CLEANING APPARATUS AND METHOD

Abstract

A door for providing access to a rotatably mounted drum of a cleaning apparatus, the door having a flow pathway for wash liquor and a multiplicity of solid particles and a separator, the separator being arranged to direct the multiplicity of solid particles from the flow pathway into the drum and wherein the separator is further arranged to direct a portion of the wash liquor from the flow pathway to a location other than into the drum.

Description

FIELD OF THE INVENTION

The present invention relates to a cleaning apparatus that employs a solid particulate material. In operation, the apparatus may require the use of only limited quantities of energy, water and detergent. Most particularly, the invention is concerned with a door for use in such a cleaning apparatus that enables separation of said solid particulate material and wash liquor from a flow pathway.

BACKGROUND TO THE INVENTION

Aqueous cleaning processes are a mainstay of conventional domestic and industrial textile fabric cleaning methods. On the assumption that the desired level of cleaning is achieved, the efficacy of such conventional processes is usually characterized by their levels of consumption of energy, water and detergent. In general, the lower the requirements with regard to these three components, the more efficient the washing process is deemed. The downstream effect of reduced water and detergent consumption is also significant, as this minimizes the need for disposal of aqueous effluent, which is both extremely costly and detrimental to the environment.

Such washing processes involve aqueous submersion of fabrics followed by aqueous soil suspension, soil removal and water rinsing. In general, within practical limits, the higher the level of energy (or temperature), water and detergent which is used, the better the cleaning. One key issue, however, concerns water consumption, as this sets the energy requirements (in order to heat the wash water), and the detergent dosage (to achieve the desired detergent concentration). In addition, the water usage level defines the mechanical action of the process on the fabric, which is another important performance parameter; this is the agitation of the cloth surface during washing, which plays a key role in releasing embedded soil. In aqueous processes, such mechanical action is provided by the water usage level in combination with the drum design for any particular washing machine. In general terms, it is found that the higher the water level in the drum, the better the mechanical action. Hence, there is a dichotomy created by the desire to improve overall process efficiency (i.e. reduce energy, water and detergent consumption), and the need for efficient mechanical action in the wash.

Various different approaches to the development of new cleaning technologies have been reported in the prior art, including methods which rely on electrolytic cleaning or plasma cleaning, in addition to approaches which are based on ozone technology, ultrasonic technology or steam technology. Thus, for example, WO2009/021919 teaches a fabric cleaning and disinfection process which utilizes UV-produced ozone along with plasma. An alternative technology involves cold water washing in the presence of specified enzymes, whilst a further approach which is particularly favored relies on air-wash technology and, for example, is disclosed in US2009/0090138. In addition, various carbon dioxide cleaning technologies have been developed, such as the methods using ester additives and dense phase gas treatments which are described in U.S. Pat. No. 7,481,893 and US2008/0223406, although such methods generally find greater applicability in the field of dry cleaning. Many of these technologies are, however, technically very complex.

In the light of the challenges which are associated with aqueous washing processes, the present applicant previously devised a new approach to the problem that allows the deficiencies demonstrated by the methods of the prior art to be mitigated or overcome. The method devised eliminated the requirement for the use of large volumes of water, but was still capable of providing an efficient means of cleaning and stain removal, whilst also yielding economic and environmental benefits.

Thus, in WO2007/128962 there is disclosed a method and formulation for cleaning a soiled substrate, the method comprising the treatment of the moistened substrate with a formulation comprising a multiplicity of polymeric particles, wherein the formulation is free of organic solvents. The substrate may be wetted so as to achieve a substrate to water ratio of between 1:0.1 to 1:5 w/w, and optionally, the formulation additionally comprises at least one cleaning material, which typically comprises a surfactant, which most preferably has detergent properties. In embodiments, the substrate comprises a textile fiber. The polymeric particles may, for example, comprise particles of polyamides, polyesters, polyalkenes, polyurethanes or their copolymers, a particular example being nylon beads.

The use of this cleaning method, however, presents a requirement for the nylon beads to be efficiently separated from the cleaned substrate at the conclusion of the cleaning operation, and this issue was initially addressed in WO2010/094959, which provides a novel design of cleaning apparatus requiring the use of two internal drums capable of independent rotation, and which finds application in both industrial and domestic cleaning processes.

With a view to providing a simpler, more economical means for addressing the problem of efficient separation of the cleaning beads from the substrate at the conclusion of the cleaning process, however, a further apparatus is disclosed in WO2011/064581. The apparatus of WO2011/064581, which finds application in both industrial and domestic cleaning processes, comprises a perforated drum and a removable outer drum skin which is adapted to prevent the ingress or egress of fluids and solid particulate matter from the interior of the drum. The cleaning method requires attachment of the outer skin to the drum during a first wash cycle, after which the skin is removed prior to operating a second wash cycle, following which the cleaned substrate is removed from the drum.

The apparatus and method of WO2011/064581 is found to be extremely effective in successfully cleaning substrates, but the requirement for the attachment and removal of the outer skin detracts from the overall efficiency of the process and the present inventors have, therefore, sought to address this aspect of the cleaning operation and to provide a process wherein this procedural step is no longer necessary. Thus, by providing for continuous circulation of the cleaning beads during the cleaning process, it has been found possible to dispense with the requirement for the provision of an outer skin.

Thus, in WO2011/098815, the present inventors provided an apparatus for use in the cleaning of soiled substrates, the apparatus comprising housing means having a first upper chamber with a rotatably mounted cylindrical cage mounted therein and a second lower chamber located beneath the cylindrical cage, and additionally comprising at least one recirculation means, access means, pumping means and a multiplicity of delivery means, wherein the rotatably mounted cylindrical cage comprises a drum having perforated side walls where up to 60% of the surface area of the side walls comprises perforations comprising holes having a diameter of no greater than 25.0 mm.

The apparatus of WO2011/098815 is used for the cleaning of soiled substrates by means of methods which comprise the treatment of the substrates with formulations comprising solid particulate cleaning material and wash water, the methods typically comprising the steps of:

• • (a) introducing solid particulate cleaning material and water into the lower chamber of the apparatus;
  • (b) agitating and heating the solid particulate cleaning material and water;
  • (c) loading at least one soiled substrate into the rotatably mounted cylindrical cage via the access means;
  • (d) closing the access means so as to provide a substantially sealed system;
  • (e) introducing the solid particulate cleaning material and water into the rotatably mounted cylindrical cage;
  • (f) operating the apparatus for a wash cycle, wherein the rotatably mounted cylindrical cage is caused to rotate and wherein fluids and solid particulate cleaning material are caused to fall through perforations in the rotatably mounted cylindrical cage into the lower chamber in a controlled manner;
  • (g) operating the pumping means so as to transfer fresh solid particulate cleaning material and recycle used solid particulate cleaning material to separating means;
  • (h) operating control means so as to add the fresh and recycled solid particulate cleaning material to the rotatably mounted cylindrical cage in a controlled manner; and
  • (i) continuing with steps (f), (g) and (h) as required to effect cleaning of the soiled substrate.

As outlined above, the apparatus of WO2011/098815 therefore includes features to introduce solid particulate cleaning material into the rotatably mounted cylindrical cage and also comprises at least one recirculation means to facilitate recirculation of said solid particulate material for its re-use in cleaning operations. In addition, the apparatus of WO2011/098815 can include ducting comprising separating means for separating the solid particulate material from water and control means adapted to control entry of the solid particulate material into the cylindrical cage. In one disclosed embodiment, the separating means comprises a rigid filter material such as wire mesh located in a receptor vessel above the cylindrical cage, and the control means comprises a valve located in feeder means, preferably in the form of a feed tube attached to the receptor vessel, and connected to the cage.

Although the apparatus disclosed in WO2011/098815 provided considerable improvements for the cleaning of soiled substrates with formulations comprising solid particulate cleaning material and wash water, there remain several drawbacks associated with using an apparatus of this type when separating the solid particulate material from water prior to its use and re-use in the cleaning operation. In particular, separation of the solid particulate material from the apparatus in WO2011/098815 is carried out using a separation vessel external to the housing of the apparatus and above the cylindrical cage. Placement of the separating device in this position was considered to be necessary as the solid particulate material, in the form of beads, falls under gravity to the filter material before entering the cylindrical cage. In order to recirculate, the solid particulate material was pumped along a recirculation path that extends from the enlarged sump located in the lower chamber of the apparatus to the separating vessel above the cylindrical cage.

A long recirculation path for the solid particulate material detrimentally impacts the efficiency of the apparatus as more energy is expended for pumping and a larger pump is required to transport the solid particulate material along the recirculation path. Furthermore, as beads must be pumped in combination with water along the recirculation path, water usage within the apparatus is less than optimal as the total volume of water required for recirculation is increased. In addition, the inclusion of a separating vessel above the cylindrical cage adversely increases the size of the apparatus, considerations that are particularly important for domestic washing machines.

In some embodiments, the present disclosure seeks to provide a cleaning apparatus for use in the cleaning of soiled substrates with a solid particulate material that can ameliorate or overcome the above-noted problems associated with the prior art. Particularly, there is desired an apparatus and method for the cleaning of soiled substrates with a solid particulate cleaning material comprising an improved means of separating said solid particulate material and water prior to the introduction of said solid particulate for use in the cleaning operation. Specifically, there is desired an apparatus and method for separating solid particulate material and wash water which addresses some or all of the deficiencies of the apparatus and method disclosed in WO2011/098815.

SUMMARY OF THE INVENTION

In accordance with embodiments of the present invention there is provided a door for providing access to a rotatably mounted drum of a cleaning apparatus. The door can comprise a flow pathway for wash liquor and a multiplicity of solid particles (also referred to herein as “a solid particulate material”) and a separator. The separator can be arranged to direct the multiplicity of solid particles from the flow pathway into the drum. The separator can be further arranged to direct a portion of the wash liquor from the flow pathway to a location other than into the drum.

Thus, in some advantageous embodiments, the separator can serve to effectively regulate or limit the amount of wash liquor entering into the drum thereby maximizing the cleaning effect of the solid particulate material used in the cleaning operation. Furthermore, the overall size of the cleaning apparatus can be reduced by providing such a separator as part of the door.

In some embodiments the door can define therein a first flow path to the separator for wash liquor and said solid particles and can further define therein a second flow path from the separator for a portion of said wash liquor directed to a location other than into the drum. In some advantageous embodiments the door of the invention can be adapted to define at least two independent flow paths, including a first flow path for wash liquor and solid particles to the separator and a second flow path from the separator for wash liquor which does not enter the drum.

In some embodiments the door can comprise a feed pipe for the passage of said wash liquor and said solid particles therethrough. In some embodiments said feed pipe can define a portion of said flow pathway.

In some embodiments the door can comprise an outlet downstream from the separator for said wash liquor from said flow pathway directed to a location other than into the drum. In some embodiments the door can comprise an inner portion comprising one or more channels to direct said wash liquor to said outlet.

