METHOD FOR REFRESHING FABRIC ARTICLES

A method for refreshing fabric articles without the need for additional cleaning treatment. The method comprises the steps of loading fabric articles to be treated into a drum of a home appliance, contacting said fabric articles with an aqueous fabric refreshing composition containing both antimicrobial active agent and deodorizing active agent under a temperature of from about 30° C. to about 120° C. for about 1 minute to about 120 minutes.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/063,078 filed on Jan. 31, 2008.

FIELD OF THE INVENTION

The present invention relates to a method for refreshing fabric articles. Specifically, the present invention relates to a method for refreshing fabric articles, upon the refreshing treatment of the present invention, the fabric articles are ready for use without the need for any additional cleaning treatment.

BACKGROUND OF THE INVENTION

After wearing or using fabric articles, consumers typically clean the fabric articles by conventional aqueous laundry cleaning or dry cleaning process for the next wear or use. Conventional aqueous laundry cleaning is carried out with relatively large amounts of water, typically in a washing machine at consumers' home. Although washing machines and laundry detergents have become quite sophisticated, the conventional aqueous laundry process still exposes fabric articles to the risk of dye transfer and/or shrinkage, etc. Most dry cleaning processes use non-aqueous solvents for cleaning. By avoiding water, the dry cleaning processes minimize the risk of shrinkage and wrinkling. However, the need for handling and recovering large amounts of solvents makes the dry cleaning processes inconvenient and expensive, and thus unsuitable for use in consumers' home.

In addition to the conventional need for cleaning fabric articles, there is also a need for “refreshing” fabric articles, especially for fabric articles which are worn or used for a limited times and without apparent soils on the articles. For such fabric articles, it might be superfluous to clean the fabric articles by conventional aqueous laundry cleaning or dry cleaning process for the next use. In addition, as described above, repeated aqueous laundry cleaning or dry cleaning will inevitably expose the fabric articles to the risk of damages and will add excessive burden to the environment. In fact, it is desirable to consumers that fabric articles worn or used only limited times can be used again after a simple and convenient refreshing treatment. It has been identified by consumer research that degerming and deodorizing the treated fabric articles by consumers from the refreshing treatment are the key desirable benefits. In addition, it is desirable that consumers can conduct the refreshing treatment at home with a common home appliance. Known method in the art could not provide all of the desired benefits to consumers.

Accordingly, there are unmet needs for a method for refreshing fabric articles, which method can be conveniently conducted by consumers at home and fabric articles upon the refreshing treatment are ready for use without the need for any additional cleaning treatment.

SUMMARY OF THE INVENTION

The present invention provides a method for refreshing fabric articles. The method herein includes the steps of loading fabric articles to be treated into a drum of a home appliance, contacting said fabric articles with an aqueous fabric refreshing composition under a temperature of from about 30° C. to about 120° C. for about 1 minute to about 120 minutes, wherein said fabric refreshing composition contains from about 0.001% to about 1.0% by weight of an antimicrobial active agent and from about 0.01% to about 20% by weight of an deodorizing active agent. Surprisingly, it has been found that the method herein can substantially refresh fabric articles. In other words, the method herein can substantially sanitize and/or remove microorganisms and malodors from the treated fabric articles. The treated fabric articles are therefore ready for wear or use without the need for any additional cleaning treatment. In addition, the method herein can be conveniently conducted by consumers at home using a common home appliance, such as a washing machine, dryer, etc. This avoids the inconvenience of having multiple different appliances at home.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the term “fabric article” means any article that is customarily cleaned in a conventional aqueous laundry cleaning process or dry cleaning process. As such, the term encompasses articles of clothing, linen and drapery, clothing accessories, and floor coverings. The term also encompasses other items made in whole or in part of fabric, such as tote bags, furniture covers, tarpaulins and the like.

As used herein, the terms “refresh”, “refreshing” or “refreshed” when used in the context of treating fabric articles mean to at least substantially remove malodors from the fabric articles and substantially sanitize and/or remove microorganisms from the fabric articles. It should be understood that any additional benefits, include, but are not limited to wrinkle-reduction, softness, crispness, water and/or stain repellency, antistatic, anti-shrinkage, etc are not supposed to be excluded from the scope of refreshing treatment.

As used herein, the term “aqueous fabric refreshing composition” means compositions comprising one or more antimicrobial active agent and one or more deodorizing active agent. Said active agents are dispersed or dissolved in a media composed mainly of water.

As used herein, the articles “a” and “an”, when used in a claim, are understood to mean one or more of the material that is claimed or described.

Unless otherwise indicated, all percentages and ratios are calculated on weight basis.

Aqueous Fabric Refreshing Composition

According to the method for refreshing fabric articles herein, fabric articles to be treated are contacted with an aqueous fabric refreshing composition containing from about 0.001% to about 1.0%. or from about 0.005% to about 0.5%, or from about 0.01% to about 0.1% by weight of an antimicrobial active agent and from about 0.01% to about 20%, or from about 0.1% to about 5%, or from about 0.5% to about 2% by weight of an deodorizing active agent.

Antimicrobial Active Agent

An antimicrobial active agent is useful in sanitizing fabric articles. Typical concentrations of antimicrobial active agent in the aqueous fabric refreshing composition range from about 0.001% to about 1.0%, or from about 0.005% to about 0.5%, or from about 0.01% to about 0.1% by weight of the aqueous fabric refreshing composition. There is no specific limitation on the antimicrobial active agent useful herein. Antimicrobial active agents commonly found in household cleaning consumer products can be used herein. Illustrative antimicrobial active agent includes, but is not limited to antibacterial halogenated compounds, quaternary ammonium compounds, phenyl and phenolic compounds, metallic salts, organic acid and its salts.

