WO2001033151A1

WO2001033151A1 - Coated or laminated non-woven or woven cloth or paper dryer-safe bag

Info

Publication number: WO2001033151A1
Application number: PCT/US2000/029857
Authority: WO
Inventors: James A. Smith
Original assignee: Custom Cleaner, Inc.
Priority date: 1999-11-01
Filing date: 2000-10-31
Publication date: 2001-05-10

Abstract

The invention relates to devices, especially bags (1), which include a polymer-coated (6) or polymer-laminated woven cloth, non-woven cloth or paper (7). These devices are particularly useful in fabric-treatment systems for containment and treating or freshening of one or more fabric articles in conditions of heat and tumbling in a rotary clothes dryer.

Description

COATED OR LAMINATED NON-WOVEN OR WOVEN CLOTH OR PAPER DRYER^S AFE BAG

FIELD OF THE INVENTION The present invention relates to coated or laminated devices for use in cleaning, freshemng or otherwise treating fabric or fabric articles. The devices generally are in the form of a bag, and are preferably used in fabric-treatment systems for containment of fabric articles to be treated in conditions of heat and tumbling in a rotary clothes dryer. In certain embodiments, the invention contemplates fabric-treatment systems including coated or laminated non- woven cloth or paper dryer-safe bags in which fabric articles to be treated and/or freshened are placed, along with a fabric-treatment composition.

BACKGROUND OF THE INVENTION

Methods for dry-cleaning fabrics commonly employ organic solvents which can readily dissolve or disperse soils such as water-insoluble substances, including greases, oily dirts and the like, and which exhibit low solvent boiling points, enabling easy recovery of the solvents. The use of solvent-based dry-cleaning methods has been primarily limited to commercial cleaning operations that employ expensive specialized equipment. Such equipment includes stills with condensers to contain vapors from the cleaning solvents, which are often toxic. As a result, to utilize such dry-cleaning processes, particularly to remove water-insoluble spots and/or stains from clothes, the user must bring the clothes to a specialized dry-cleaning establishment and pick up the cleaned clothes at a later date. This results in inconvenient expenditures of time in going to the dry-cleaner, waiting for the clothes to be properly cleaned, picking up the clothes, and dealing with damaged and lost articles of clothing. Moreover, articles of clothing and fabric items from many different sources are dry-cleaned with the same batch of solvent, which can result in malodorous residues.

Methods are available for consumers to dry-clean their clothing at home in a rotary hot air dryer. In one such process, soiled fabric articles are placed in a plastic or nylon bag with an added sheet coated with a cleaning/freshening composition. The bag is closed and placed in a dryer where it is tumbled at elevated temperatures for a period of time, so that the cleaning/freshening composition acts to clean or freshen the clothing. The bags utilized in these methods are typically heat resistant but are expensive or inconvenient to produce, such as certain plastic or nylon bags that require costly materials. Such bags may also be made out of types of plastic that may not be as appealing to some or as soft to the touch as, for instance, a fabric bag.

SUMMARY OF THE INVENTION The present invention provides novel heat-resistant, tear-resistant devices, which are formed out of generally flammable or combustible substrate materials. In general, the substrate material by itself is not heat- resistant, and may be easily frayed, ripped or degraded (such as by heat and/or moisture). However, when combining the substrate with a polymer layer, a composite material is formed which is able to withstand elevated temperatures over a period of time without melting or incinerating. In addition, these composite materials may also be resistant to degradation, abrasion or tearing. Preferably the device is in the form of a bag, as this form has any number of uses including certain of the fabric-treatment embodiments of this invention. In one embodiment, the invention includes a substrate material, such as nonwoven fabric, woven fabric or paper material, where at least one of surface of the substrate is wholly or partially covered with a polymer layer. Any polymer layer may be used, but preferably the polymer has the characteristics of compatibility with the substrate, flexibility, and heat resistance. The polymer may be applied to the substrate using layer using any means known in the art (such as, for instance, by coating, lamination, vapor deposition, etc.). Where the device is in the form of a bag, either or both of the exterior (outside) surface and interior (inside) surface may include the polymer layer. It is not necessary that the entire exterior or interior surface be covered with the polymer layer, although this may be preferred in certain embodiments of the invention. The invention also includes polymer-layered devices where only a portion of the interior and/or exterior surface is covered. For instance, the polymer may be applied to strips of the substrate, or as dots and the like, by any means known in the art.

Alternatively, a polymer layer may be included as a third layer, between the interior and exterior layers within the walls of the device. In one preferred embodiment utilizing the polymer-layered devices, the invention is directed to fabric-treatment systems adapted for cleaning, freshening and/or treating all types of fabric articles, even including delicate fabric articles (such as, for instance, 100% acetate, 100% silk, 100% rayon and blends of these fabrics). The fabric-treatment system is particularly useful to contain and treat one or more fabric articles in conditions of heat and tumbling in a rotary clothes dryer. This is carried out, for example, by enclosing the fabric articles in a polymer-coated bag together with a cleaning/freshening composition. The polymer-coated bags of the invention are advantageous in that they provide a dryer-safe device comprised of a material that is generally unsuitable or unstable for exposure to high temperatures (such as non-woven fabric, woven fabric, and, especially, paper), which material is rendered both suitable and safe by coating it wholly or partially with a polymer layer. Generally, the coated bags are also beneficial because they are substantially air and moisture impervious, are lightweight, have a soft exterior or interior feel, resist degradation by moisture or heat, and/or resist abrasion or tearing in conditions of tumbling (or other agitation). Often one or both of the substrate material and the polymer are inexpensive, and consequently, the bag device is cost-effective to produce on small or large scale.