In some embodiments the separator can comprise a web or substrate having a plurality of apertures formed therein wherein said apertures are sized so as to permit the passage of wash liquor whilst preventing the passage of said solid particles therethrough.

In some embodiments the separator can comprise an inlet, an outlet and a curved body portion disposed between said inlet and said outlet. In some embodiments said curved body portion comprises said web or substrate having a plurality of apertures formed therein wherein said apertures are sized so as to permit the passage of wash liquor whilst preventing the passage of said solid particles therethrough.

In other embodiments the separator can comprise an inlet, an outlet and a body disposed between said inlet and said outlet, said body comprising a first planar wall member joined to a second planar wall member at a common point wherein said second planar wall member is inclined with respect to said first planar wall member and wherein said second planar wall member comprises said web or substrate having a plurality of apertures formed therein wherein said apertures are sized so as to permit the passage of wash liquor whilst preventing the passage of said solid particles therethrough. In further embodiments said second planar wall member can be located upstream of said first planar wall member. In this context, the term upstream is used with reference to the direction of flow of wash liquor and solid particles through the separator.

In some embodiments the separator can comprise a plurality of apertures sized so as to permit the passage of wash liquor whilst preventing the passage of said solid particles therethrough wherein said apertures are further arranged to capture lint and/or fine particulate matter entrained in the wash liquor.

In some embodiments the separator can comprise a mesh.

In accordance with further embodiments of the present invention there is provided a cleaning apparatus for use in the cleaning of at least one soiled substrate with a multiplicity of solid particles (also referred to herein as “a solid particulate material”), said cleaning apparatus comprising:

• • (a) a housing containing a drum rotatably mounted therein;
  • (b) a door moveable between an open position wherein said at least one soiled substrate can be placed within the drum and a closed position wherein the cleaning apparatus is substantially sealed;
  • (c) at least one delivery means for the addition of wash liquor;
  • (d) pumping means configured to pump wash liquor and a multiplicity of solid particles from a first location to the door;
    • wherein said door can comprise a flow pathway for said wash liquor and said solid particles and a separator arranged to direct the multiplicity of solid particles from the flow pathway into the drum. The separator can be further arranged to direct a portion of the wash liquor from the flow pathway to a location other than into the drum.

In some embodiments said pumping means can be configured to pump said wash liquor and said multiplicity of solid particles upwardly from said first location to the door. In some embodiments the separator can be arranged to receive an upward flow of said wash liquor and said solid particles from said first location and said separator can be further arranged to direct said multiplicity of solid particles into the drum from said upward flow. In some embodiments said first location can be in a lower portion of the housing. In some embodiments said lower portion of the housing can be beneath the drum.

In some embodiments the separator can be arranged to receive a downward flow of said wash liquor and said solid particles and wherein the separator is further arranged to direct said multiplicity of solid particles into the drum from said downward flow.

In some embodiments the separator can be arranged to receive a horizontal flow of said wash liquor and said solid particles and wherein the separator is further arranged to direct said multiplicity of solid particles into the drum from said horizontal flow.

In some embodiments the separator can be arranged to receive a flow of said wash liquor and said solid particles from said pumping means and can be further arranged to direct at least 1 percent of the total mass of the wash liquor from said flow to said location other than into the drum. In some embodiments the separator can be further arranged to direct at least 10 percent of the total mass of the wash liquor from said flow to said location other than into the drum. In some embodiments the separator can be further arranged to direct at least 40 percent of the total mass of the wash liquor from said flow to said location other than into the drum. In some embodiments the separator can be further arranged to direct at least 70 percent of the total mass of the wash liquor from said flow to said location other than into the drum. In some embodiments the separator can be further arranged to direct at least 90 percent of the total mass of the wash liquor from said flow to said location other than into the drum.

In some embodiments the separator can be arranged to receive a flow of said wash liquor and said solid particles from said pumping means and can be further arranged to direct no greater than 99 percent of the total mass of the wash liquor from said flow to said location other than into the drum. In some embodiments the separator can be arranged to receive a flow of said wash liquor and said solid particles from said pumping means and can be further arranged to direct no greater than 90 percent of the total mass of the wash liquor from said flow to said location other than into the drum.

In some embodiments the separator can comprise an inlet arranged to receive a substantially vertical flow of said wash liquor and said solid particles from said pumping means and an outlet arranged to direct said solid particles into said drum wherein at least some of the solid particles, and preferably all of the solid particles, exit said outlet at an angle of between about 60° and about 120° to the flow of wash liquor and solid particles entering said inlet. In certain embodiments said angle at which the solid particulate material exits the separator outlet is about 90° to the substantially vertical flow of wash liquor and solid particles entering the separator via said inlet. In some advantageous embodiments the outlet of the separator can be arranged to direct the solid particles into the centre of the drum.

In some embodiments said flow pathway for said the wash liquor and said solid particles can extend directly from said pumping means to the door and from the door into the drum. In some advantageous embodiments pumping wash liquor and said solid particles along said flow pathway can facilitate a shorter transport for the solid particles to enter the drum thereby reducing the demand on the pumping means of the cleaning apparatus.

In further embodiments said first location can comprise a sump. In some embodiments the cleaning apparatus can comprise a flow path downstream from the separator so that wash liquor from said flow pathway directed to a location other than into drum can return to the sump.

In some embodiments the cleaning apparatus can further comprise a tub wherein said drum is mounted within the tub. In some embodiments said door can be mounted to a portion of the tub.

In some embodiments the tub includes said sump. In some advantageous embodiments the provision of an integrated tub and sump can facilitate the ease of transport of the wash liquor and said solid particles from the sump to the door.

In some embodiments the sump can comprise a first end proximate to said door and a second end distal to said door. In some embodiments the sump can comprise a sloping floor arranged to direct said solid particles to said first end of said sump. In some embodiments said pumping means can be located proximate to said first end. In some advantageous embodiments the sump and the pumping means can be arranged to facilitate a more efficient delivery path for the solid particles.

In some embodiments said solid particles can be recirculated along a recirculation path from the lower portion of the housing to the rotatably mounted drum. In some advantageous embodiments the inclusion of a separator in the door of the invention can reduce the path length for reutilization of the solid particles in the cleaning operation.

In some embodiments said drum can comprise collecting and transferring means adapted to facilitate collection of said multiplicity of solid particles and transfer of said solid particles from said drum to a lower portion of the housing.

In some embodiments said drum can be mounted about a substantially horizontal axis.

In some embodiments said drum can comprise a rotatably mounted cylindrical cage comprising perforated side walls wherein said perforations can comprise holes have a diameter of no greater than 5.0 mm. In some embodiments said perforations can comprise holes have a diameter of no greater than 3.0 mm.

In some embodiments said drum can have a capacity of approximately 10 to 7000 liters. In certain embodiments said drum can have a capacity of approximately 10 to 700 liters. In further embodiments said drum can have a capacity of approximately 30 to 150 liters.

In some embodiments the door (b) of the cleaning apparatus can comprise any of the features of the door herein described above.

In some embodiments the cleaning apparatus can be a washing machine. In further embodiments the cleaning apparatus can be a domestic washing machine such as a machine configured for location in a private dwelling such as a house or apartment. In other embodiments the cleaning apparatus can be a commercial washing machine.

In some embodiments said at least one soiled substrate can comprise a textile material, in particular one or more garments, linens, napery, towels or the like.

The multiplicity of solid particles or solid particulate material as referred to herein is distinguished from, and should not be construed as being, a conventional washing powder (that is laundry detergent in powder form). Washing powder is generally soluble in the wash water and is included primarily for its detergent qualities. The washing powder is disposed of during the wash cycle since it is sent to drain in grey water along with removed soil. In contrast, a significant function of the multiplicity of solid particles referred to herein is a mechanical action on the substrate which enhances cleaning of the substrate.

In some embodiments the multiplicity of solid particles can comprise or can consist of a multiplicity of polymeric particles.

In some embodiments the multiplicity of solid particles can comprise or can consist of a multiplicity of non-polymeric particles.

In some embodiments the multiplicity of solid particles can comprise or can consist of a mixture of polymeric solid particles and non-polymeric solid particles.

In some embodiments the polymeric particles can be selected from particles of polyalkenes, polyamides, polyesters, polysiloxanes, polyurethanes or copolymers thereof.

In some embodiments the polymeric particles can comprise particles selected from particles of polyalkenes or copolymers thereof.

In some embodiments the polymeric particles can comprise particles of polyamide or polyester or copolymers thereof.

In some embodiments the polyester particles can comprise particles of polyethylene terephthalate or polybutylene terephthalate.

In some embodiments the polyamide particles can comprise particles of nylon. In further embodiments said nylon can comprise Nylon 6 or Nylon 6,6.

In some embodiments the non-polymeric particles can comprise particles of glass, silica, stone, wood, metals or ceramic materials.

In some embodiments the polymeric particles can have an average density of from about 0.5 to about 2.5 g/cm³.

In some embodiments the non-polymeric particles can have an average density of from about 3.5 to about 12.0 g/cm³.

In some embodiments the multiplicity of solid particles can be in the form of beads.

In some embodiments the solid particles can be reused one or more times for cleaning of said at least one soiled substrate in, with or by said cleaning apparatus.

In some embodiments the wash liquor can be water. In some embodiments the wash liquor can comprise at least one detergent or detergent composition. In some embodiments the wash liquor can comprise one or more additives as detailed further hereinbelow.

In further embodiments of the invention there is disclosed a method for cleaning at least one soiled substrate comprising the treatment of the substrate with a multiplicity of solid particles using the cleaning apparatus as herein described.

In some embodiments the method can comprise the steps:

• • (a) loading said at least one soiled substrate into the drum and closing said door;
  • (b) introducing wash liquor to moisten the substrate and causing the drum to rotate;
  • (c) operating said pumping means to pump wash liquor and said multiplicity of solid particles from said first location to the door and introducing said multiplicity of solid particles into the drum via said separator.

In some embodiments said first location in the method of step c) can be the lower portion of the housing. In some embodiments said first location can be the sump. In further embodiments the method of step c) can comprise operating said pumping means to pump said wash liquor and said solid particles upwardly from said first location to the door.

In some embodiments the method further comprises the step:

• • (d) operating said cleaning apparatus for a wash cycle wherein wash liquor and said multiplicity of solid particles can be transferred from the drum into a lower portion of the housing as said drum rotates.

In some embodiments the method further comprises the steps:

• • (e) operating said pumping means so as to pump additional wash liquor and solid particles from said first location to said door and to recirculate solid particles used in step c) for re-use in the cleaning operation; and
  • (f) continuing with steps c), d) and e) as required to effect cleaning of the at least one soiled substrate.