Antibacterial Halogenated Compounds. Biguanides are a group of robust antimicrobial halogenated compounds which can function as disinfectants/sanitizers, and are useful in the fabric refreshing composition herein. Illustrative biguanides include 1,1′-hexamethylene bis(5-(p-chlorophenyl)biguanide), commonly known as chlorhexidine, and its salts, e.g., with hydrochloric, acetic and gluconic acids. The digluconate salt is highly water-soluble, about 70% in water, and the diacetate salt has a solubility of about 1.8% in water. Other useful biguanide compounds include Cosmoci™ CQ™, Vantocil™ IB, including poly(hexamethylene biguanide)hydrochloride. Other useful biguanides include the bis-biguanide alkane and its water soluble salts, such as chlorides, bromides, sulfates, alkyl sulfonates such as methyl sulfonate and ethyl sulfonate, phenylsulfonates such as p-methylphenyl sulfonates, nitrates, acetates, gluconates, and the like. Examples of suitable bis-biguanide compounds are chlorhexidine; 1,6-bis-(2-ethylhexylbiguanidohexane)dihydrochloride; 1,6-di-(N1,N1′-phenyldiguanido-N5,N5′)-hexane tetrahydrochloride; 1,6-di-(N1,N1′-phenyl-N1,N1′-methyldiguanido-N5,N5′)-hexane dihydrochloride; 1,6-di(N1,N1′-o-chlorophenyldiguanido-N5,N5′)-hexane dihydrochloride; 1,6-di(N1,N1′-2,6-dichlorophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di[N1,N1′-beta-(p-methoxyphenyl)diguanido-N5,N5′]-hexane dihydrochloride; 1,6-di(N1,N1′-alpha-methyl-beta-phenyldiguanido-N5,N5′)-hexane dihydrochloride; 1,6-di(N1,N1′-p-nitrophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-2,4-dichlorophenyldiguanido-N5,N5′)hexane tetrahydrochloride; 1,6-di(N1,N1′-p-methylphenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-2,4,5-trichlorophenyldiguanido-N5,N5′)hexane tetrahydrochloride; 1,6-di[N1,N1′-.alpha.-(p-chlorophenyl)ethyldiguanido-N5,N5′]hexane dihydrochloride; omega. Omega′-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)m-xylene dihydrochloride; 1,12-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)dodecane dihydrochloride; 1,10-di(N1,N1′-phenyldiguanido-N5,N5′)-decane tetrahydrochloride; 1,12-di(N1,N1′-phenyldiguanido-N5,N5′)dodecane tetrahydrochloride; 1,6-di(N1,N1′-o-chlorophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)-hexane tetrahydrochloride; ethylene bis(1-tolyl biguanide); ethylene bis-(p-tolyl biguanide); ethylene bis(3,5-dimethylphenyl biguanide); ethylene bis(p-tert-amylphenyl biguanide); ethylene bis(nonylphenyl biguanide); ethylene bis(phenyl biguanide); ethylene bis(N-butylphenyl biguanide); ethylene bis(2,5-diethoxyphenyl biguanide); ethylene bis(2,4-dimethylphenyl biguanide); ethylene bis(o-diphenylbiguanide); ethylene bis(mixed amyl naphthyl biguanide); N-butyl ethylene bis(phenylbiguanide); trimethylene bis(o-tolyl biguanide); N-butyl trimethylene bis(phenyl biguanide); and the corresponding pharmaceutically acceptable salts of all of the above such as the acetates; gluconates; hydrochlorides; hydrobromides; citrates; bisulfites; fluorides; polymaleates; N-coconutalkylsarcosinates; phosphites; hypophosphites; perfluorooctanoates; silicates; sorbates; salicylates; maleates; tartrates; fumarates; ethylenediaminetetraacetates; iminodiacetates; cinnamates; thiocyanates; arginates; pyromellitates; tetracarboxybutyrates; benzoates; glutarates; monofluorophosphates; and perfluoropropionates, and mixtures thereof. Preferred antimicrobials from this group are 1,6-di-(N1,N1′-phenyldiguanido-N5,N5′)-hexane tetrahydrochloride; 1,6-di(N1,N1′-o-chlorophenyldiguanido-N5,N5′)-hexane dihydrochloride; 1,6-di(N1,N1′-2,6-dichlorophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-2,4-dichlorophenyldiguanido-N5,N5′)hexane tetrahydrochloride; 1,6-di[N1,N1′-.alpha.-(p-chlorophenyl)ethyldiguanido-N5,N5′]hexane dihydrochloride; omega,omega′-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)m-xylene dihydrochloride; 1,12-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)dodecane dihydrochloride; 1,6-di(N1,N1′-o-chlorophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)-hexane tetrahydrochloride; and mixtures thereof; more preferably, 1,6-di(N1,N1′-o-chlorophenyldiguanido-N5,N5′)-hexane dihydrochloride; 1,6-di(N1,N1′-2,6-dichlorophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-2,4-dichlorophenyldiguanido-N5,N5′)hexane tetrahydrochloride; 1,6-di[N1,N1′-.alpha.-(p-chlorophenyl)ethyldiguanido-N5,N5′]hexane dihydrochloride; omega,omega′-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)m-xylene dihydrochloride; 1,12-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)dodecane dihydrochloride; 1,6-di(N1,N1′-o-chlorophenyldiguanido-N5,N5′)hexane dihydrochloride; 1,6-di(N1,N1′-p-chlorophenyldiguanido-N5,N5′)-hexane tetrahydrochloride; and mixtures thereof. As stated hereinbefore, the bis biguanide of choice is chlorhexidine its salts, e.g., digluconate, dihydrochloride, diacetate, and mixtures thereof. These materials are commercially available from various suppliers.

