3. The method ofclaim 2 wherein the predetermined amount of fluid depends on a type of cycle selected by a user of the method.

4. The method ofclaim 2 wherein the predetermined amount of fluid is about 2%-5% fluid by weight of the fabric.

5. The method ofclaim 2 wherein the predetermined amount of fluid is about 5%-10% fluid by weight of the fabric.

6. The method ofclaim 2 wherein the predetermined amount of fluid is about 10%-20% fluid by weight of the fabric.

7. The method ofclaim 1 wherein the type of fluid is determined by a type of cycle selected by a user of the method.

8. The method ofclaim 1 wherein the fluid is water.

9. The method ofclaim 1 wherein the flow of air through the chamber is heated at least part of the time.

10. The method ofclaim 1, further comprising moving the fabric in the chamber to facilitate the wetting of the fabric with the mist.

11. The method ofclaim 10 wherein the movement of the fabric is caused by rotation of the chamber.

12. The method ofclaim 1, further comprising providing relative movement between the fabric and a low absorbency textured surface.

13. The method ofclaim 12 wherein the low absorbency textured surface is at least partially disposed on an inside surface of the chamber.

14. The method ofclaim 1, further comprising providing relative movement between the fabric and a non-absorbent textured surface.

15. The method ofclaim 1, further comprising prior to the step of directing the mist into the chamber, a step of selecting a cycle, the cycle being selected being differentiated from at least one other cycle by at least one of the following parameters:

whether the fabric is dewatered prior to the step of directing the mist into the chamber;

what type of fluid is supplied during the step of directing the mist into the chamber;

when, if ever, additional quantities of fluid are added to the chamber;

when, if ever, additional types of fluid are added to the chamber;

when, if ever, the flow of air is heated;

when, if ever, the flow of air is cooled;

when, if ever, a fluid is heated;

when, if ever, a fluid is cooled;

how much of the fluid is supplied to the chamber;

how long the fluid remains in contact with the fabric before the step of removing the fluid begins;

how much motion is provided to the fabric; and

what type of motion is provided to the fabric.

16. The method ofclaim 1, further comprising revitalizing the fabric by at least one of the following:

ionizing the air flow;

photo-activating a fluid used with the fabric;

applying wrinkle releaser to the fabric;

applying a disinfecting chemistry to the fabric;

applying a cleaning chemistry to the fabric;

applying an odor removal chemistry to the fabric;

applying a fragrance to the fabric;

applying an insect repellent to the fabric;

applying heat to remove odor from the fabric;

controlling heat applied to the fabric to minimize at least one of wrinkles, odors, and shrinkage;

applying mechanical action to effect cleaning of the fabric;

controlling chamber rotation to minimize fabric damage;

sanitizing by controlling dryer heat or fluid dispersion;

hydrating the fabric about an equilibrium moisture level to provide a predetermined amount of free moisture that can participate in background soil removal;

applying an oxidizing agent to the fabric, wherein the oxidizing agent comprises at least one of hydrogen peroxide and electrolytic water;

applying silver; and

applying a process aid selected from aqueous fluids, semi-aqueous fluids, non-aqueous fluids, or a mixture of these fluids.

17. The method ofclaim 1, further comprising applying a process aid selected from builders, surfactants, enzymes, bleach activators, bleach catalysts, bleach boosters, bleaches, alkalinity sources, antibacterial agents, colorants, perfumes, pro-perfumes, finishing aids, lime soap dispersants, composition malodor control agents, odor neutralizers, polymeric dye transfer inhibiting agents, softening agents, anti-static agents, crystal growth inhibitors, photobleaches, heavy metal ion sequestrants, anti-tarnishing agents, anti-microbial agents, anti-oxidants, linkers, anti-redeposition agents, electrolytes, pH modifiers, thickeners, abrasives, divalent or trivalent ions, metal ion salts, enzyme stabilizers, corrosion inhibitors, diamines or polyamines and/or their alkoxylates, suds stabilizing polymers, solvents, process aids, fabric softening agents, optical brighteners, hydrotropes, suds or foam suppressors, suds or foam boosters, fabric softeners, antistatic agents, dye fixatives, dye abrasion inhibitors, anti-crocking agents, wrinkle reduction agents, wrinkle resistance agents, soil release polymers, soil repellency agents, sunscreen agents, anti-fade agents and mixtures thereof.

18. The method ofclaim 1, further comprising dispensing fluid from a low absorbency pad.

19. The method ofclaim 1, further comprising dispensing fluid from a substantially non-absorbent pad.

20. The method ofclaim 1, further comprising filtering the flow of air using at least one of:

a locked down sealed edge filter;

a filter for at least one of a vapor, a fog, and a colloidal suspension;

an electrostatic filter;

a filter impregnated with a catalyst for producing at least one of a specie and radical for cleaning;

a filter impregnated with a reactant to chemically treat a substance present in air;

a neutralizing filter to remove a previous treatment; and

an air permeable matrix having a plurality of pores with a greatest pore dimension in a range from about 0.10 micron to about 1500 microns

21. The method ofclaim 1, further comprising inserting vapor into the chamber to wet the fabric.

22. The method ofclaim 21, further comprising using the vapor to dispense fluid into the chamber.

23. The method ofclaim 1, further comprising inserting steam into the chamber to wet the fabric.

24. The method ofclaim 23, further comprising using the steam to dispense fluid into the chamber.

25. The method ofclaim 1 wherein the mist comprises one of a spray and a vapor.

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