In some embodiments the method can further comprise introducing at least one additional cleaning agent into said drum. In some embodiments the at least one cleaning agent can comprise at least one detergent composition. In some embodiments said at least one detergent composition can comprise cleaning components and post-treatment components. In some embodiments said cleaning components can be selected from the group consisting of: surfactants, enzymes and bleach. In some embodiments said post-treatment components can be selected from the group consisting of: anti-redeposition additives, perfumes and optical brighteners.

In some embodiments the method can further comprise introducing at least one additive into said drum wherein said at least one additive is selected from the group consisting of: builders, chelating agents, dye transfer inhibiting agents, dispersants, enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal agents, suds suppressors, dyes, structure elasticizing agents, fabric softeners, starches, carriers, hydrotropes, processing aids and pigments.

The composition of the wash liquor may depend at any given time on the point which has been reached in the cleaning cycle for the soiled substrate using the apparatus of the invention. Thus, for example, at the start of the cleaning cycle, the wash liquor may be water. At later point in the cleaning cycle the wash liquor may include detergent and/or one of more of the above mentioned additives. During a cleaning stage of the cleaning cycle, the wash liquor may include suspended soil removed from the substrate.

In some embodiments the method can be carried out so as to achieve a wash liquor to substrate ratio of between about 5:1 to 0.1:1 w/w in said drum.

In some embodiments the ratio of said multiplicity of solid particles to substrate being cleaned can be in the range of from about 0.1:1 to about 30:1 w/w.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be further illustrated by reference to the following drawings, wherein:

FIG. 1 shows an external view of the cleaning apparatus according to an embodiment of the invention;

FIG. 2 shows a cross-sectional front view of the cleaning apparatus according to an embodiment of the invention;

FIG. 3 shows a cross-sectional a side view of the cleaning apparatus through section A-A of the image in FIG. 2 according to an embodiment of the invention;

FIG. 4 shows a further cross-sectional front view of the cleaning apparatus including the drum according to an embodiment of the invention;

FIG. 5A shows a side cross-sectional view of the door according to an embodiment of the invention;

FIG. 5B shows a frontal view of the door according to an embodiment of the invention;

FIG. 6 shows an isometric cross-sectional view of the door according to an embodiment of the invention;

FIG. 7 shows an exploded view of the door and a portion of the tub according to an embodiment of the invention;

FIG. 8 shows an isometric view of the separator as used in a door or apparatus to an embodiment of the invention;

FIG. 9 shows a cross-sectional view of a cleaning apparatus according to an alternative embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present inventors have addressed the issues associated with using a cleaning apparatus to clean soiled substrates with a solid particulate material and particularly the problems associated with the need to separate wash liquor from the solid particulate material prior to its use in said cleaning apparatus.

As described herein, “wash liquor” pertains to an aqueous medium used in the cleaning apparatus and can comprise water or water when combined with at least one cleaning agent such as a detergent composition and/or any further additives as detailed further hereinbelow.

Referring to FIG. 1, there is provided a cleaning apparatus (10) comprising a housing (80). The housing (80) can comprise an upper portion (80A) and a lower portion (80B). In certain embodiments of the invention the housing (80) comprises therein a rotatably mounted drum. The drum can be in the form of a rotatably mounted cylindrical cage (60). In some embodiments the rotatably mounted cylindrical cage (60) is located in the upper portion of the housing (80A). In further embodiments the rotatably mounted cage is mounted in a casing or tub (70). The tub (70) can circumferentially surround a portion of the rotatably mounted cage (60) and can store wash liquor.

In certain embodiments of the invention the rotatably mounted cylindrical cage (60) can comprise perforated side walls (perforations are shown in FIG. 3), wherein said perforations comprise holes have a diameter of from 2 to 25 mm. In some embodiments said perforations can comprise holes having a diameter of from 2 to 10 mm. In further embodiments said perforations can comprise holes having a diameter of no greater than 5 mm. In yet further embodiments said perforations can comprise holes having a diameter of no greater than 3 mm.

In certain embodiments said perforations permit the ingress and egress of fluids and fine particulate materials of lesser diameter than the holes, but are adapted so as to prevent the egress of said solid particulate material.

In other embodiments said perforations permit the ingress and egress of fluids and said solid particulate material.

In some embodiments of the invention the cleaning apparatus (10) can comprise a door (20) to allow access to the interior of the rotatably mounted cylindrical cage (60). In certain embodiments the door (20) can be hingedly coupled or mounted to a portion of the tub (70). The door (20) can be moveable between an open and a closed position. When the door (20) is moved to an open position, access is permitted to the inside of the drum (60). When the door (20) is moved to a closed position, the cleaning apparatus (10) is substantially sealed. Mounting the door (20) to a portion of the tub (70) can, in some embodiments, shorten the pumping flow path for when the wash liquor and solid particulate material is pumped through the door (20) and into the drum (60) from a sump (50) located in the lower portion of the housing (80B). Mounting of the door (20) to the tub (70) instead of, for example, mounting the door (20) to the housing or cabinet facilitates the provision of a simplified flow path from the sump to the door. If the door were to be mounted to the housing, a dynamic link would be required between the sump and the tub increasing the complexity of the arrangement.

In certain embodiments the rotatably mounted cylindrical cage (60) can be mounted about an essentially horizontal axis within the housing (80). Consequently, in such embodiments of the invention, said door (20) is located in the front of the cleaning apparatus (10), thereby providing a front-loading facility.

Rotation of said rotatably mounted cylindrical cage (60) can be effected by use of drive means, which typically can comprise electrical drive means, in the form of an electric motor. Operation of said drive means can be effected by control means which may be operated by a user.

In some embodiments the cleaning apparatus of the present invention can be a commercial washing machine. In certain embodiments said rotatably mounted cylindrical cage (60) can be of the size which is to be found in most commercially available washing machines and tumble driers, and can have a capacity of approximately 10 to 7000 liters. A typical capacity for a domestic washing machine would be of approximately 30 to 150 liters whilst, for an industrial washer-extractor, capacities anywhere in the range of from 150 to 7000 liters are possible. A typical size in this range is that which is suitable for a 50 kg washload, wherein the drum has a volume of 450 to 650 liters and, in such cases, said cage (60) would generally comprise a cylinder with a diameter of approximately 75 to 120 cm, preferably from 90 to 110 cm, and a length of between 40 and 100 cm, preferably between 60 and 90 cm.

In some embodiments the cleaning apparatus of the present invention can be a domestic washing machine. Typically said domestic washing machine can comprise a rotatably mounted cylindrical cage (60) having a capacity of from 30 to 150 liters. In some embodiments, the rotatably mounted cylindrical cage (60) can have a capacity of from 50 to 150 liters. Generally the cage (60) of said domestic washing machine will be suitable for a 5 to 15 kg washload. In such embodiments, the rotatably mounted cage (60) can typically comprise a cylinder with a diameter of approximately 40 to 60 cm and a length of approximately 25 cm to 60 cm. In some embodiments the cage can typically have 20 to 25 liters of volume per kg of washload to be cleaned.

In some embodiments the housing (80) or cabinet of the cleaning apparatus of the present invention can have a length dimension of from about 40 cm to about 120 cm, a width dimension of from about 40 cm to about 100 cm and a height of from about 70 cm to about 140 cm.

In some embodiments the housing (80) or cabinet of the cleaning apparatus of the present invention can have a length dimension of from about 50 cm to about 70 cm, a width dimension of from about 50 cm to about 70 cm and a height of from about 75 cm to about 95 cm. In further embodiments, the housing (80) or cabinet of the cleaning apparatus can have a length dimension of about 60 cm, a width dimension of about 60 cm and a height of about 85 cm. In certain embodiments the cleaning apparatus of the present invention can be comparable in size to a typical front-loading domestic washing machine commonly used in the Europe.

In some embodiments the housing (80) or cabinet of the cleaning apparatus of the present invention can have a length dimension of from about 50 cm to about 100 cm, a width dimension of from about 40 cm to about 90 cm and a height of from about 70 cm to about 130 cm. In further embodiments the housing (80) or cabinet can have a length dimension of from about 70 cm to about 90 cm, a width dimension of from about 50 cm to about 80 cm and a height of from about 85 cm to about 115 cm. In still further embodiments the housing (80) or cabinet of the cleaning apparatus can have a length dimension of from about 77.5 cm to about 82.5 cm, a width dimension of from about 70 cm to about 75 cm and a height of from about 95 cm to about 100 cm. In yet still further embodiments the housing (80) or cabinet of the cleaning apparatus of the present invention can have a length dimension of about 71 cm (28 inches), a width dimension of about 80 cm (31.5 inches) and a height of about 96.5 cm (38 inches). In some embodiments the cleaning apparatus of the present invention can be comparable in size to a typical front-loading domestic washing machine commonly used in the USA.

Advantageously, the location of the separator in the door enables the overall dimensions of the washing machine to be reduced as separation of solid particulate material is no longer necessary at a position external to the housing such as is adopted in comparable bead cleaning washing machines known in the art. Furthermore, positioning of the separator in the door obviates the need to expand other areas of the housing to accommodate the separation device. Consequently, the apparatus of the present invention can exhibit dimensionality which is similar or equivalent to conventional domestic washing machines.

The cleaning apparatus (10) of the present invention is designed to operate in conjunction with soiled substrates and cleaning media comprising a solid particulate material, which, in some embodiments, is in the form of a multiplicity of polymeric or non-polymeric particles. These polymeric or non-polymeric particles can be efficiently circulated to promote effective cleaning and the cleaning apparatus (10), therefore, can include circulation means. Thus, the inner surface of the cylindrical side walls of said rotatably mounted cylindrical cage (60) can comprise a multiplicity of spaced apart elongated protrusions affixed essentially perpendicularly to said inner surface. In some embodiments, said protrusions additionally comprise air amplifiers which are typically driven pneumatically and are adapted so as to promote circulation of a current of air within said cage. Typically said cleaning apparatus (10) can comprise from 3 to 10, preferably 4, of said protrusions, which are commonly referred to as lifters.

In some embodiments the cleaning apparatus (10) can comprise lifters which can collect the solid particulate material and transfer it to a lower portion of the housing (80B). Particularly said lifters can facilitate transportation of the solid particulate material to a sump (50) in said lower portion of the housing (80B). Referring now to FIG. 4, the lifters (68) can comprise collecting and transferring means (68A) in the form of a plurality of compartments. The lifters (68) can be located at equidistant intervals on the inner circumferential surface of the rotatably mounted cylindrical cage (60).

The lifters (68) can comprise a first aperture allowing ingress of solid particulate material into a capturing compartment and a second aperture allowing transfer of said solid particulate material. The dimensions of the apertures can be selected in line with the dimensions of the solid particulate material, so as to allow efficient ingress and transfer thereof.