Quaternary Ammonium Compounds. A wide range of quaternary ammonium compounds can also be used as antimicrobial active agents in the aqueous fabric refreshing composition herein. Non-limiting examples of useful quaternary ammonium compounds include: (1) benzalkonium chlorides and/or substituted benzalkonium chlorides such as commercially available Barquat™ (available from Lonza), Maquat™ (available from Mason), Variquat™ (available from Witco/Sherex), and Hyamine™ (available from Lonza); (2) di(C6-C14)alkyl di-short chain (C1-4 alkyl and/or hydroxyalkyl) quaternary ammonium compound, such as Bardac™ products of Lonza; (3) Mono(C6-C14)alkyl tri-short chain (C1-4 alkyl and/or hydroxyalkyl) quaternary ammonium compound; (4) N-(3-chloroallyl)hexaminium chlorides such as Dowicide™ and Dowicil™ available from Dow; (5) benzethonium chloride such as Hyamine™ 1622 from Rohm & Haas; (6) methylbenzethonium chloride represented by Hyamine™ 10× supplied by Rohm & Haas, (7) cetylpyridinium chloride such as Cepacol chloride available from Merrell Labs. Examples of preferred dialkyl quaternary ammonium compounds are di(C8-C12)alkyl dimethyl ammonium chloride, such as didecyldimethylammonium chloride (Bardac™ 22), and dioctyldimethylammonium chloride (Bardac™ 2050).

Phenyl and Phenolic Compounds. Non-limiting examples of phenyl and phenolic compounds suitable for use as the antimicrobial active agents herein are: 4,4′-diamidino-α,ω-diphenoxypropane diisethionate, commonly known as propamidine isethionate, with water solubility of about 16%; and 4,4′-diamidino-α,ω-diphenoxyhexane diisethionate, commonly known as hexamidine isethionate. Other examples are benzyl alcohol, with a water solubility of about 4%; 2-phenylethanol, with a water solubility of about 2%; and 2-phenoxyethanol, with a water solubility of about 2.67%; typical effective level of phenyl and phenoxy alcohol is from about 0.1% to about 0.5%, by weight of the fabric refreshing composition.

Metallic Salts. Metallic salts can be used as the antimicrobial active agent of the fabric refreshing composition herein. Useful metallic salts herein include, but is not limited to copper salts, zinc salts, silver salts and mixtures thereof. Illustrative metallic salts useful herein include cupric abietate as a fungicide, copper acetate as a mildew inhibitor, cupric chloride as a fungicide, copper lactate as a fungicide, and copper sulfate as a germicide. Metallic salts also possess some malodor control abilities, such as to absorb amine and sulfur-containing compounds of low molecular weight. Low molecular weight sulfur-containing compounds, e.g., sulfide and mercaptans and low molecular weight amines, are components of many types of malodors, e.g., food odors (garlic, onion), body/perspiration odor, breath odor, etc. See also U.S. Pat. No. 3,172,817, Leupold, et al.

Organic Acid and its Salts. Organic acid and its salts known for having antimicrobial effective in the technical field can be used as the antimicrobial active agent herein. Suitable organic acid and its salts can be citric acid, lactic acid, ascorbic acid, isoascorbic acid, tartaric acid, formic acid, maleic acid, malic acid, malonic acid, propionic acid, acetic acid, dehydroacetic acid, benzoic acid, hydroxybenzoic acid and its salt.

It is known in the art that certain type of odors is generated by microbial. Therefore, by sterilizing and/or removing microbial and/or prevent the growth of microbial, some antimicrobial active agents may also performs as a deodorizing active agent. Description of such material as an antimicrobial active agent herein does not suppose to exclude executions of using such materials as deodorizing active agent from the scope of the present invention.

Deodorizing Active Agent

Deodorizing active agent is useful in removing malodors from fabric articles. Typical concentrations of deodorizing active agent in the aqueous fabric refreshing composition range from about 0.01% to about 20%, or from about 0.1% to about 5%, or from about 0.5% to about 2% by weight of the aqueous fabric refreshing composition. Illustrative deodorizing active agent includes, but is not limited to cyclodextrin, water-soluble polyionic polymer, pH-adjusting mineral salts, zeolite, activated carbon, etc.