Additional advantages of the various embodiments of this invention will become readily apparent to persons skilled in the art from the following discussion.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of one embodiment of the invention, which shows a bag device where the interior surface is coated with a polymer layer.

Figure 2 is a perspective view of another embodiment, which shows a bag device where the exterior surface is coated with a polymer layer.

Figure 3 is a perspective view of another embodiment, which shows a bag device having either or both the interior or exterior surfaces coated with a polymer, and optional vents in the sides of the bag.

DETAILED DESCRIPTION OF THE INVENTION The present invention, including the above-described embodiments and various versions thereof, is more fully described in the following detailed discussion.

A. Polymer-Coated Bags

The bags should be formed of at least two materials: (1) a substrate material, and (b) a polymer. The substrate may be formed of any material that is capable of supporting the polymer in the form of a coating, laminate, film, layer, etc. (collectively, "layer"), while substantially maintaining the shape and integrity of the bag, which material can readily be selected by someone having ordinary skill in the art. Preferably the material is flexible. When the device is a bag, the bag defines an opening and includes sides or walls each having an interior surface and an exterior surface, and preferably there is a fastening system for closing the opening.

The substrate may even be a material that by itself is flammable or melts in elevated temperatures (such as the temperatures reached in a dryer). In fact, one of the advantages of this invention is that materials generally thought to be unusable for exposure to high temperatures can now be made useful for that purpose. For example, suitable materials for forming the substrate include non-woven fabric, woven fabric, paper, or a multiple or layered complex comprising such materials. For instance, the woven or non- woven fabric or paper may include one or more generally adhesively or thermally bonded fibrous products having a web or corded fiber structure, or those which comprise fibrous mats in which the fibers are distributed haphazardly or in a random array. Woven fabrics may include, but are not limited to, one or more of polyester, cotton, linen, denim, wool, acetate, fleece, blends of fabrics, and the like. The non- woven fabric fibers can be natural, such as wool, silk, jute, hemp, cotton, linen, sisal, or ramie; or synthetic such as rayon, cellulose ester, polyvinyl derivatives, polyolefms, polyamides or polyesters. Generally, any diameter or dernier of fiber is useful as a substrate. Preferably, non-woven cloth materials are chosen which do not tend to tear or separate when used, for example, in an automatic dryer. Particularly useful non-woven cloths are those that have higher tensile strength due to the haphazard or random array of fibers in the material imparting strength in all directions. Suitable paper substrates may include, but are not limited to, one or more of brown paper, acid free paper, white or colored paper, recycled paper cardboard, and the like.

Combinations of these materials may also be used to form the substrate. The fabric and paper bags may be constructed using conventional means, such as disclosed in U.S. Patent Nos. 4,473,422 and 5,271,998.

The polymer forming the polymer layer comprises any polymer that is compatible with the substrate, and is flexible. Preferably, the polymer imparts heat resistance to the bag, as well as tear resistance.

The polymer may be water-based or solvent-based. Suitable polymers include, but are not limited to, polyurethanes, vinyl acetates, acrylics, acrylic copolymers, polyvinyl alcohols, polyvinyl pyrrolidones, polyvinyl chlorides, polyvinylidine dichlorides, polyesters, epoxy resins, melamine formaldehydes, styrene butadines, blends of these materials, and the like. Furthermore, the polymer may be filled with a variety of materials, as desired, such as inorganic materials, diatomacious earth, carbon blacks, silicas, fibers, and the like. In addition, a plastic lamination may be quite useful, such as, for instance, polyethylene, polypropylene, polyamide, or mixtures thereof.

Preferably, the polymer coating/laminate/film has a thickness between about 12 microns and about 50 microns. However, the polymer layer may be of any thickness, according to the desired end- use. The polymer may be applied in layers, which would increase overall thickness and may impart greater strength and heat resistance, as well as decreasing permeation of vapor or liquid components through the material of the bag.

A polymer layer can be applied to the substrate material by known processes such as vacuum coating (continuous or semi- continuous), evaporation, vapor deposition, electrodeposition, liquid spray, powder spray, saturation bonding, roll-coating (including knife-over roll-coating), chemical reaction, electron beam, sputtering (magnetion sputtering, reactive sputtering, drode sputtering, triode sputtering, etc.), doctor blade application, plasma treatment, lamination using an adhesive, and direct deposition. The polymer layer may also be applied by any other suitable method known in the art.

The bag may be constructed using any methods known in the art. For instance, the bag may be constructed so that at least one seam is placed on at least one side (also called a side-seam bag).