In operation, agitation is provided by rotation of said rotatably mounted cylindrical cage (60) of said cleaning apparatus (10). However, in some embodiments of the invention, there is also provided additional agitating means, in order to facilitate the efficient removal of residual solid particulate material at the conclusion of the cleaning operation. In certain embodiments, said agitating means can comprise an air jet.

In some embodiments the cleaning apparatus (10) according to the invention can comprise at least one delivery means. The delivery means can facilitate the entry of wash liquor constituents (notably water and/or cleaning agents) directly (that is, otherwise than by way of the sump 50 and pumping means 52 as herein described below) to the rotatably mounted cylindrical cage (60) as required. In further embodiments, the cleaning apparatus (10) can comprise a multiplicity of delivery means. Suitable delivery means can include one or more spraying means such as spray nozzle (12) as illustrated in FIG. 5A. The delivery means can deliver, for example, water, one or more cleaning agents or water in combination with said one or more cleaning agents. In some embodiments the delivery means of the cleaning apparatus (10) can be adapted to first add water to moisten the substrate before commencing the wash cycle. In some embodiments the delivery means can be adapted to add one or more cleaning agents during the wash cycle. In some embodiments, the delivery means can be mounted on a portion of the door (20).

In certain embodiments the housing (80) can include standard plumbing features, in addition to said multiplicity of delivery means, by virtue of which at least water and, optionally, cleaning agents such as surfactants, can be circulated and prior to their introduction to the rotatably mounted cylindrical cage (60).

The cleaning apparatus (10) can additionally comprise means for circulating air within said housing (80), and for adjusting the temperature and humidity therein. Said means may typically include, for example, a recirculating fan, an air heater, a water atomizer and/or a steam generator. Additionally, sensing means can also be provided for determining, inter alia, the temperature and humidity levels within the cleaning apparatus (10), and for communicating this information to control means which can be worked by an operative.

In certain embodiments the rotatably mounted cylindrical cage (60) can be mounted in said tub (70). Referring to FIG. 2, the tub (70) can comprise an upper portion (70A) and a lower portion (70B). The rotatably mounted cylindrical cage (60) can be mounted in the upper portion (70A) of the tub (70). The upper portion (70A) can be dimensioned to support the rotatably mounted cylindrical cage (60) and facilitate mounting thereof. In certain embodiments the upper portion (70A) of the tub can comprise a curved portion (76) that can circumferentially surround the rotatably mounted cage (60). The tub (70) can further comprise a first sidewall (71) and a second sidewall (73) extending from the curved portion (76). The first sidewall (71) and second sidewall (73) can be respectively opposed to each other and extend from the curved portion (76) to the base of the tub (72). Furthermore, the first and second sidewalls (71, 73) can each comprise a linear portion.

In some embodiments the lower portion (70A) of the tub (70) can include a sump (50). The sump (50) can function as a chamber for retaining the solid particulate material. The sump (50) can further contain water and/or one or more cleaning agents. The sump (50) can further comprise heating means allowing its contents to be raised to a preferred temperature for use in the cleaning operation. The heating means can comprise one or more heater pads attached to the outer surface of the sump (50).

Thus, in some embodiments, the sump (50) may be integrally formed with the tub (70) such that the sump (50) and the tub (70) can comprise a single unit. Advantageously, the inclusion of a combined sump and tub arrangement in the above noted embodiments can facilitate the ease of transport of the solid particulate from the sump (50) to the drum (60).

In some embodiments the unitary nature of the tub (70) can enable the upper portion (70A) containing the drum (60) and the lower portion (70B) comprising the sump (50) to move together as one body in response to vibrations induced by rotation of the drum (60). The cleaning apparatus (10) can therefore further comprise one or more dampers connected to the tub (70) to reduce the extent to which vibrations from the drum are transmitted to the housing (80). The one or more dampers can be connected to the lower portion (70B) of the tub (70). As shown in FIG. 2, the cleaning apparatus can comprise a first damper (62) connected to the first sidewall (71) and a second damper (64) connected to the second sidewall (73) of the tub (70). Thus, in some embodiments, the cleaning apparatus can comprise a plurality of dampers connected to the tub (70).

In certain embodiments, and as illustrated in FIGS. 2 and 3, the sump (50) can be defined in the lower portion (70B) of the tub (70) between a front wall (78), a rear wall (74), first and second sidewalls (71, 73) and the base (72) of the tub (70). In further embodiments the sump (50) can comprise a first end (56) and a second end (58). The first end (56) can be towards the front of the cleaning apparatus (10) adjacent to the front wall (78) of the tub (70) and proximate to the door (20). The second end (58) can be towards the rear of the cleaning apparatus (10) distal to the door (20) and adjacent to the rear wall (74) of the tub (70). In some embodiments the base of the tub (70) or the floor of the sump (50) can be sloped. The floor can be sloped such that the solid particulate material is directed towards the first end (56) of the sump (50). Thus, in some embodiments, the floor may be inclined downwardly from the second end (58) in the direction of the first end (56). The inclusion of the sloping floor can ensure that any solid particles residing in the sump (50) are localized predominantly of approximately the first end (56). Advantageously this feature can facilitate the effective emptying of the sump (50) and ease of recirculation of the solid particulate cleaning material.

In certain embodiments the sump (50) can be enlarged in comparison to those found in conventional domestic washing machines. In such embodiments the distance between the drum (60) and the base (72) of the tub (70) can be at least 10 cm. Advantageously, this can allow for a greater capacity to retain the solid particulate material for use in the cleaning apparatus.

Typically, in some embodiments, the sump (50) can comprise said solid particulate material prior to first use of the cleaning apparatus (10). In operation, water can be added to the solid particulate material in the sump (50). When a threshold or desired volume of water is present in the sump (50), the water and solid particulate material can be pumped through the door (20) and into the rotatably mounted cylindrical cage (60). During the wash cycle, water and/or one or more cleaning agents can be added from the delivery means into the rotatably mounted cage (60) and ultimately any fluids can be transferred (e.g. via perforations in the walls of the rotatably mounted cage) to the sump (50). Thus, during the course of the wash cycle, the contents of the sump (50) can comprise water in combination with one or more cleaning agents and the solid particulate material.

The cleaning apparatus (10) can comprise pumping means (52) to pump wash liquor and the solid particulate material. In some embodiments pumping means (52) can be located in the lower portion of the housing (80B). In some embodiments the pumping means (52) can be located in or can be connected to the sump (50). In further embodiments the sump (50) can comprise pumping means (52). In some embodiments the pumping means (52) can be located proximate to the first end (56) of the sump (50). In certain embodiments the pumping means (52) can be located beneath the door (20). In certain embodiments the pumping means (52) can be adapted to pump wash liquor in combination with the solid particulate material from the sump (50) to the door (20). Positioning of the pumping means (52) proximate said first end of the sump (50) can advantageously facilitate a short pumping path for the introduction of the solid particulate material into the drum (60) via the door (20).

The cleaning apparatus (10) can thus comprise means to recirculate the wash liquor and the solid particulate material. The solid particulate material can be recirculated from the lower portion of the housing (80B) to the upper portion of the housing (80A). Recirculation of the solid particulate material enables its re-use in the cleaning operation. In some embodiments, the solid particulate cleaning material can be recirculated along a path between the sump (50) and the rotatably mounted cylindrical cage (60). To facilitate transport of said solid particulate material along said recirculation path, the cleaning apparatus (10) can comprise ducting (40) extending from a lower portion of the housing (80B). The pumping means (52) can be adapted to pump said solid particulate material and wash liquor along said recirculation path via the ducting (40).

In certain embodiments of the invention, the cleaning apparatus (10) can comprise a door (20) wherein the door (20) comprises a separator (90) to facilitate separation of liquid from solid particulate material in a flow pathway and particularly wherein said liquid comprises wash liquor.

In some embodiments the door (20) can be in the form of an assembly comprising several components. Referring now to FIGS. 1, 5A, 5B, 6 and 7 the door (20) can comprise an outer portion (22) and an inner portion (24). In some embodiments the separator (90) can be located in the inner portion (24) of the door (20). In some embodiments the door (20) can comprise a door ring (28), an inner face (28a) and an outer face (28b). The inner portion (24) of the door (20) can comprise a first segment (28c) and a second segment (28d) upstanding from the inner face (28a). The first segment (28c) and the second segment (28d) can each respectively comprise a sloping wall joined to a substantially vertical wall. The vertical walls of each segment (28c, 28d) can be spaced apart by a gap that defines a channel (26) extending from the centre of the inner portion (24). In further embodiments the door (20) can comprise a window (28e) enabling a user to see within the rotabably mounted cage (60) when the cleaning apparatus (10) is in use. In some embodiments portions of the door (20) can be constructed of transparent material. In this way, the separator (90) can be seen during the operation of the cleaning apparatus (10).

In certain embodiments the door (20) can comprise a separating assembly (30). The separating assembly (30) can be received by or coupled to the inner portion (24) of the door (20). In certain embodiments the separating assembly (30) can comprise a feed pipe (34) and a separator (90) wherein the feed pipe (34) is connected to the separator (90). In some embodiments there can be defined an internal space or cavity (31) within the inner portion (24) of the door (20) between the components of the separating assembly (30) and the inner face (28a).

In some embodiments, the separating assembly (30) can comprise a connecting element (32) that is sized and shaped to receive both the feed pipe (34) and the separator (90). Thus the connecting element (32) can comprise a first coupling member (37a) and a second coupling member (37b) adapted to respectively receive the first end and the second end of the feed pipe (34). The connecting element (32) can further comprise a wall member (36) which can extend alongside, and in spaced apart relation to, the feed pipe (34). In certain embodiments the connecting element (32) can comprise an upper surface comprising a cut-out (38) dimensioned to receive the separator (90).

As shown in FIG. 7, the inner portion (24) of the door (20) can be dimensioned such that it is received by a throat (77) of the tub (70) when the door (20) is moved to a closed position. The throat of the tub (70) can comprise an aperture (77A) formed therein. In some embodiments the feed pipe (34) of the separating assembly (30) can comprise a first end proximate the aperture (77A) formed in the tub (70) and a second end connected to the separator (90). In some embodiments the first end of the feed pipe (34) can be in registry with the aperture (77A) of the tub (70).

In certain embodiments, when the door (20) is moved to a closed position, wash liquor in combination with the solid particulate material can be pumped from a lower portion of the housing (80B) to the separating assembly (30) via ducting (40). Thus, in some embodiments, the aperture (77A) of the tub (70) can be in alignment with an end portion of the ducting (40). When the door (20) is moved to a closed position a flow path can therefore be defined through ducting (40) and feed pipe (34) via aperture (77A). The door (20) can further comprise a sealing ring (42) disposed between the aperture (77A) and the flow pipe (34).

In certain embodiments, as noted above, the door (20) can comprise a separator (90). Referring now to FIG. 8, the separator (90) can comprise an inlet (92) and an outlet (94). The inlet (90) can be adapted to receive wash liquor and said solid particulate material from the feed pipe (34).