Cyclodextrin. As used herein, the term “cyclodextrin” includes any of the known cyclodextrins such as unsubstituted cyclodextrins containing from six to twelve glucose units, especially, alpha-cyclodextrin, beta-cyclodextrin, gamma-cyclodextrin and/or their derivatives and/or mixtures thereof. The specific coupling and conformation of the glucose units give the cyclodextrins rigid, conical molecular structures with hollow interiors of specific volumes. The unique shape and physical-chemical properties of the cavity enable the cyclodextrin molecules to absorb (form inclusion complexes with) organic molecules or parts of organic molecules which can fit into the cavity. Many odorous molecules can fit into the cavity including many malodorous molecules and perfume molecules. Therefore, cyclodextrins, and especially mixtures of cyclodextrins with different size cavities, can be used to control odors caused by a broad spectrum of organic odoriferous materials, which may, or may not, contain reactive functional groups. The cavities within the cyclodextrin in the solution of the fabric refreshing composition should remain essentially unfilled (the cyclodextrin remains uncomplexed) while in solution, in order to allow the cyclodextrin to absorb various odor molecules when the solution is applied to a surface. Preferably, the cyclodextrins used herein are highly water-soluble such as, alpha-cyclodextrin and/or derivatives thereof, gamma-cyclodextrin and/or derivatives thereof, derivatized beta-cyclodextrins, and/or mixtures thereof. The derivatives of cyclodextrin consist mainly of molecules wherein some of the —OH groups are converted to —OR groups. Cyclodextrin derivatives include, e.g., those with short chain alkyl groups such as methylated cyclodextrins, and ethylated cyclodextrins, wherein R is a methyl or an ethyl group; those with hydroxyalkyl substituted groups, such as hydroxypropyl cyclodextrins and/or hydroxyethyl cyclodextrins, wherein R is a —CH2—CH(OH)—CH3 or a —CH2CH2—OH group; branched cyclodextrins such as maltose-bonded cyclodextrins; cationic cyclodextrins such as those containing 2-hydroxy-3-(dimethylamino)propyl ether, wherein R is —CH2—CH(OH)—CH2—N(CH3)2 which is cationic at low pH; quaternary ammonium, e.g., 2-hydroxy-3-(trimethylammonio)propyl ether chloride groups, wherein R is —CH2—CH(OH)—CH2—N+(CH3)3Cl−; anionic cyclodextrins such as carboxymethyl cyclodextrins, cyclodextrin sulfates, and cyclodextrin succinylates; amphoteric cyclodextrins such as carboxymethyl/quaternary ammonium cyclodextrins; cyclodextrins wherein at least one glucopyranose unit has a 3-6-anhydro-cyclomalto structure, e.g., the mono-3-6-anhydrocyclodextrins, as disclosed in “Optimal Performances with Minimal Chemical Modification of Cyclodextrins”, F. Diedaini-Pilard and B. Perly, The 7th International Cyclodextrin Symposium Abstracts, April 1994, p. 49, said references being incorporated herein by reference; and mixtures thereof. Other cyclodextrin derivatives are disclosed in U.S. Pat. No. 3,426,011, Parmerter et al., issued Feb. 4, 1969; U.S. Pat. Nos. 3,453,257; 3,453,258; 3,453,259; and 3,453,260, all in the names of Parmerter et al., and all issued Jul. 1, 1969; U.S. Pat. No. 3,459,731, Gramera et al., issued Aug. 5, 1969; U.S. Pat. No. 3,553,191, Parmerter et al., issued Jan. 5, 1971; U.S. Pat. No. 3,565,887, Parmerter et al., issued Feb. 23, 1971; U.S. Pat. No. 4,535,152, Szejtli et al., issued Aug. 13, 1985; U.S. Pat. No. 4,616,008, Hirai et al., issued Oct. 7, 1986; U.S. Pat. No. 4,678,598, Ogino et al., issued Jul. 7, 1987; U.S. Pat. No. 4,638,058, Brandt et al., issued Jan. 20, 1987; and U.S. Pat. No. 4,746,734, Tsuchiyama et al., issued May 24, 1988; all of said patents being incorporated herein by reference.

Highly water-soluble cyclodextrins are those having water solubility of at least about 10 g in 100 ml of water at room temperature, preferably at least about 20 g in 100 ml of water, more preferably at least about 25 g in 100 ml of water at room temperature. The availability of solubilized, uncomplexed cyclodextrins is essential for effective and efficient odor control performance. Solubilized, water-soluble cyclodextrin can exhibit more efficient odor control performance than non-water-soluble cyclodextrin when deposited onto surfaces, especially fabric. Examples of preferred water-soluble cyclodextrin derivatives suitable for use herein are hydroxypropyl alpha-cyclodextrin, methylated alpha-cyclodextrin, methylated beta-cyclodextrin, hydroxyethyl beta-cyclodextrin, and hydroxypropyl beta-cyclodextrin. Hydroxyalkyl cyclodextrin derivatives preferably have a degree of substitution of from about 1 to about 14, more preferably from about 1.5 to about 7, wherein the total number of —OR groups per cyclodextrin is defined as the degree of substitution. Methylated cyclodextrin derivatives typically have a degree of substitution of from about 1 to about 18, preferably from about 3 to about 16. A known methylated beta-cyclodextrin is heptakis-2,6-di-O-methyl-β-cyclodextrin, commonly known as DIMEB, in which each glucose unit has about 2 methyl groups with a degree of substitution of about 14. A preferred, more commercially available, methylated beta-cyclodextrin is a randomly methylated beta-cyclodextrin, commonly known as RAMEB, having different degrees of substitution, normally of about 12.6. RAMEB is more preferred than DIMEB, since DIMEB affects the surface activity of the preferred surfactants more than RAMEB. The preferred cyclodextrins are available, e.g., from Cerestar USA, Inc. and Wacker Chemicals (USA), Inc.

It is also preferable to use a mixture of cyclodextrins. Such mixtures absorb odors more broadly by complexing with a wider range of odoriferous molecules having a wider range of molecular sizes. Preferably at least a portion of the cyclodextrins is alpha-cyclodextrin and its derivatives thereof, gamma-cyclodextrin and its derivatives thereof, and/or derivatized beta-cyclodextrin, more preferably a mixture of alpha-cyclodextrin, or an alpha-cyclodextrin derivative, and derivatized beta-cyclodextrin, even more preferably a mixture of derivatized alpha-cyclodextrin and derivatized beta-cyclodextrin, most preferably a mixture of hydroxypropyl alpha-cyclodextrin and hydroxypropyl beta-cyclodextrin, and/or a mixture of methylated alpha-cyclodextrin and methylated beta-cyclodextrin.