In a first embodiment, the polymer-coated device is a bag formed of a substrate material and has a polymer layer as the exterior surface. Preferably, the substrate material may be woven or non- woven fabric, or paper, or combinations of these. In a second embodiment, the system uses a polymer-coated bag much like the bag described in the first embodiment but having the polymer layer as the interior surface of the bag rather than the exterior surface.

Several embodiments are shown in Figures 1 and 2. In Figure 1, the bag 1 defines an opening 8 and includes an optional fastening system or closure mechanism 3 to open and close the opening 8. In Figure 1 , exterior layer 2 is coated with a polymer layer 6. In Figure 2, the exterior surface is coated with a polymer layer 6. The closure mechanism 3 in Figures 1-3 is shown to operate by manual folding of the top edges and fastening the closure mechanism 3. The opening 8 is closed by folding the top edges 5 and fastening the closure mechanism 3. The bag 1 may also be closed by a closure mechanism absent the folding. Of course, the bag may include any type of known fastening system, or may have none at all, depending on the desired end-use. For example, the bag's closure mechanism may include press-studs, a zipper, Velcro®, hook and loop, magnetic strips, folds, snaps, buttons, a latch and/or a Ziplock® fastener. Further, the opening need not necessarily be at the top of the bag, but may be anywhere in the sides of the bag, and of any design. The bottom edges 12 and the side edges 14 of the bag 1 may be connected by folding, heat sealing, gluing or a combination thereof.

In one particular embodiment, the opening in the bags may be closed by a hook and loop fastening system, such as Velcro®, where the hook and loop portions are attached to the bag via glue. A disadvantage of the glue- applied fastening systems is that the glue may melt in high-temperature dryers and leave undesirable residues on the walls of the dryer drum. Alternatively, the hook and loop portions are attached to the bag via heat-sealing. A further option is to form the hook portion as part of the bag itself, where the hook is formed of the same or similar material as the bag (e.g, polyethylene, polypropylene, nylon, etc.) when the bag is produced. The portion of the bag comprising the hook system may be made of a heavier gauge than the rest of the bag, and therefore is less flexible, which may permit the fastening system to be conveniently fastened by the user in virtually the same position for every use. One advantage of both heat-sealed hook and loop systems, and systems using a hook formed as part of the bag, is that these systems withstand high temperatures without melting or breakdown.

In another embodiment, the opening of the bag is sealed prior to use, and is conveniently opened by the user via a tear strip or other mechanism. The bag may also include a fastening system, such as any described above, so that the bag may be reversably fastened shut when in use. This tear strip embodiment is particularly useful if it is desirable that the bags are vapor-impermeable prior to use, such as during storage (for instance, where the interior surface of the bag contains a composition, such as described below). In an additional embodiment, the bags may be formed of a polypropylene capable of resisting melting at high temperatures (for instance, up to about 324°F). For instance, such polypropylene materials are available from Copol, Inc. (Nova Scotia, Canada). These bags are exceptionally strong, and are preferably formed by cast filming so as to produce bags that are smooth and shiny.

Another advantage of bags formed of this material is they may be heat-sealed. Thus, a three-sided, heat-sealed bag can be easily produced in a cost-efficient manner. Preferably, the bags are about 3.5 mils thick, which imparts high heat resistance. To further reduce transmission of vapors and chemicals (such as components of fabric-treatment compositions) from within the bag, a means for sealing any fastening on the bag can be used to prevent escape of vapors from the bag opening. For instance, the seal may be hermetic. This may be in addition to the fastening system, or the fastening system itself may be designed to seal the opening.

In one particular embodiment, the opening in the bags may be closed by a hook and loop fastening system, such as Velcro®, where the hook and loop portions are attached to the bag via glue. A disadvantage of the glue-applied fastening systems is that the glue may melt in high-temperature dryers and leave undesirable residues on the walls of the dryer drum. Alternatively, the hook and loop portions are attached to the bag via heat-sealing. A further option is to form the hook portion as part of the bag itself, where the hook is formed of the same or similar material as the bag (e.g, polyethylene, polypropylene, nylon, etc.) when the bag is produced. The portion of the bag comprising the hook system may be made of a heavier gauge than the rest of the bag, and therefore is less flexible, which may permit the fastening system to be conveniently fastened by the user in virtually the same position for every use. One advantage of both heat-sealed hook and loop systems, and systems using a hook formed as part of the bag, is that these systems withstand high temperatures without melting or breakdown.

In another embodiment, the opening of the bag is sealed prior to use, and is conveniently opened by the user via a tear strip or other mechanism. The bag may also include a fastening system, such as any described above, so that the bag may be reversably fastened shut when in use. This tear strip embodiment is particularly useful if it is desirable that the bags are vapor-impermeable prior to use, such as during storage (for instance, where the interior surface of the bag contains a composition, such as described below).