The separator (90) can further comprise a body (96) extending between the inlet (92) and the outlet (94). The body (96) can comprise a plurality of apertures (98) formed therein. The plurality of apertures (98) can be sized and shaped to permit the passage of liquid therethrough but not the solid particulate material. In some embodiments, each of said of apertures (98) can have a length dimension of approximately from about 20 mm to about 40 mm and a width dimension of approximately from about 1.5 mm to about 3 mm.

In further embodiments the separator can comprise a plurality of apertures that are arranged or dimensioned to capture lint and/or unwanted fine particulate matter arising from the cleaning process. In these embodiments a portion of the body of the separator can comprise or can be in the form of a mesh. In some embodiments the maximum dimension of the holes/apertures in the mesh are about 1.5 mm or about 1 mm or smaller. Examples of suitable mesh types that can be used include those with 12 holes per inch with 54.1% open area or 18 holes per inch with 53.7% open area. In certain embodiments, the apertures of the separator are thus small enough to capture lint and/or other unwanted fine particulate matter entrained in the wash liquor.

In certain embodiments the body (96) of the separator (90) can comprise a substantially curved region and the plurality of apertures (98) can be formed in said curved region. In some embodiments the curved region of the body (96) comprises an outer curved portion (96b) and an inner curved portion (96a).

In further embodiments an alternative construction can be provided for the body of the separator (90). In such embodiments, the body (96) can comprise a first planar wall member joined to a second planar wall member at a common point. The second planar wall member is angled or inclined with respect to the first planar wall member. Preferably, the second planar wall member is located upstream of said first planar wall member wherein upstream refers to the direction of flow of wash liquor and solid particles through the separator (90). Thus, the second planar wall member can be located nearer to the outlet (94) than the first planar wall member. A plurality of apertures (98) are formed in a portion of the second planar wall member. In some embodiments, the angle at which the second planar wall member is inclined with respect to the first planar wall member can be between about 60° and about 120°. In some embodiments the angle at which the second planar wall member is inclined with respect to the first planar wall member is about 90°.

In some embodiments, when the cleaning apparatus (10) is in use, wash liquor combined with the solid particulate material from the sump (50) is transported to the separating assembly (30) in the door (20). Thus wash liquor and the solid particulate material is pumped from the sump (50), along the ducting (40) and upwardly into the feed tube (34). Wash liquor and the solid particulate material can then continue substantially vertically along the feed tube (34) to the separator (90). Wash liquor is permitted to exit through the plurality of apertures (98) formed in the body (96) of the separator (90) however, as the solid particulate material is too large to exit via said apertures, the solid particulate material is deflected by the internal surface of the body (96) towards the outlet (94). In this manner, separation of at least a portion of the wash liquor from the solid particulate material can be achieved.

In some embodiments the separator (90) can direct at least 1 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60) with the solid particulate material. In certain embodiments the separator (90) can direct at least 10 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60). In further embodiments the separator (90) can direct at least 25 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60). In yet further embodiments the separator (90) can direct at least 40 percent, in still further embodiments at least 50 percent, in yet still further embodiments at least 70 percent and in yet still further embodiments at least 90 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60). In other embodiments the separator (90) can direct at least 95 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60). In certain embodiments wash liquor is directed to a location so as to not enter the drum (60) via the plurality of apertures (98).

In some embodiments the separator (90) can be arranged to direct no greater than 99 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60) with the solid particulate material. Thus, in some embodiments, up to 1 percent by mass of wash liquor entering via inlet (92) is permitted to enter the drum. In some embodiments, the separator (90) can be arranged to direct no greater than 90 percent by mass of wash liquor entering via inlet (92) to a location so as to not enter the drum (60) with the solid particulate material. Thus, in further embodiments, up to 10 percent by mass of wash liquor entering via inlet (92) is permitted to enter the drum. Thus in some embodiments a limited amount of the wash liquor from the flow pathway is permitted to enter the drum. The entry of a restricted amount of wash liquor into said drum can advantageously facilitate moistening of the soiled substrates for the cleaning operation.

In certain embodiments, wash liquor exiting the separator (90) through the plurality of apertures (98) can be directed into the cavity (31). The separated wash liquor can then flow along a downward flow path defined by the channel extending from the centre of the inner portion (24) of the door (20) and between the first and second segments (28c, 28d). The sloping walls of the first and second segments (28c, 28d) can serve to funnel fluid exiting from the plurality of apertures (98) of the separator (90) into said channel. In further embodiments separated wash liquor that does not enter the drum (60) can also flow along a further downward flowpath in the region between the feed pipe (34) and the wall member (36) of the connecting element (32).

Notably the action of the separator (90) in the present application is distinguished from the mode of operation of the bead separation vessel disclosed in the above-cited prior art document WO2011/098815. In WO2011/098815, the separation vessel comprises a gate valve and filtering arrangement to first enable water to drain from the mass of solid particulate material before the gate valve is actuated to release the solid particulate material into a delivery tube to be fed into the drum. Thus the flow of solid particulate material is first arrested to allow water to drain before the solid particulate material can be delivered to the drum. By contrast, the cleaning apparatus of the present application can, in some embodiments, provide a direct pathway from the lower portion of the housing (80B) and into the drum (60) as there is no requirement to intercept the solid particulate material along said pathway for the purpose of draining water.

In some embodiments, the door (20) can comprise an outlet or drain (44) to enable wash liquor to be returned to a lower portion of the housing (80B) following its passage through the separator (90). The drain (44) can thus be positioned downstream from the separator (90) ((by comparison upstream of the separator (90) would encompass, for example, the feed pipe (34)). Furthermore, the drain (44) can provide a route for said wash liquor to flow to the sump (50). In certain embodiments the drain (44) can be located proximate to the aperture (77A) of the tub (70). The tub (70) can comprise a recess (79) adjacent to said aperture (77A) to permit wash liquor to flow to the sump (50). The inclusion of such drainage means promotes efficient use of water in the apparatus.

In some embodiments, the outlet (94) of the separator (90) is arranged such that, following deflection from the internal surface of the body (96), the solid particulate material is directed into the rotatably mounted cylindrical cage (60). In some advantageous embodiments, said curved or angled (e.g. wherein the separator (90) comprises a second planar wall member inclined with respect to a first planar wall member) region of the body (96) of the separator (90) improves the separation of the solid particulate material by enabling wash liquor and solid particulate material to adopt different directional paths. The path of wash liquor exiting from the separator (90) via said apertures (98) is shown by arrow B and the path of solid particulate material exiting the separator (90) via the outlet (94) is shown by arrow A in FIG. 8. In some embodiments the outlet of the separator (94) can be arranged to direct the solid particulate material into the centre of the drum (60). In certain embodiments at least some of the solid particulate material, and preferably most or all of the solid particulate material, exits the separator (90) via the outlet (94) at an angle of between about 60° and about 120° to the path of wash liquor and solid particulate material entering the separator at inlet (92). In certain embodiments said angle at which the solid particulate material exits the separator outlet (94) is about 90° to the path of wash liquor and solid particulate material entering the separator at inlet (92). In further embodiments the path of wash liquor and solid particulate material entering the separator at inlet (92) is substantially vertical.

Advantageously, the action of the separator (90) can facilitate the direction of the solid particulate material into the centre of the washload contained in the cage (60) whilst simultaneously facilitating the direction of wash liquor towards a convenient return path for drainage and/or re-use. Thus, separated wash liquor exiting via the plurality of apertures (96) can be directed into the cavity (31) and along a downward path through the door (20) and towards the sump (50).

In some embodiments, the separator (90) is removable from the separating assembly (30). Thus the separator (90) can, in some embodiments, be easily detached from the connecting element (32). Advantageously, this enables routine maintenance to be carried out on the separator (90) and facilitates its simple replacement if such an operation is necessary. In embodiments wherein the separator (90) is configured to capture lint and other unwanted fine particulate matter, the separator (90) can be periodically removed and inspected after each cleaning cycle or after a set number of cleaning cycles performed with the cleaning apparatus. If necessary, the separator (90) can be subjected to a cleaning operation following its removal from the separating assembly in order to detach any unwanted materials that may have built up within the device. In such embodiments the separator can thus advantageously serve dual purposes by separating wash liquor from solid particles and in capturing lint and other unwanted fine particulate matter.

An alternative embodiment of the cleaning apparatus (10B) is shown in FIG. 9. The apparatus (10B) includes a housing (80) and drum (60) such as that described above. By contrast, the door (20B) of the apparatus comprises a shroud (22B) within which an alternative separating device (90B) is located. The shroud (22B) can be configured to provide a sealing arrangement such that wash liquor and solid particulate material can only enter and exit the door (20B) via flow paths defined therein. The separating device (90B) can be in the form of plate comprising a curved portion and a plurality of apertures formed therein. The apertures can have the same dimensions as those referred to for the separating device (90) above.

The separating device (90B) can receive a flow of wash liquor and solid particulate material from a feeding device (35) via ducting (40B). The ducting (40B) can extend over a top portion of the housing (80) and is connected to a pumping device (not shown). The feeding device (35) can be in the form of a feed nozzle. The feeding device directs a flow of wash liquor and solid particulate material towards the separating device (90B) which enables wash liquor to pass through. Solid particles are however directed into the interior of the drum (60) in the general direction of arrow B by virtue of the curved plate. In some embodiments the flow of wash liquor and solid particles can be directed towards the separating plate at a specified angle to improve separation. The angle at which the flow of wash liquor and solid particles are directed towards the plate for the embodiment illustrated in FIG. 9 is about 30° with respect to the vertical.

Wash liquor separated from the solid particles may contact one or more interior walls of the shroud (22B) before flowing in the general direction of arrow A. In addition, the door (20B) can further comprise a drain or ducting (44B) connected to the shroud (22B) to provide a return path for wash liquor to return to the sump (not shown).

The alternative described embodiment facilitates a different route for delivery of wash liquor and solid particulate to the door (20B). For example, wash liquor and solid particles can thus be pumped upwardly from the pumping device and over a top portion of the housing (80) before reaching the separator (90B) contained within the door (20B). Furthermore, wash liquor and solid particulate material pass through an exterior portion of the door (20B) to be received by the separator (90B) along a downward path.

Further arrangements are also permissible whereby the ducting (40B) instead extends around a side wall of the housing (80). In these embodiments, the ducting (40B) can first extend through an exterior side wall of the shroud (22B) before extending upwardly and then curving downwardly to deliver wash liquor and solid particulate material to the separator (90B) in the manner described above. A wall of the shroud (22B) can include hinged sealing means through which the ducting (40B) can pass.

Although not shown in the Figures, other arrangements for the door (20B) and separator (90B) may be permissible to provide alternative flow paths for the wash liquor and solid particulate material. The separator (90B) and associated flow paths can thus be arranged so that the separator (90B) receives a horizontal flow of wash liquor and solid particles. Solid particles from said horizontal flow can be directed into the drum by the separator (90B).