Water-soluble Polyionic Polymers. Water-soluble polyionic polymers can be used in the aqueous fabric refreshing composition herein to provide deodorizing benefit. Useful water-soluble polyionic polymer can be a cationic polymer, such as polyamines, or an anionic polymer, such as polyacrylic acids and their water-soluble salts. Polyamines are those containing amino, amido, etc. functional groups. Preferred polyacrylic acids and their salts have an average molecular weight of less than about 20,000, preferably less than 10,000, more preferably from about 500 to about 5,000. Polymers containing sulfonic acid groups, phosphoric acid groups, phosphonic acid groups, and their water-soluble salts are also suitable. Water-soluble polymers containing both cationic and anionic functionalities are also suitable. Examples of these polymers are given in U.S. Pat. No. 4,909,986, issued Mar. 20, 1990 to N. Kobayashi and A. Kawazoe. Another example of water-soluble polymers containing both cationic and anionic functionalities is a copolymer of dimethyldiallyl ammonium chloride and acrylic acid, commercially available under the trade name Merquat 280® from Calgon.

Such polymers are believed to be useful herein to control certain amine-type odors or acid-type odors, such as odors associated with ammonia, trimethyl amine, triethylamine, isovaric acid, butyric acid, propionic acid, etc.

PH-adjusting Mineral Salts. PH-adjusting mineral salts which adjust pH of the aqueous fabric refreshing composition to 8-12 can be used as the deodorizing active agent. By adjusting the pH of the fabric refreshing composition in the alkaline range, some acid type of odors can be neutralized by the fabric refreshing composition. Illustrative pH-adjusting mineral salts useful herein include alkali metal salts or alkali earth metal salts of boric acid, carbonic acid, phosphoric acid, pyrophosphoric acid, triphosphoric acid, etc. Specifically preferred pH-adjusting mineral salts useful herein include potassium phosphate, potassium hydrogen phosphate, potassium dihydrogen phosphate, sodium hydrogen pyrophosphate, sodium carbonate, sodium hydrogen carbonate, sodium borate and a mixture thereof.

Zeolites. A preferred class of zeolites is characterized as “intermediate” silicate/aluminate zeolites. The intermediate zeolites are characterized by SiO2/AlO2 molar ratios of less than about 10. Preferably the molar ratio of SiO2/AlO2 ranges from about 2 to about 10. The intermediate zeolites have an advantage over the “high” zeolites. The intermediate zeolites have a higher affinity for amine-type odors, they are more weight efficient for odor absorption because they have a larger surface area, and they are more moisture tolerant and retain more of their odor absorbing capacity in water than the high zeolites. A wide variety of intermediate zeolites suitable for use herein are commercially available as Valfor® CP301-68, Valfor® 300-63, Valfor® CP300-35, and Valfor® CP300-56, available from PQ Corporation, and the CBV100® series of zeolites from Conteka. Zeolite materials marketed under the trade name Abscents® and Smellrite®, available from The Union Carbide Corporation and UOP are also preferred. These materials are typically available as a white powder in the 3-5 micron particle size range. Such materials are preferred over the intermediate zeolites for control of sulfur-containing odors, e.g., thiols, mercaptans.

Activated Carbon. The carbon material suitable for use in the present invention is the material well known in commercial practice as an absorbent for organic molecules and/or for air purification purposes. Often, such carbon material is referred to as “activated” carbon or “activated” charcoal. Such carbon is available from commercial sources under such trade names as; Calgon-Type CPG®; Type PCB®; Type SGL®; Type CAL®; and Type OL®.

Carrier

Water is the main liquid carrier of antimicrobial active agent and deodorizing active agent in the aqueous fabric refreshing composition herein due to its low cost, availability, safety, and environmental compatibility. As used herein, water can be distilled, deionized, or tap water. Water not only serves as a liquid carrier for the antimicrobial active agent and deodorizing active agent, but it also provides some odor controlling effect of its own. It has been discovered that the intensity of odor generated by some polar, low molecular weight organic amines, acids, and mercaptans is reduced when the odor-contaminated fabrics are treated with an aqueous solution. Water is also very useful for fabric wrinkle removal or reduction. Not to be bound by theory, it is believed that water breaks many intra-fiber and inter-fiber hydrogen bonds that keep the fabric in a wrinkle state. It also swells, lubricates and relaxes the fibers to help the wrinkle removal process.

Optionally, in addition to water, the carrier can contain a low molecular weight organic solvent that is highly soluble in water, e.g., ethanol, propanol, isopropanol, and the like, and mixtures thereof. Low molecular weight alcohols can help the treated fabric articles to dry faster and also provide some antimicrobial benefit. The optional water soluble low molecular weight solvent can be used at a level of up to about 50%, typically from about 1% to about 20%, preferably from about 2% to about 15%, more preferably from about 5% to about 10%, by weight of the total composition. Factors that need to be considered when a high level of solvent is used in the composition are odor, flammability, and environment impact.

Optional Ingredients

The fabric refreshing composition herein may further contain one or more optional ingredients typically used in fabric care product category. Illustrative optional ingredients include, but are not limited to surfactant, fabric wrinkle control agent, fabric softening agent, perfume, anti-static agent, chelating agent, insect and moth repelling agent, colorant, preservative, and mixtures thereof. The total level of optional ingredients is low, preferably less than about 5%, or less than about 3%, or less than about 2%, by weight of the composition.