In an additional embodiment, the bags may be formed of a polypropylene capable of resisting melting at high temperatures (for instance, up to about 324°F). For instance, such polypropylene materials are available from Copol, Inc. (Nova Scotia, Canada). These bags are exceptionally strong, and are preferably formed by cast filming so as to produce bags that are smooth and shiny. Another advantage of bags formed of this material is they may be heat-sealed. Thus, a three-sided, heat-sealed bag can be easily produced in a cost-efficient manner. Preferably, the bags are about 3.5 mils thick, which imparts high heat resistance.

In a further embodiment, the polymer layer does not cover the entire substrate, but covers only a portion or portions of the substrate. That is, the polymer layer need not completely cover the interior and/or exterior surface, or be throughout the whole wall/side of the device. For instance, the polymer layer may take the form of strips, dots, or the like, which may be on the interior surface, exterior surface, and/or within the wall/side of the device.

A single polymer layer is sufficient when used alone to be advantageous. However, the polymer-layered bags may optionally have a second polymer layer on the oppposite surface and/or within the walls of the device. One advantage to this structure is that it further increases heat resistance and overall tensile strength of the bag.

In another embodiment, a bag has a polymer layer within the sides or walls of the bag. For instance, the polymer layer may be positioned between two pieces of substrate material, in a sandwich fashion. In one embodiment, the bag is formed of a polymer-coated material that is capable of reducing (or virtually eliminating) the amount of vapor, chemicals and air that would pass through a non- coated material. This can be accomplished by forming a bag that is coated with a polymer layer on either the exterior surface or interior surface of the bag, wherein the coating/film becomes either the exterior or interior surface of the bag, respectively. This is also accomplished by placing a polymer layer between the exterior and interiors surfaces of the bag, or a combination of these.

In one embodiment, the material making up the bag includes a substrate layer, a polymer layer and a metal and/or silica layer. In general, the metal and/or silica is in the form of a layer and is applied to the substrate layer using any means known in the art (such as, for instance, by coating, lamination, vapor deposition, etc.). Either or both of the exterior (outside) surface and interior (inside) surface may include the metal and/or silica layer. It is not necessary that the entire exterior or interior surface be metalized (or silica-coated). Furthermore, in variations of this embodiment only a portion of the interior and/or exterior surface is metalized (or silica-coated). For instance, the metalization (or silica coating) may take the form of strips, dots, and the like, which are applied to the surfaces by any means known in the art. Alternatively, a metal and/or silica layer may be included as a third layer, between the interior and exterior layers within the walls of the bag. In another embodiment, the bags of the invention can include at least one moisture releasing means which permits moisture, air and vapor to flow in or out through the interior and exterior surfaces of the bag. The moisture releasing means may be found anywhere on the bag (including the sides, the top portion, bottom portion, etc.), and may take any convenient form, such as vents, pores, slits, holes, and the like. For instance, vents may be conveniently formed near the fastening system, or be a part of the fastening system. For example, the fastening system may be designed so that air or moisture may pass in or out of the bag around the outer edges of the fastening system. In the alternative, these bags release moisture via separate fitment or valve which is suitable for releasing vapor from one direction only—either in or out depending on the use of the bag.

In one form of this embodiment, Figure 3 shows a bag that includes at least one vent 10 which permits moisture, air, vapor, odor and pressure to flow in and/or out through the surfaces of the bag. The vent 10 may be in a variety of forms, including pores, slits, holes, and the like. As shown in Figure 3, the vent is in the shape of a half moon with a complementary flap 10a. For example, in certain of the fabric-treatment systems described below, the bags of this embodiment are particularly useful for generally treating, and especially softening damp or wet fabric articles, where the vents serve to facilitate exhausting humidity, odors, vapors, etc. from the bag as it tumbles in the heated dryer. In one specific embodiment, if clothing has been washed and the user desires to treat/soften selected pieces of the washed clothing, the fabric-treatment composition is placed in the bag along with the selected wet clothing, and the bag is closed and tumbled with the rest of the wet clothing (which is outside the bag, in the dryer) under conditions of heat. Preferably, but not always, the vent design will allow the clothing in the bag to dry as it tumbles without treating the clothing outside the bag.

In another construction, the polymer-coated bag comprises a front panel and a back panel, each having a top edge, a bottom edge and two side edges. There is also opposite gussetted side panels connecting the front panel to the back panel at the side edges. The gussetted side panels are foldable to permit the bag to be stored in a flat configuration and expandable (for instance, to permit the bag to hold a plurality of fabric articles). A bottom portion connects the front panel and the back panel at the bottom edges. Preferably, the bottom portion is substantially flat when the side panels are expanded so as to permit the bag to stand upright on a flat surface. A top portion connects the front panel and the back panel at the top edges. In another construction, the bag comprises a front panel and a back panel, each having a top edge, a bottom edge and two side edges. The front and back panels are fastened together at the respective top and bottom edges. Opposite longitudinally gussetted side panels connect the front panel to the back panel at the side edges. The gussetted side panels are foldable to permit the bag to be stored in a flat configuration and expandable to form a generally pillow- shaped configuration (for instance, to permit the bag to hold a plurality of fabric articles therein). A closure mechanism is located at or near the top edge of the front panel, for opening and closing the bag. In a further construction, the bag comprises a generally planar

(flat) bottom with outside edges, the bottom having a diameter d. A straight-walled (i.e., little or no taper) or tapered body is attached to the outside edges of the bottom. Where the straight-walled embodiment is utilized, a top portion defines an opening, and has a width w. The diameter d is substantially the same as the width w. For example, a bag in this embodiment may be generally cylindrical or box-shaped. Where the tapered embodiment is utilized, a top portion defines an opening, and has a width w. The diameter d is greater than the width w, and the body tapers from the bottom to the top. Optionally, a fastening system closes the top portion. For example, a bag in this embodiment may generally form a cone shape or a pyramid shape.