Despite the existence of said alternative embodiments providing different flow paths, preferred arrangements for the invention are those associated with the receipt of an upward flow of wash liquor and solid particulate material by the separating device. This type of configuration can help to provide the most efficient pumping route for the solid particles to enter the drum.

The cleaning apparatus according to the invention is principally designed for use in the cleaning of substrates comprising a textile material, in particular one or more garments, linens, napery, towels or the like. The cleaning apparatus of the invention has been shown to be particularly successful in achieving efficient cleaning of textile fibers which may, for example, comprise either natural fibers, such as cotton, wool, silk or man-made and synthetic textile fibers, for example nylon 6,6, polyester, cellulose acetate, or fiber blends thereof.

The solid particulate material for use in the invention can comprise a multiplicity of polymeric particles or a multiplicity of non-polymeric particles. In some embodiments, the solid particulate material can comprise a multiplicity of polymeric particles. Alternatively, the solid particulate material can comprise a mixture of polymeric particles and non-polymeric particles. In other embodiments, the solid particulate material can comprise a multiplicity of non-polymeric particles. Thus the solid particulate material in embodiments of the invention can comprise exclusively polymeric particles, exclusively non-polymeric particles or mixtures of polymeric and non-polymeric particles.

The polymeric particles or non-polymeric particles can be of such a shape and size as to allow for good flowability and intimate contact with the substrate and particularly with textile fiber. A variety of shapes of particles can be used, such as cylindrical, ellipsoidal, spheroidal, spherical or cuboid; appropriate cross-sectional shapes can be employed including, for example, annular ring, dog-bone and circular. In some embodiments, the particles can comprise generally cylindrical or spherical beads.

The polymeric particles or non-polymeric particles can have smooth or irregular surface structures and can be of solid, porous or hollow structure or construction.

In some embodiments the polymeric particles can be of such a size as to have an average mass of about 1 mg to about 70 mg. In certain embodiments the polymeric particles can be of such a size as to have an average mass of about 1 mg to about 50 mg. In further embodiments the polymeric particles can be of such a size as to have an average mass of about 1 mg to about 35 mg. In yet further embodiments the polymeric particles can be of such a size as to have an average mass of about 10 mg to about 30 mg. In still further embodiments the polymeric particles can be of such a size as to have an average mass of about 12 mg to about 25 mg.

In some embodiments the non-polymeric particles can be of such a size as to have an average mass of about 1 mg to about 1 g. In further embodiments the non-polymeric particles can be of such a size as to have an average mass of about 10 mg to about 100 mg. In still further embodiments the non-polymeric particles can be of such a size as to have an average mass of about 25 mg to about 100 mg.

In some embodiments the polymeric or non-polymeric particles can have a surface area of 10 mm² to 120 mm². In further embodiments the polymeric or non-polymeric particles can have a surface area of 15 mm² to 50 mm². In still further embodiments the polymeric or non-polymeric particles can have a surface area of 20 mm² to 40 mm².

In some embodiments the polymeric particles can have an average density in the range of from about 0.5 to about 2.5 g/cm³. In further embodiments the polymeric particles can have an average density in the range of from about 0.55 to about 2.0 g/cm³. In still further embodiments the polymeric particles can have an average density in the range of from about 0.6 to about 1.9 g/cm³.

In certain embodiments the non-polymeric particles can have an average density greater than the polymeric particles. Thus, in some embodiments, the non-polymeric particles can have an average density in the range of about 3.5 to about 12.0 g/cm³. In still further embodiments, the non-polymeric particles can have an average density in the range of about 5.0 to about 10.0 g/cm³. In yet further embodiments, the non-polymeric particles can have an average density in the range of about 6.0 to about 9.0 g/cm³.

In some embodiments the average volume of the polymeric and non-polymeric particles is in the range of 5 to 275 mm³. In further embodiments the average volume of the polymeric and non-polymeric particles is in the range of 8 to 140 mm³ and in still further embodiments said average volume is in the range of 10 to 120 mm³.

In some embodiments the solid particles can have an average particle diameter of from 1.0 mm to 10 mm. In further embodiments the solid particles can have an average diameter of from 2.0 mm to 8.0 mm. In yet further embodiments the solid particles have an average diameter of from 2.0 mm to 6.0 mm. The effective average diameter can also be calculated from the average volume of a particle by simply assuming the particle is a sphere. The average is preferably a number average. The average is preferably performed on at least 10, more preferably at least 100 particles and especially at least 1000 particles.

In some embodiments the solid particles can have a length of from 1.0 mm to 10 mm. In further embodiments the solid particles can have a length of from 2.0 mm to 8.0 mm. In yet further embodiments the solid particles can have a length of from 2.0 mm to 6.0 mm. The length can be defined as the maximum 2 dimensional length of each 3 dimensional solid particle. The average is preferably a number average. The average is preferably performed on at least 10, more preferably at least 100 particles and especially at least 1000 particles.

In some embodiments the polymeric or non-polymeric particles can be substantially cylindrical or substantially spherical in shape.

In certain embodiments the cylindrical particles can be of oval cross section. In such embodiments, the major cross section axis length, a, can be of approximately from 2.0 to 6.0 mm. In further embodiments a can be of approximately from 2.2 to 5.0 mm and in still further embodiments a can be of approximately from 2.4 mm to 4.5 mm. The minor cross section axis length, b, can be of approximately from 1.3 to 5.0 mm. In further embodiments b can be of approximately from 1.5 to 4.0 mm and in still further embodiments b can be of approximately from 1.7 mm to 3.5 mm. For an oval cross section, a>b. In certain embodiments the length of the cylindrical particles, h, can be in the range of from about 1.5 mm to about 6 mm. In further embodiments the length h can be from about 1.7 mm to about 5.0 mm. In yet further embodiments the length h of the particle can be from about 2.0 mm to about 4.5 mm. The ratio h/b can typically be in the range of from 0.5-10.

In certain embodiments the cylindrical particles can be of circular cross section. The typical cross section diameter, d_c, can be of approximately from 1.3 to 6.0 mm. In further embodiments d_c can be of approximately from 1.5 to 5.0 mm and in still further embodiments d_c can be of approximately from 1.7 mm to 4.5 mm. In certain embodiments the length of such particles, h_c, can be in the range of from about 1.5 mm to about 6 mm. In further embodiments the length h_c can be from about 1.7 mm to about 5.0 mm. In yet further embodiments the length of the particle h_c can be from about 2.0 mm to about 4.5 mm. The ratio h_c/d_c can typically be in the range of from 0.5-10.

In some embodiments of the invention the particles can be generally spherical in shape (but not a perfect sphere) having a particle diameter, d_s, of approximately from 2.0 to 8.0 mm. In further embodiments d_s can be of approximately from 2.2 to 5.5 mm and in still further embodiments d_s can be of approximately from about 2.4 mm to about 5.0 mm.

In certain embodiments of the invention the particles can be perfectly spherical in shape having a particle diameter, d_ps, of approximately from 2.0 to 8.0 mm. In further embodiments d_ps can be of approximately from 3.0 to 7.0 mm and in still further embodiments d_ps can be of approximately from about 4.0 mm to about 6.5 mm.

In some embodiments the polymeric particles can comprise polyalkenes such as polyethylene and polypropylene, polyamides, polyesters, polysiloxanes or polyurethanes. Furthermore, said polymers can be linear, branched or crosslinked. In certain embodiments, said polymeric particles can comprise polyamide or polyester particles, particularly particles of nylon, polyethylene terephthalate or polybutylene terephthalate, typically in the form of beads. Said polyamides and polyesters are found to be particularly effective for aqueous stain/soil removal, whilst polyalkenes are especially useful for the removal of oil-based stains.

Various nylon homo- or co-polymers can be used including, but not limited to, Nylon 6 and Nylon 6,6. In some embodiments, the nylon can comprise Nylon 6,6 copolymer having a molecular weight of approximately from about 5000 to about 30000 Daltons, such as from about 10000 to about 20000 Daltons, or such as from about 15000 to about 16000 Daltons. Useful polyesters can have a molecular weight corresponding to an intrinsic viscosity measurement in the range of from about 0.3 to about 1.5 dl/g, as measured by a solution technique such as ASTM D-4603.

In some embodiments the polymeric particles can comprise foamed polymers. In further embodiments the polymeric particles can comprise unfoamed polymers.

Optionally, copolymers of the above polymeric materials may be employed for the purposes of the invention. Specifically, the properties of the polymeric materials can be tailored to specific requirements by the inclusion of monomeric units which confer particular properties on the copolymer. Thus, the copolymers can be adapted to attract particular staining materials by including monomer units in the polymer chain which, inter alia, are ionically charged, or include polar moieties or unsaturated organic groups. Examples of such groups can include, for example, acid or amino groups, or salts thereof, or pendant alkenyl groups.

In some embodiments the non-polymeric particles can comprise particles of glass, silica, stone, wood, or any of a variety of metals or ceramic materials. Suitable metals include, but are not limited to, zinc, titanium, chromium, manganese, iron, cobalt, nickel, copper, tungsten, aluminum, tin and lead, and alloys thereof. Suitable ceramics include, but are not limited to, alumina, zirconia, tungsten carbide, silicon carbide and silicon nitride.

In further embodiments the present invention provides a method for cleaning a soiled substrate using the cleaning apparatus as herein described wherein the method can comprise the treatment of the substrate with a formulation comprising said solid particulate material and wash liquor.

In order to provide additional lubrication to the cleaning apparatus and thereby improve the transport properties within the system, wash liquor, which can be water, is added. Thus, more efficient transfer of the cleaning material to the substrate is facilitated, and removal of soiling and stains from the substrate occurs more readily. The solid particulate material can thus elicit a cleaning effect on the substrate and water can simply aid the transport of said solid particulate material. Optionally, the soiled substrate may be moistened by wetting with mains or tap water prior to loading into the cleaning apparatus of the invention. Wetting of the substrate within the apparatus of the invention is preferable. In any event, water can be added to the rotatably mounted cylindrical cage (60) of the invention such that the washing treatment is carried out so as to achieve a wash water or wash liquor to substrate ratio in the cage (60) which, in some embodiments is between 5:1 and 0.1:1 w/w. In certain embodiments the wash liquor to substrate ratio is between 2.5:1 and 0.1:1 w/w. In further embodiments the ratio is between 2.0:1 and 0.8:1. By means of example, particularly favorable results have been achieved at ratios such as 1.75:1, 1.5:1, 1.2:1 and 1.1:1. Most conveniently, the required amount of water can be introduced into the rotatably mounted cylindrical cage (60) of the apparatus according to the invention after loading of the soiled substrate into said cage.