In a preferred embodiment, the aqueous fabric refreshing composition herein contains from about 0.005% to 0.1% or from about 0.01% to about 0.5% by weight of a surfactant. Surfactant provides a low surface tension that permits the composition to spread readily and more uniformly on hydrophobic surfaces, such as polyester and nylon. It has been found that the aqueous fabric refreshing composition containing surfactant spreads satisfactorily on fabric articles. The spreading of the composition also allows it to dry faster, so that the treated fabric articles are ready for use sooner. Furthermore, fabric refreshing composition containing a surfactant can penetrate hydrophobic, oily soil better for improved malodor control. The surfactant is also needed in the fabric refreshing composition herein that contains a wrinkle control agent such as silicone and/or shape retention polymer. For such agents, the surfactant is also needed, e.g., as a dispersing agent, an emulsifying agent and/or a solubilizing agent. The surfactant for use in providing the required low surface tension in the composition herein should be compatible with other components in the composition. For example, it should not form a complex with cyclodextrin so as to diminish performance of the cyclodextrin and/or the surfactant. Complex formation diminishes both the ability of the cyclodextrin to absorb odors and the ability of the surfactant to lower the surface tension of the aqueous composition.

In another preferred embodiment herein, the fabric refreshing composition contains from about 0.1% to about 10%, or from about 0.5% to about 7%, or from about 1% to about 5%, by weight of a fabric wrinkle control agent, preferably selected from the group consisting of: silicone, shape retention polymer, hydrophilic plasticizer, lithium salt, and mixtures thereof. Silicone can be used herein to impart a lubricating property or increased gliding ability to fibers in fabric, particularly clothing. The preferred silicones have pendant alkyl groups having less than about 8, preferably less than about 6, carbon atoms, and do not have pendant aryl groups. Nonlimiting examples of useful silicones include noncurable silicones such as polydimethylsilicone and volatile silicones, and curable silicones such as aminosilicones and hydroxysilicones. Optionally, the composition can contain hydrophilic plasticizer to soften both the fabric fibers, especially cotton fibers. Examples of preferred hydrophilic plasticizers are short chain polyhydric alcohols, such as glycerol, ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol, sorbitol, erythritol or mixtures thereof, more preferably diethylene glycol, dipropylene glycol, ethylene glycol, propylene glycol and mixtures thereof. Lithium salts can be used in the aqueous fabric refreshing composition to improve fabric wrinkle control performance. Non-limiting examples of lithium salts that are useful herein are lithium bromide, lithium bromide hydrate, lithium chloride, lithium chloride hydrate, lithium acetate, lithium acetate dihydrate, lithium lactate, lithium sulfate, lithium sulfate monohydrate, lithium tartrate, lithium bitartrate, and mixtures thereof.

Method and Home Appliances

According to the method herein, as the first step, fabric articles to be treated are loaded into a drum of a home appliance. Aqueous fabric refreshing compositions and hot air are then charged into the drum. It is not critical whether the aqueous fabric refreshing composition and hot air are charged into the drum simultaneously or not; however the temperature in the drum shall be maintained within the range of from about 30° C. to about 120° C., or from about 50° C. to about 70° C. during a substantial period of the refreshing treatment process. The time that fabric articles contact with the aqueous fabric refreshing compositions are typically from about 1 minute to about 120 minutes or from about 20 to about 45 minutes. Surprisingly, it has been found that fabric articles treated by the method herein are substantially degermed and deodorized and therefore are ready for the next wear or use without the need for any additional cleaning treatment. In a preferred embodiment, the fabric refreshing composition is applied to the fabric articles while the drum is rotated. Rotation of the drum can be either horizontal or vertical and the rotation speed is typically less than about 200 rotations per minute, RPM, or from about 10 RPM to 100 RPM, or from about 20 RPM to about 50 RPM. It has been found that an even distribution and penetration of the aqueous fabric refreshing composition can be achieved by rotating the drum while dispensing the aqueous fabric refreshing composition.

The aqueous fabric refreshing composition is preferably dispensed into the drum during the initial stage of the refreshing treatment process. For example, dispensing of the aqueous fabric refreshing composition can be completed within the first 30 seconds to about 5 minutes upon the initiation of the refreshing treatment. The amount of the aqueous fabric refreshing composition charged into the drum is typically from about 0.1% to about 50% or from about 1% to about 10% by weight of the dry weight of loaded fabric articles. In other words, the weight ratio of the aqueous fabric refreshing composition to the dry load fabric articles is from about 1:1000 to about 1:1, or from about 1:100 to about 1:10.

The method of the present invention can be conveniently conducted by consumers at home using known home appliances, for example, the method herein can be conducted in the existed drying cycle of washing machines or dryers. Alternatively, a refreshing cycle can be specifically programmed in the commercialized washing machines or dryers to conduct the method herein. In both circumstances, the home appliances will retain their original washing and/or drying functions. Exemplary home appliances useful herein typically include:

(i) a fluid-impervious stationary containment chamber;

(ii) a fluid-pervious drum arranged to receive and retain a load of fabric articles, said drum being driven by;

(iii) an electric motor, preferably has variable speed;

(iv) motor speed control means for controlling the speed of said motor;

(v) a storage means for storing the aqueous fabric refreshing composition. The storage means can be integral with or non-detachable from the home appliances, or can be in detachable cartridge form, or can be a detachable container other than cartridge;