Another optional embodiment for the bag is that at least a portion of the interior surface of the bag is formed of an absorptive material. For this embodiment, the bag may be formed as above, except that it should have an interior absorptive layer portion. Preferably, the innermost layer will be a reticulated plastic film formed in situ, a solid granular or porous absorbent solid filled plastic film or a combination of both foamed and solids loaded plastic. Examples of such materials include, but are not limited to, polyethylene, diatomacious earth-filled polyethylene, polypropylene, activated carbon, hydrophilic urethane, non-hydrophilic urethane, fiberglass, glass balls, and other solid absorbents dispersed in film.

In this embodiment, the bag is optionally formed in two steps. The outer layer of the bag is pre-formed and an absorptive material subsequently attached to the inside surface of the bag in a second step.

Non- woven cloth materials useful in the present invention to form the absorbent interior surface of the bag are generally adhesively or thermally bonded fibrous products laving a web or corded fiber structure, or those which comprise fibrous mats in which the fibers are distributed haphazardly or in a random array. The fibers can be natural, such as wool, silk, jute, hemp, cotton, linen, sisal, or ramie; or synthetic such as rayon, cellulose ester, polyvinyl derivatives, polyolefms, polyamides or polyesters. Generally, any diameter or dernier of fiber is useful in the present invention. The non-woven cloth materials are preferably not prone to tear or separate when used, for example, in an automatic dryer, due to the haphazard or random array of fibers in the non- woven material which impart excellent strength in all directions. Some examples of preferred non-woven cloth material useful as substrates in the present invention include 100% rayon sheets, available as described above.

The interior absorptive portion of the bag may be rendered suitably absorptive by a number of means. For example, the bag may have one or more multiple layers of substrate, the innermost film being absorptive, i.e., a reticulated plastic foam, a solid granular or porous absorbent solid filled plastic film or a combination of both foamed and solids loaded plastic.

Preferably the bags suitable for use in the present invention will have dimensions ranging from about 18" x 23" up to about 36" x 40". The most preferred size of bag for use in the present invention range is from about 20" x 28" to about 26" x 38". These dimensions preferably result in the bag having a surface area in the range of about 1120 in², and most preferably from about 1120 in² to about 1560 in². The bags may also be sufficiently small (such as, for example, for containment of a single soiled fabric article or several small fabric articles), with dimensions ranging from about 18" x 22" up to about 20" x 26", and preferably 20" x 24".

B. Methods of Use of the Polymer-Coated Bags

One utilization of the polymer-layered devices is via fabric- treatment systems for dry-cleaning, freshening or otherwise treating fabric articles. The term "fabrics" or "fabric articles" encompasses not only clothing, but any other textile items which are commonly dry-cleaned or treated, including sheets, draperies, rugs, upholstery coverings, towels and the like. For this invention, the term "fabrics" also can include wool, wool blends, linen, cotton, knits, double-knits, polyester, twill, synthetics, etc., as well as delicate fabrics, such as 100% acetate, silk, rayon and blends of these fabrics. The polymer- layered bag and fabric-treatment systems can accommodate fabrics that are in a wet, moist, or dry state.

As used herein with respect to the fabrics to be dry-cleaned, freshened or otherwise treated, the term "soil" includes odoriferous compounds such as tobacco smoke, residue, perfume, mustiness, perspiration and the like, as well as visible spots and stains.

Therefore, as used herein, the term "treating" or "treatment" encompasses any chemical treatment of fabric, including but not limited to dry-cleaning and freshening. The term "freshen" includes the removal, deodorizing, chemical neutralizing and/or masking of odoriferous compounds on or within a fabric with a desirable scent. As used herein, the term "dry cleaning" or "cleaning" includes the removal of both kinds of "soil". As used herein, the term "dryer" refers to a rotary hot air dryer, which tumbles the clothes in a drum with warm or heated air at an elevated temperature. The temperature within is usually between about 40°C and about 95°C, although the temperature may reach as high as about 200°C at points within the dryer, especially at the walls of the dryer unit and near the hot air inlet (often referred to as "hot spots" within the dryer). These higher temperatures are also characteristic of industrial dryers or Laundromat dryers. Preferably, however, the temperature within the dryer will be between about 50°C and about 90°C, for preselected periods of time (preferably, between about 15 and about 45 minutes). The fabric-treatment systems contemplated comprise at least two components: (a) a polymer-coated/laminated bag such as one described above, and (b) a fabric-treatment composition. In general, the bag defines an opening and includes sides or walls each having an interior surface and an exterior surface. Preferably there is a fastening system for closing the opening. As noted above, the polymer-layered bag should include at least two components: (a) a substrate material, and (b) at least one layer of applied polymer. The polymer may be in the form of a layer, a coating, a laminate, a film, or the like, applied to the exterior of the bag, interior of the bag and/or as a layer within the walls of the bag.