In some embodiments the wash liquor to substrate ratio can be maintained between predetermined limits throughout the wash cycle. The predetermined limits may be different in different stages of the wash cycle. In embodiments noted above wherein the mass of wash liquor separated from the solid particulate material by the action of the separator is less than 100 percent, an additional amount of water can migrate into the cage (drum) (60) during the addition of the solid particulate material through the separating assembly (30). However the amount of additional water permitted to enter the cage (60) is regulated due to the action of the separator (90) and the required wash liquor to substrate ratio can be effectively maintained throughout the wash cycle within an acceptable limit. For example, if the wash liquor to substrate ratio is between 2.5:1 and 0.1:1, the action of the separator can ensure that the extremes of this range are not exceeded during the wash cycle. Advantageously the separator can therefore serve to maintain the desired wash liquor to substrate ratio by substantially limiting excess water from entering the cage during the wash cycle.

Whilst, in some embodiments, the method of the invention envisages the cleaning of a soiled substrate by the treatment of a moistened substrate with only solid particulate material (i.e. in the absence of any further additives) optionally in other embodiments the formulation employed can additionally comprise at least one cleaning agent. The at least one cleaning agent can include at least one detergent composition. In some embodiments said at least one cleaning agent can be introduced into the drum of the cleaning apparatus before or following commencement of the wash cycle. In other embodiments said particles comprised in said solid particulate material can be coated with said at least one cleaning agent.

The principal components of the detergent composition can comprise cleaning components and post-treatment components. In some embodiments, the cleaning components can comprise surfactants, enzymes and bleach, whilst the post-treatment components can include, for example, anti-redeposition additives, perfumes and optical brighteners.

However, the formulations for use in the method of the invention can further optionally include one or more other additives such as, for example builders, chelating agents, dye transfer inhibiting agents, dispersants, enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal agents, suds suppressors, dyes, structure elasticizing agents, fabric softeners, starches, carriers, hydrotropes, processing aids and/or pigments.

Examples of suitable surfactants that can be included in the detergent composition can be selected from non-ionic and/or anionic and/or cationic surfactants and/or ampholytic and/or zwitterionic and/or semi-polar nonionic surfactants. The surfactant can typically be present at a level of from about 0.1%, from about 1%, or even from about 5% by weight of the cleaning compositions to about 99.9%, to about 80%, to about 35%, or even to about 30% by weight of the cleaning compositions.

The detergent composition can include one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, other cellulases, other xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, [beta]-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination can comprise a mixture of enzymes such as protease, lipase, cutinase and/or cellulase in conjunction with amylase.

Optionally, enzyme stabilizers can also be included amongst the cleaning components. In this regard, enzymes for use in detergents may be stabilized by various techniques, for example by the incorporation of water-soluble sources of calcium and/or magnesium ions in the compositions.

The detergent composition can include one or more bleach compounds and associated activators. Examples of such bleach compounds include, but are not limited to, peroxygen compounds, including hydrogen peroxide, inorganic peroxy salts, such as perborate, percarbonate, perphosphate, persilicate, and mono persulphate salts (e.g. sodium perborate tetrahydrate and sodium percarbonate), and organic peroxy acids such as peracetic acid, monoperoxyphthalic acid, diperoxydodecanedioic acid, N,N′-terephthaloyl-di(6-aminoperoxycaproic acid), N,N′-phthaloylaminoperoxycaproic acid and amidoperoxyacid. Bleach activators include, but are not limited to, carboxylic acid esters such as tetraacetylethylenediamine and sodium nonanoyloxybenzene sulphonate.

Suitable builders can be included as additives and include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicates, polycarboxylate compounds, ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof.

The additives can also optionally contain one or more copper, iron and/or manganese chelating agents and/or one or more dye transfer inhibiting agents.

Suitable polymeric dye transfer inhibiting agents for use in the detergent composition include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof.

Optionally, the detergent composition can also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms.

Said anti-redeposition additives that can be included in the detergent composition are physico-chemical in their action and include, for example, materials such as polyethylene glycol, polyacrylates and carboxy methyl cellulose.

Optionally, the detergent composition can also contain perfumes. Suitable perfumes are generally multi-component organic chemical formulations which can contain alcohols, ketones, aldehydes, esters, ethers and nitrile alkenes, and mixtures thereof. Commercially available compounds offering sufficient substantivity to provide residual fragrance include Galaxolide (1,3,4,6,7,8-hexahydro-4,6,6,7,8,8-hexamethylcyclopenta(g)-2-benzopyran), Lyral (3- and 4-(4-hydroxy-4-methyl-pentyl)cyclohexene-1-carboxaldehyde and Ambroxan ((3aR,5aS,9aS,9bR)-3a,6,6,9a-tetramethyl-2,4,5,5a,7,8,9,9b-octahydro-1H-benzo[e][1]benzofuran). One example of a commercially available fully formulated perfume is Amour Japonais supplied by Symrise® AG.

Suitable optical brighteners that can be used in the detergent composition fall into several organic chemical classes, of which the most popular are stilbene derivatives, whilst other suitable classes include benzoxazoles, benzimidazoles, 1,3-diphenyl-2-pyrazolines, coumarins, 1,3,5-triazin-2-yls and naphthalimides. Examples of such compounds include, but are not limited to, 4,4′-bis[[6-anilino-4(methylamino)-1,3,5-triazin-2-yl]amino]stilbene-2,2′-disulphonic acid, 4,4′-bis[[6-anilino-4-[(2-hydroxyethyl)methylamino]-1,3,5-triazin-2-yl]amino]stilbene-2,2′-disulphonic acid, disodium salt, 4,4′-Bis[[2-anilino-4-[bis(2-hydroxyethyl)amino]-1,3,5-triazin-6-yl]amino]stilbene-2,2′-disulphonic acid, disodium salt, 4,4′-bis[(4,6-dianilino-1,3,5-triazin-2-yl)amino]stilbene-2,2 ‘-disulphonic acid, disodium salt, 7-diethylamino-4-methylcoumarin, 4,4’-Bis[(2-anilino-4-morpholino-1,3,5-triazin-6-yl)amino]-2,2′-stilbenedisulphonic acid, disodium salt, and 2,5-bis(benzoxazol-2-yl)thiophene.

Said above components can be used either alone or in a desired combination and can be added at appropriate stages during the washing cycle in order to maximize their effects.

In some embodiments the ratio of solid particulate material to substrate is generally in the range of from about 0.1:1 to about 30:1 w/w. In certain embodiments the ratio of solid particulate material to substrate is in the range of from about 0.1:1 to about 20:1 w/w. In still further embodiments the ratio of solid particulate material to substrate is in the range of from about 0.1:1 to about 15:1 w/w and in yet further embodiments said ratio is in the range of from about 0.1:1 to about 10:1 w/w. In certain embodiments the ratio of solid particulate material to substrate is of approximately from about 0.5:1 to about 5:1 w/w. In further embodiments the ratio of solid particulate material to substrate is between about 1:1 and about 3:1 w/w and, in still further embodiments, around 2:1 w/w. Thus, for example, for the cleaning of 5 g of fabric, 10 g of polymeric or non-polymeric particles could be employed in one embodiment of the invention.

In some embodiments the ratio of solid particulate material to substrate can be maintained at a substantially constant level throughout the wash cycle. Consequently, pumping of fresh and recycled or recirculated solid particulate material can, in some embodiments, proceed at a rate sufficient to maintain approximately the same level of solid particulate material in the rotatably mounted cylindrical cage throughout the cleaning operation, and to thereby ensure that the ratio of solid particulate material to soiled substrate stays substantially constant until the wash cycle has been completed.

The apparatus and the method of the present invention can be used for either small or large scale batchwise processes and finds application in both domestic and industrial cleaning processes. In some embodiments the present invention can be applied to domestic washing machines and processes.

In a typical wash cycle using the cleaning apparatus (10) of the invention, soiled substrates are first placed into the rotatably mounted cylindrical cage (60). Then, an appropriate amount of wash liquor (water, together with any additional cleaning agent) can be added to said rotatably mounted cylindrical cage (60) via the delivery means. In some embodiments, water can be pre-mixed with the cleaning agent prior to its introduction into the cage (60). Typically, water can be added first in order to suitably wet or moisten the substrate before further introducing any cleaning agent. Optionally the water and the cleaning agent can be heated. Following the introduction of water and any optional cleaning agents, the wash cycle can commence by rotation of the cage (60). The solid particulate material and (further) wash liquor residing in the sump (50), which optionally can be heated to a desired temperature, is then pumped upwardly via ducting (40) and through the separating portion (30) of the door (20). Solid particulate material is consequently propelled from the outlet (94) of the separator (90) and into the centre of the washload in the rotatably mounted cylindrical cage (60).

During the course of agitation by rotation of the cage (60), water including any cleaning agents falls through the perforations in the cage (60) and into the sump (50). In certain embodiments a quantity of the solid particulate material can also fall through perforations in the cage (60) and into the sump (50). In other embodiments, lifters disposed on the inner circumferential surface of the cage (60) can collect the solid particulate material as the cage (60) rotates and transfer the solid particulate material to the sump (50). On transfer to the sump (50), the sloping floor (72) directs the solid particulate material and water plus any cleaning agents to the first end (56) of the sump (50) proximate the door (20). The sump (50), via the use of pumping means (52) proximate said first end (56), again pumps wash liquor in combination with the solid particulate material upwardly via ducting (40) and through the separating portion (30) of the door (20). Consequently, additional solid particulate material can be entered into the cage (60) during the wash cycle. Furthermore, solid particulate material used in the cleaning operation and returned to the sump (50) can be reintroduced into the cage (60) and can therefore be re-used in either a single wash cycle or subsequent wash cycles. Wash liquor pumped upwardly from the sump (50) through the separating portion (30) with the solid particulate material and which does not enter the rotatably mounted cage (60) can be returned to the sump (50) via the drain (44) in the door (20) and recess (79) in the tub (70).

The cleaning apparatus (10) can perform a wash cycle in a similar manner to a standard washing machine with the cage (60) rotating at between 30 and 40 rpm for several revolutions in one direction, then rotating a similar number of rotations in the opposite direction. This sequence can be repeated for up to about 60 minutes. During this period, solid particulate material can be introduced and reintroduced to the cage (60) from the sump (50) via the separator (90) in the manner as described above.

As previously noted, the apparatus and method of the invention can find particular application in the cleaning of textile fibers. The conditions employed in such a cleaning system do, however, allow the use of significantly reduced temperatures from those which typically apply to the conventional wet cleaning of textile fabrics and, as a consequence, offer significant environmental and economic benefits. Thus, typical procedures and conditions for the wash cycle require that fabrics are generally treated according to the method of the invention at, for example, temperatures of between 5 and 95° C. for a duration of between about 5 and 120 minutes in a substantially sealed system. Thereafter, additional time may be required for the completion of the rinsing and any further stages of the overall process, so that the total duration of the entire cycle is typically of approximately about 1 hour. The operating temperatures for the method of the invention can be in the range of from about 10 to about 60° C. and, in some embodiments, from about 15 to about 40° C.