(vi) a dispensing device fluidly-conducted with the storage means. The dispensing device is used for releasing or dispensing the aqueous fabric refreshing composition and for even application of the aqueous fabric refreshing composition on fabric articles;

(vii) a heater to heat aqueous fabric refreshing composition, fabric articles or air. The heater may include a heating element over which air must pass prior to entering into the drum. A suitable heating element is a resistive coil, the temperature of which is adjusted by regulating coil voltage. Alternative heating means may also be used, for example, an infrared radiation source, a heat-pump system or a microwave radiation source. In an alternative embodiment, the air can be supplemented with steam;

(viii) a control system, such as an electronic control device with a processing circuit, and input and output circuits. The control systems can for example enable the user to select the size of the fabric load, the time for the refreshing treatment, etc. Alternatively, the user can use pre-set refreshing cycle, or the appliance can control the length of the cycle, based on any number of ascertainable parameters. In one embodiment herein, the appliances used may comprise a program selector. This selector may be in any suitable form, such as a dial, buttons, touch pads, panel (which would typically include buttons or assorted selection means) or combinations thereof;

(viiii) one or more sensors, such as a temperature sensor, a smell sensor, a humidity sensor, or a vapor and/or gas sensor. The temperature can be sensed by a temperature sensor which is preferably of a thermistor type and sends a signal to the heater. In a preferred embodiment, the temperature sensor is attached in the air duct (inlet/outlet) or the drum, etc. of the home appliance. The temperature sensor can control the on and off of the heater switch so as to maintain the temperature of the fabric refreshing composition or the temperature in the drum to be under the flash point of the fabric refreshing composition. In another preferred embodiment herein, a smell sensor for detecting odor level inside the drum of the home appliance is provided, such as in the air circuit lines and/or inlet/outlet air filters. The smell sensor can be used to control the loading level of the aqueous fabric refreshing composition or to indicate the need for cleaning or change of air filter by detecting the odor level in the drum or in the air circuit filter. In another embodiment, a humidity sensor can be provided to control the loading level of the aqueous fabric refreshing composition or heating power, heating time or air force level suitably by measuring humidity level;

(x) one or more input devices, such as a control panel switch, touch panel switch, wireless input system and/or a keypad;

(xi) one or more indicating devices, such as color lights or LED's.

In a preferred embodiment, the aqueous fabric refreshing composition is dispensed in the form of fine droplets having an average droplet size of less than about 5 mm, or from about 10 μm to about 1000 μm, or from about 20 μm to about 300 μm, or from about 30 μm to about 120 μm. Fine droplets are preferred herein as it has been found that fine droplets provide an even distribution and better penetration of fabric refreshing composition in fabric articles and thus lead to a better degerming and deodorizing performance. Dispensing devices discharging the aqueous fabric refreshing composition in the form of fine droplets are known in the art, such as spray nozzle or fluid atomizing nozzle. A spray nozzle or a fluid atomizing nozzle typically provides an average droplet size that is less than about 1000 microns, typically from about 100 to about 1000 microns, or from about 120 to about 500 microns, or from about 150 to about 300 microns. When a spray nozzle is covered with a fine grid or a membrane to produce a finer mist, the average particle size of the mist can be less than 100 microns. Nebulizers, atomizers and the like devices well known in the art can also be used as the dispensing devices herein. A suitable device for use herein is a nebulizer that has at least one ultrasonic sonotrode, or ultrasonic vibrating cell. Typical nebulizer is commercially available under the tradename of Acu Mist® from Sono Tek Corporation, Milton, N.Y. Still other examples of such devices are available from Omron Health Care, GmbH, Germany; and from Flaem Nuove, S.P.A, Italy. One or multiple nozzles can be used to dispense fabric refreshing composition in fine droplets. Also the nozzles can be fixed or removably mounted on the home appliances. In one embodiment, an air-compressor is mounted in the home appliance, for example in the air circuit lines of the home appliance to increase pressure level in the drum of the home appliance. The higher pressure in the home appliance will be helpful in improving the penetration of the aqueous fabric refreshing composition into fabric articles for a better degerming and deodorizing performance.

In an alternative embodiment, the air may be ionized before it contacts the fabric articles, for example by corona discharge. In another alternative embodiment, ozone may be added to the air before it contacts the fabric articles. Alternatively, the ozone may be added to the rotatable drum through a system of conduits which is independent of the air circulation system.

More detailed disclosure of apparatus, components and elements can be found in U.S. patent application No. 60/191,965 to Noyes et. al., filed Mar. 24, 2000.

Test Method

The de-germing effect of the method herein can be tested by the following test method:

    • 1) Cut cotton knit into pieces of 19 cm×9.5 cm (about 4 grams each piece), and sterilize the cotton knit in an autoclave at about 120° C. for about 25 min;
    • 2) Incubate Proteus mirabilis stock culture on a fresh nutrient tryptic soy agar;
    • 3) After 1 day incubation, add 5 mL of phosphate buffer solution to the incubated agar and remove activated germ from the surface of the agar;
    • 4) Add the germ suspended solution into a flask containing 5 g of sterile glass beads;
    • 5) Add 5 mL of phosphate buffer into the flask to make homogenized germ solution, and mix it well for a few minutes;
    • 6) Prepare a 0.6% by weight of bovine serum albumin (BSA) solution;
    • 7) Mix the germ suspension with BSA solution in a volume ratio of about 1:1. The mixture is used as inoculum;
    • 8) Spike 1 mL of the inoculum to each piece of the sterile cotton knit and leave the inoculum for 15 minutes. The amount of Proteus mirabilis on each piece of the cotton knit is 1.9×109 cfu (colony formation unit, about 9.27 log);
    • 9) The cotton knits prepared by the above steps are divided into three groups. Each group has 3 pieces of cotton knit;
    • 10) About 3 grams of the aqueous fabric refreshing composition as described in the following Table 2 is sprayed onto each piece of the cotton knit of Group A and Group B. Leave the cotton knits for about 20 minutes. Cotton knits of Group C are kept on the lab bench without any treatment during this period.
    • 11) Cotton knits of Group A and Group C are then put on the rack in a Sanyo washing machine (Model: Sanyo AQ-1 manufacture by SANYO Electric Co., Ltd.) separately and treated with the ready-to-wear non tub-rotation cycle but without charging ozone to the drum by cutting the electrical supply line to the ozone generator. During the refreshing treatment in the Sanyo washing machine, hot air is blown into the drum and the temperature inside the drum is gradually increased from about 25° C. to about 70° C. and is maintained around 70° C. during the whole cycle for about 30 minutes;
    • 12) Cotton knits of Group B are left under room temperature without any additional treatment;
    • 13) The treated cotton knits are put into a sterile bag separately. Add 50 mL water solution containing 0.85% saline, 0.2% Tween 80, 0.5% sodium thiosulfate and balance of sterilized pure water to the bag;
    • 14) Use Stomacher (Model: Stomacher 400T manufacture by ORGANO Corporation) to extract the leftover Proteus mirabilis germs on the treated cotton knits for 5 minutes;
    • 15) Make a series of dilutions by 0.00425% phosphate buffer solution. Take 1 mL diluted solution, and pour-plate with nutrient agar (TSA);
    • 16) Once the agar is hardened, incubate the hardened agar plate at 35° C. for 2 days in an incubator. After the incubation, count the number of colonies formed on the incubated agar plate. The number of residual germs on each piece of the cotton knits treated are shown in the below Table 1.

TABLE 1 Group B: Group A: Cotton Cotton knits knits treated treated with fabric Group C: Cotton with a method refreshing knits subjected to the present composition heating treatment invention only only Residual #1 2.50 6.08 4.87 germ level #2 2.70 5.69 4.70 (log)* #3 2.71 5.80 4.74 Average* 2.64 5.86 4.77 *The number is germ count level, small number is showing better degerming efficacy

The above data shows that the method of the present invention (refreshing treatment with fabric refreshing composition and heat: Group A) provides a significant better degerming efficacy versus method of treating fabrics with refreshing composition only (Group B) and method of treating fabrics with heat only (Group C).

TABLE 2 Aqueous Fabric Refreshing Composition Ingredient Function % by weight Didecyl dimethyl ammonium chloride antimicrobial 0.27 active agent Citric Acid chelator 0.10 2-Hydroxypropyl-beta-cyclodextrin deodorizing 2.50 active agent Glycerol-Polyethylene Glycol surfactant 0.17 Oxystearate Poly(Dimethylsiloxane-Co-Me-(3-Oh- surfactant 0.10 Propyl)-Siloxane) Perfume 0.02 Water and balance carrier Balance

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. A method for refreshing a fabric article, comprising the steps of loading the fabric article to be treated into a drum of a home appliance, contacting said fabric article with an aqueous fabric refreshing composition under a temperature of from about 30° C. to about 120° C. for about 1 minute to about 120 minutes, wherein said fabric refreshing composition comprises from about 0.001% to about 1.0% by weight of an antimicrobial active agent and from about 0.01% to about 20% by weight of an deodorizing active agent.

2. The method of claim 1, wherein such refreshed fabric articles are ready for use without the need for additional cleaning treatment.

3. The method of claim 1, wherein said fabric refreshing composition is applied to said fabric articles in the form of fine droplets having an average droplet size of from about 10 microns to about 1000 microns.

4. The method of claim 3, wherein said fine droplets have an average droplet size of from about 20 microns to about 120 microns.

5. The method of claim 1, wherein weight ratio of said fabric refreshing composition to said fabric articles to be treated is from about 1:1000 to about 1:1.

6. The method of claim 1, wherein said fabric refreshing composition is applied to the fabric articles while said drum is under rotation.

7. The method of claim 1, wherein said home appliance is selected from the group consisting of a washing machine and a dryer.

8. The method of claim 1, wherein said antimicrobial active agent is selected from the group consisting of an antibacterial halogenated compound, a quaternary ammonium compound, a phenyl or phenolic compound, a metallic salt, an organic acid or its salts and a mixture thereof.

9. The method of claim 8, wherein said antimicrobial active agent is di-(C6-C14)alkyl di-(C1-C4)alkyl quaternary ammonium compound.

10. The method of claim 1, wherein said deodorizing active agent is selected from the group consisting of a cyclodextrin, a water-soluble polyionic polymer, a pH-adjusting mineral salt, a zeolite, an activated carbon or a mixture thereof.

11. The method of claim 1, wherein said fabric articles contact with the fabric refreshing composition at a temperature of from about 50° C. to about 70° C. for about 20 minutes to about 45 minutes.

Patent History
Publication number: 20090193593
Type: Application
Filed: Feb 2, 2009
Publication Date: Aug 6, 2009
Inventors: Hiroshi Kirigakubo (Kobe), Ryohei Ohtani (Nishinomiya), Kenichi Nakaoka (Nishinomiya)
Application Number: 12/363,971
Classifications
Current U.S. Class: Dry Cleaning (8/142)
International Classification: D06L 1/20 (20060101);