In one embodiment, the polymer layer is thick enough so as to make the bag substantially air and moisture impermeable. This is beneficial in reducing or even eliminating permeation of components of the fabric-treatment composition (such as, for example, organic solvent or fragrance) or other ingredients from inside the bag to air outside the exterior surface of the bag. For instance, for this embodiment the polymer coating thickness may be between about 12 microns and about 50 microns, although as mentioned above, the thickness can vary from this range as desired.

For use with the fabric-treatment systems, it is preferred that the polymer-coated bags exhibit sufficient thermal stability for use in the rotary hot air dryer. In addition, it is preferred that the containment bag will not be substantially damaged upon exposure to conditions including a temperature effective to cause release of the fabric-treatment composition from the substrate, fabric, etc. (which is described in more detail below). Preferably, the bag can resist "hot spots" within the dryer, where the temperature may reach as high as about 200°C. In one fabric-treatment system embodiment, an effective amount of the fabric-treatment composition contacts the soiled fabric (or fabrics) and treats it chemically. The composition contacts soiled, spotted and/or stained portions of fabric therein and removes or decreases the soil, spots and/or stains. In addition to, or in the alternative, the composition contacts the fabric and freshens it.

Preferably, the fabric-treatment compositions are effective when subjected to heat. Therefore, in one preferred practice of this embodiment, the soiled fabric (or fabrics) is added to the bag along with an effective amount of at least one fabric-treatment composition, and the bag is subjected to agitation and heat effective to release the composition in liquid and/or in vaporous form from the substrate, vehicle, fabric, interior absorptive surface of the bag, etc., on which the composition is present in the bag. The composition in liquid and/or vaporous form contacts the fabric article and treats it. Moreover, the composition contacts spotted and/or stained portions of fabric therein and cleans, removes or decreases the spots and/or stains. In addition to, or in the alternative, the composition contacts the fabric and freshens it.

The bag of the present invention can be placed in a rotary hot air clothes dryer to provide the effective amount of heat and agitation, or tumbling. Thus, in another embodiment, the present invention provides a method for cleaning and/or freshening soiled fabric articles comprising (a) placing a soiled fabric article (i.e., spotted, stained and/or in need of freshening) in a polymer-layered bag along with a fabric-treatment composition; (b) closing the bag; and (c) tumbling the bag and its contents in a dryer at a temperature effective to release the fabric-treatment composition in liquid and/or vapor form and for a time effective to contact an effective amount of the released composition with the soiled fabric, so as to treat, clean and/or freshen the fabric. One of the advantages of this fabric-treatment system is the strength and heat resistance of the polymer-layered bag. Another advantage is that the bag can make use of a generally combustible and flimsy substrate material, which is made thermally stable when combined with the polymer-coat. Similarly, the substrate-polymer combination renders the bag resistant to degradation by moisture, and resistant to abrasion or tearing in conditions of tumbling (or other agitation). In addition, the bags may be lightweight and have an appealing soft exterior or interior feel due to the soft substrate. Generally, at least the substrate material is inexpensive (and often the polymer as well), and thus the bag is cost-effective to produce. These coated bags are also beneficial because they may be substantially air and moisture impervious, and even reduce or eliminate permeation of chemicals (such as fragrance, organic solvent or volatile substances) that may be present in the fabric-treatment composition, through the material of the bag. The fabric-treatment systems of the invention contemplate any type of fabric-treatment composition. In general, the fabric-treatment composition should not react with the substrate or the polymer layer of the bag in any harmful or deleterious manner. For instance, the fabric-treatment composition may comprise water and fragrance, and optionally an organic solvent and/or optionally a surfactant. Alternatively, they may be organic solvent-based systems, with large amounts of organic solvent.

The composition may be comprised of a fabric-treatment agent, alone or in combination with another ingredient. Common agents include, for instance, dry-cleaning and fabric-softening agents. Examples of other fabric-treatment agents are anti-creasing agents, fatty acid condensates, anti-soil agents, bacteriostatic agents, brightening agents, bodying agents, dyes, coloring agents, fiber emollients, finishing agents, fragrances, germicides, lubricants, mildew-proofing agents, moth-proofing agents, shrinkage controllers, preservatives, fiber emollients, stain-removing agents, deodorants, insect repellents, sizing agents, starch, and the like, and mixtures thereof. Where organic solvent is used as part of a fabric-treatment composition, another advantage of certain of the embodiments is that the amount of organic solvent that escapes from the bag through the walls is decreased. As a consequence, the clothes are more effectively and efficiently cleaned/freshened within the bag during tumbling in the dryer.

When organic solvent is present in the fabric-treatment composition, it may make up between about 2 to about 99 total weight percent based on the total weight percent of the composition, and preferably between about 5 to about 50 weight percent. Although, total amounts may vary as desired and depending on the presence of other components, as would be understood by someone of ordinary skill in this art.