The results obtained when cleaning with the apparatus of the invention are very much in line with those observed when carrying out conventional wet (or dry) cleaning procedures with textile fabrics. The extent of cleaning and stain removal achieved with fabrics treated by the method of the invention is seen to be very good, with particularly outstanding results being achieved in respect of hydrophobic stains and aqueous stains and soiling, which are often difficult to remove. The energy requirement, the total volume of water used, and the detergent consumption when using the cleaning apparatus of the invention are all significantly lower than those levels associated with the use of conventional aqueous washing procedures, again offering significant advantages in terms of cost and environmental benefits.

Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

1. A door for providing access to a rotatably mounted drum of a cleaning apparatus, the door comprising a flow pathway for wash liquor and a multiplicity of solid particles and a separator, the separator being arranged to direct the multiplicity of solid particles from the flow pathway into the drum and wherein the separator is further arranged to direct a portion of the wash liquor from the flow pathway to a location other than into the drum.

2. The door as claimed in claim 1, wherein the door defines therein a first flow path to the separator for wash liquor and the solid particles and further defines therein a second flow path from the separator for a portion of the wash liquor directed to a location other than into the drum.

3. The door as claimed in claim 1, wherein the door comprises a feed pipe for the passage of the wash liquor and the solid particles therethrough.

4. The door as claimed in claim 1, wherein the door further comprises an outlet downstream from the separator for the wash liquor from the flow pathway directed to a location other than into the drum.

5. The door as claimed in claim 4, wherein the door comprises an inner portion comprising one or more channels to direct the wash liquor to the outlet.

6. The door as claimed in claim 1, wherein the separator comprises a web or substrate having a plurality of apertures formed therein wherein the apertures are sized so as to permit the passage of wash liquor whilst preventing the passage of the solid particles therethrough.

7. The door as claimed in claim 6, wherein the separator comprises an inlet, an outlet and a curved body portion disposed between the inlet and the outlet and wherein the curved body portion comprises the web or substrate having a plurality of apertures formed therein.

8. The door as claimed in claim 6, wherein the separator comprises an inlet, an outlet and a body disposed between the inlet and the outlet, the body comprising a first planar wall member joined to a second planar wall member at a common point wherein the second planar wall member is inclined with respect to the first planar wall member and wherein the second planar wall member comprises the web or substrate having a plurality of apertures formed therein.

9. The door as claimed in claim 1, wherein the separator comprises a plurality of apertures sized so as to permit the passage of wash liquor whilst preventing the passage of the solid particles therethrough wherein the apertures are further arranged to capture lint and/or fine particulate matter entrained in the wash liquor.

10. A cleaning apparatus for use in the cleaning of at least one soiled substrate with a multiplicity of solid particles comprising:

a housing containing a drum rotatably mounted therein;

a door moveable between an open position wherein the at least one soiled substrate can be placed within the drum and a closed position wherein the cleaning apparatus is substantially sealed;

at least one delivery means for the addition of wash liquor; and

pumping means configured to pump wash liquor and a multiplicity of solid particles from a first location to the door;

wherein the door comprises a flow pathway for the wash liquor and the solid particles and a separator arranged to direct the multiplicity of solid particles from the flow pathway into the drum and wherein the separator is further arranged to direct a portion of the wash liquor from the flow pathway to a location other than into the drum.

11. The apparatus as claimed in claim 10, wherein the pumping means is configured to pump the wash liquor and the solid particles upwardly from the first location to the door.

12. The apparatus as claimed in claim 11, wherein the separator is arranged to receive an upward flow of the wash liquor and the solid particles from the first location and wherein the separator is further arranged to direct the multiplicity of solid particles into the drum from the upward flow.

13. The apparatus as claimed in claim 10, wherein the separator is arranged to receive a downward flow of the wash liquor and the solid particles and wherein the separator is further arranged to direct the multiplicity of solid particles into the drum from the downward flow.

14. The apparatus as claimed in claim 10, wherein the separator is arranged to receive a horizontal flow of the wash liquor and the solid particles and wherein the separator is further arranged to direct the multiplicity of solid particles into the drum from the horizontal flow.

15. The apparatus as claimed in claim 10, wherein the separator is arranged to receive a flow of the wash liquor and the solid particles from the pumping means and is further arranged to direct at least 1 percent of the total mass of water from the flow to the location other than into the drum.

16. The apparatus as claimed in claim 10, wherein the separator is arranged to receive a flow of the wash liquor and the solid particles from the pumping means and is further arranged to direct at least 70 percent of the total mass of water from the flow to the location other than into the drum.

17. The apparatus as claimed in claim 10, wherein the separator is arranged to receive a flow of the wash liquor and the solid particles from the pumping means and is further arranged to direct no greater than 99 percent of the total mass of the wash liquor from the flow to the location other than into the drum.

18. The apparatus as claimed in claim 10, wherein the separator comprises an inlet arranged to receive a substantially vertical flow of the wash liquor and the solid particles from the pumping means and an outlet arranged to direct the solid particles into the drum wherein at least some of the solid particles exit the outlet at an angle of between about 60° and about 120° to the flow of wash liquor and solid particles entering the inlet.

19. The apparatus as claimed in claim 10, wherein the flow pathway for the wash liquor and the solid particles extends directly from the pumping means to the door and from the door into the drum.

20. The apparatus as claimed in claim 10, wherein the first location comprises a sump.

21. The apparatus as claimed in claim 20 further comprising a flow path downstream from the separator so that wash liquor from the flow pathway directed to a location other than into drum can return to the sump.

22. The apparatus as claimed in claim 10, wherein the cleaning apparatus further comprises a tub and wherein the drum is mounted within the tub.

23. The apparatus as claimed in claim 22, wherein the door is mounted to a portion of the tub.

24. The apparatus as claimed in claim 20, wherein the cleaning apparatus further comprises a tub and wherein the drum is mounted within the tub, and wherein the tub includes the sump.

25. The apparatus as claimed in claim 20, wherein the sump comprises a first end proximate to the door and a second end distal to the door and wherein the sump further comprises a sloping floor arranged to direct the solid particles to the first end of the sump.

26. The apparatus as claimed in claim 25, wherein the pumping means is located proximate to the first end of the sump.

27. The apparatus as claimed in claim 10, wherein the solid particles are recirculated along a recirculation path from the lower portion of the housing to the rotatably mounted drum.

28. The apparatus as claimed in claim 10, wherein the drum comprises collecting and transferring means adapted to facilitate collection of the multiplicity of solid particles and transfer of the solid particles from the drum to a lower portion of the housing.

29. The apparatus as claimed in claim 10, wherein the drum is mounted about a substantially horizontal axis.

30. The apparatus as claimed in claim 10, wherein the drum comprises a rotatably mounted cylindrical cage comprising perforated side walls wherein the perforations comprise holes having a diameter of no greater than 5.0 mm.

31. The apparatus as claimed in claim 10, wherein the drum comprises a rotatably mounted cylindrical cage comprising perforated side walls wherein the perforations comprise holes having a diameter of no greater than 3.0 mm.

32. The apparatus as claimed in claim 10, wherein the drum has a capacity of approximately 10 to 700 liters.

33. The apparatus as claimed in claim 10, wherein the drum has a capacity of approximately 30 to 150 liters.

34. The apparatus as claimed in claim 10 comprising the door of claim 1.

35. The apparatus as claimed in claim 10, wherein the cleaning apparatus is a domestic washing machine.

36. The apparatus as claimed in claim 10, wherein the at least one soiled substrate comprises a textile material.

37. The apparatus as claimed in claim 10, wherein the multiplicity of solid particles comprise a plurality of polymeric particles.

38. The apparatus as claimed in claim 10, wherein the multiplicity of solid particles comprise a plurality of non-polymeric particles.

39. The apparatus as claimed in claim 10, wherein the multiplicity of solid particles comprise a mixture of polymeric solid particles and non-polymeric solid particles.

40. The apparatus as claimed in claim 37, wherein the polymeric particles are selected from the group consisting of polyalkenes, polyamides, polyesters, polysiloxanes, polyurethanes and copolymers thereof.

41. The apparatus as claimed in claim 40, wherein the polymeric particles are selected from the group consisting of polyalkenes and copolymers thereof.

42. The apparatus as claimed in claim 40, wherein the polymeric particles are selected from the group consisting of polyamide, polyester, and copolymers thereof.

43. The apparatus as claimed in claim 42, wherein the polyester particles are selected from the group consisting of polyethylene terephthalate and polybutylene terephthalate.

44. The apparatus as claimed in claim 42, wherein the polyamide particles comprise particles of nylon.

45. The apparatus as claimed in claim 38, wherein the non-polymeric particles are selected from the group consisting of glass, silica, stone, wood, metals and ceramic materials.

46. The apparatus as claimed in claim 37, wherein the polymeric particles have an average density of from about 0.5 to about 2.5 g/cm3.

47. The apparatus as claimed in claim 38, wherein the non-polymeric particles have an average density of from about 3.5 to about 12.0 g/cm3.

48. The apparatus as claimed in claim 10, wherein the multiplicity of solid particles are in the form of beads.

49. The apparatus as claimed in claim 10, wherein the solid particles are reused one or more times for cleaning of the at least one soiled substrate in, with or by the cleaning apparatus.

50. A method for cleaning at least one soiled substrate comprising treating the substrate with a multiplicity of solid particles using the cleaning apparatus as claimed in claim 10.

51. The method as claimed in claim 50 further comprising:

(a) loading the at least one soiled substrate into the drum and closing the door;

(b) introducing wash liquor to moisten the substrate and causing the drum to rotate; and

(c) operating the pumping means to pump wash liquor and the multiplicity of solid particles from the first location to the door and introducing the multiplicity of solid particles into the drum via the separator.

52. The method of claim 51 further comprising:

(d) operating the cleaning apparatus for a wash cycle wherein wash liquor and the multiplicity of solid particles are transferred from the drum into a lower portion of the housing as the drum rotates.

53. The method of claim 52 further comprising:

(e) operating the pumping means so as to pump additional wash liquor and solid particles from the first location to the door and to recirculate the cleaning formulation used in step c) for re-use in the cleaning operation; and

(f) continuing with steps (c), (d) and (e) as required to effect cleaning of the at least one soiled substrate.

54. The method of claim 50 further comprising introducing at least one additional cleaning agent into the drum wherein the at least one cleaning agent comprises at least one detergent composition.

55. The method of claim 50, wherein the method is carried out so as to achieve a wash liquor to substrate ratio of between about 5:1 to 0.1:1 w/w in the drum.

56. The method of claim 50, wherein the ratio of the multiplicity of solid particles to substrate being cleaned is in the range of from about 0.1:1 to about 30:1 w/w.