When both water and organic solvent are present in the fabric- treatment composition, the organic is preferably solvent water- miscible, or at least partially water-miscible. One example of a useful organic solvent is a glycol ether. These materials are lower(alkoxy)- or lower(alkoxy)lower(alkoxy)-ethers of ethanol or isopropanol. Some examples of preferred glycol ethers are available under the trade names Arcosolv® (Arco Chemical Co.) or Cellosolve®, Carbitol®, or Propasol® (Union Carbide Corp.), and include, e.g., butylCarbitol®, hexylCarbitol®, methylCarbitol®, and

Carbitol® itself, (2-(2-ethoxy)ethoxy)ethanol.

Other organic solvents include dipropylene glycol n-propyl ether, dipropylene glycol n-butyl ether, tripropylene glycol methyl ether, 3-methoxy-3-methyl-l-butanol and γ-butyrolactone. Other glycol ethers include diethylene glycol monobutyl ether, triethylene glycol monobutyl ether, ethylene glycol monohexyl ether, diethylene glycol monohexyl ether, dipropylene glycol monobutyl ether, butylethoxypropylene glycol, diethylene glycol monomethyl ether, triethylene glycol monomethyl ether, diethylene glycol monoethyl ether, triethylene glycol monoethyl ether, ethylene glycol monopropyl ether, diethylene glycol monopropyl ether, ethylene glycol monobutyl ether, propylene glycol monomethyl ether, dipropylene glycol monomethyl ether, propylene glycol monopropyl ether, propylene glycol monobutyl ether, propylene glycol methyl ether, propylene glycol ethyl ether, propylene glycol n-propyl ether, propylene glycol t-butyl ether, propylene glycol n-butyl ether, dipropylene glycol methyl ether, dipropylene glycol t-butyl ether, dripropylene glycol n-butyl ether, ethylene glycol methyl ether, ethylene glycol ethyl ether, ethylene glycol propyl ether, ethylene glycol butyl ether, ethylene glycol hexyl ether, ethylene glycol ethyl hexyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol propyl ether, diethylene glycol butyl ether, tripropylene glycol n-butyl ether, propylene glycol phenyl ether, propylene glycol n-phenyl ether, ethylene glycol n-butyl ether, diethylene glycol n-butyl ether, triethylene glycol butyl ether, triethylene glycol methyl ether, ethylene glycol phenyl ether, aromatic-based glycol ethers, butoxy propoxy propanol, methoxy propoxy propanol, ethoxy propoxy propanol, propoxy propoxy propanol, and mixtures thereof. Such glycol ethers are commercially available, for instance, from Dow, Union Carbide and Arco. Of course, the choice of glycol ether can be readily made by one of ordinary skill in the art on the basis of its volatility, weight percent of the total dispersion and the like. Alcohols which can be employed as co-solvents include liquid polyethylene glycols, i.e., polyethylene glycol-200, 300, 400 or 600, wherein the suffixed numbers indicate the approximate molecular weight of the glycol. Other co-solvents include other alcohols, for example, C₂-C₄ polyols, such as a diol or triol, e.g., ethylene glycol, propylene glyol, glycerol, 1,2-octanediol, or mixtures thereof. Other organic solvents can also be used including conventional chlorinated dry-cleaning solvents. Examples of these solvents are the di- to tetrachlorinated derivatives of methane, the di- to pentachlorinated derivatives of ethane and of ethylene, the mono- to trichlorinated derivatives of cyclohexane, and monochlorobenzene. Specific examples of this type include carbon tetrachloride, methylenechloride, 1,1-dichloroethane, 1,2-dichloroethane, 1,1-trichloroethane, 1,1,2-trichloroethane, 1,1,1 -trichloroethane, 1 , 1 ,2-trichloroethane, trichloroethylene, 1 , 1 ,2,2-tetrachloroethane, tetrachloroethylene, pentachloroethane, monochlorocyclohexane, 1 ,4-dichlorocyclohexane, monochlorobenzene and mixtures of the foregoing. Further, hydrocarbon solvents such as isoparaffmic solvents (available commercially as Isopar K made by Exxon, and DP-2000) can be useful.

The fabric-treatment composition can include minor but effective amounts of one or more surfactants. The surfactants may act as cleaning intensifiers to facilitate removal of the soil upon release of the fabric-treatment composition from the substrate in the dryer. Non-ionic, amphoteric and anionic surfactants may be used in the compositions. The fabric-treatment compositions may be present on a substrate (for instance, a sheet, a sponge, a ball, a dauber, a stick, granules or a cube). The substrate should be of sufficient size to contain an effective amount of the fabric-treatment composition. A sheet is the preferred substrate, such as, for instance, a plastic sheet or a porous sheet, and the composition may be stably impregnated, coated or otherwise applied onto the sheet.

Usually the fabric-treatment compositions remain in a moist or wet state when present on a substrate. In the alternative, the compositions may be present in a spray or roll on solution, or even be in a dry state, such as powder or granules.

The fabric-treatment compositions of the invention may be applied to soiled fabric articles in any manner. Preferably, the fabric-treatment composition is present in the fabric-treatment system on a substrate such as described above. A sheet is the preferred substrate. Fabric materials useful to form the sheet (which should be flexible) include woven or, preferably, non-woven fibers that are generally adhesively or thermally bonded. Fibrous sheets having a web or corded fiber structure, or those which comprise fibrous mats in which the fibers are distributed haphazardly or in a random array can also be used.

The fibers can be natural, such as wool, silk, jute, hemp, cotton, linen, sisal, or ramie; or synthetic such as rayon, cellulose ester, polyvinyl derivatives, polyolefms, polyamides or polyesters. Generally, any diameter or dernier of fiber is useful in the present invention. Preferably, the non-woven cloth materials are not prone to tear or separate when used, for example, in an automatic dryer, which may be due to the haphazard or random array of fibers in the non- woven material imparting strength in all directions.

Some examples of preferred non- woven cloth material useful as substrates in the present invention include 100% rayon sheets,

100% polypropylene sheets, or blended sheets (such as, for example, blends of cellulosic rayon and synthetic fibers).

Preferably the sheets have dimensions ranging from about 3" X 4" up to about 14" X 16". However, the sheet must also be of a sufficient size to carry a desirable load of fabric-treatment composition. Thus, the most preferred size of sheets range from about 4" X 14", particularly from about 5" X 12" to about 9" X 10". In conjunction therewith, the preferred sheets have surface areas ranging from about 12 inches squared to about 224 inches squared, and most preferably from about 48 inches squared to about 120 inches squared. When the bag is sufficiently small for containment of a single soiled fabric article or several small fabric articles (e.g., having dimensions ranging from about 18" x 22" up to about 20" x 26", and preferably 20" x 24") the sheet should also be suitably small (e.g., having dimension ranging between about 3" X 4" up to about 6" x 9", and preferably 5 5/8" x 8 1/2").

The fabric-treatment composition of the present invention is released from the sheet, sponge, ball, dauber, stick, cube, granules, etc. upon physical contact with the fabric articles in any manner desired, such as, for example, when the fabric articles and the sheet, sponge, ball, dauber, stick, cube, granules, etc. are tumbled together in the bag, preferably under heated conditions.

For instance, in one embodiment of the invention, one or more fabric articles and a suitably sized, flexible sheet containing a fabric-treatment composition are placed into the polymer-layered bag, the opening of the bag is closed, and then the bag is subjected to an amount of agitation and/or heat effective to release the composition from the flexible sheet upon contacting the fabric articles. The sheet "tumbles" among the fabric articles, thus dispersing the composition evenly onto them. Thus contacted, the fabric articles are cleaned, freshened or otherwise treated by the composition.

In one aspect of the invention, the polymer-layered bag, containing the flexible sheet and the fabric article(s), can be placed in a rotary hot air clothes dryer to provide the effective amount of heat and/or agitation, or tumbling, usually at a temperature of about 40°C-95°C, preferably at about 50°-90°C, for preselected periods of time. For example, about 15-45 minutes of tumbling are sufficient to release the fabric-treatment composition from the sheet interior surface of the bag at these temperatures and to clean or freshen the fabric articles.

In an alternative embodiment, the fabric-treatment composition may further be applied directly to the soiled fabric to be cleaned, e.g., by spraying, sponging, applying via squeeze bottle, rolling on wet or sprinkling via dry or moist powder or granule, the dry-cleaning composition onto the fabric. The fabric is subsequently placed into the bag, the bag opening fastened shut and the system rotated in a hot air clothes dryer.

One option with the invention, instead of or in addition to placing into the bag an effective amount of the fabric-treatment composition, is that at least a portion of the interior surface of the bag has an effective amount of the fabric-treatment composition releasably absorbed thereinto. For example, the interior absorptive surface may be a non-woven fabric attached to the inside surface of the bag after formation of the bag itself, as a second step. The fabric- treatment composition may be applied to the interior absorptive surface of the bag wall, i.e., by spraying, after the manufacture of the bag. Once the composition has been applied, the soiled fabric can be introduced into the bag, the bag fastened and tumbled in a clothes dryer. The composition cleans the soil from the fabric, and optionally, excess moisture and the removed soil are absorbed by the interior absorptive surface of the bag. In addition, the spotted and/or stained sections of the fabric may be manually rubbed on the inside of the impregnated bag to pre-treat the soiled areas with the composition in order to loosen the soil. After use, the bag may be discarded, or if desired, it may be constructed of a suitable material to allow repeated usage in a plurality of cleaning cycles.

Alternatively, the composition is applied to the fabric in another suitable manner, and the absorptive surface need not contain the composition at all. In that case, the absorptive surface may be useful for absorbing soil and excess moisture during the cleaning process.

The invention also relates to kits for treating a fabric article. These kits comprise, packaged in association,

(i) at least one of the polymer-layered bags, and (ii) an effective amount of at least one fabric-treatment composition.

The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. All references cited herein are incorporated by reference in their entirety.

Claims

WHAT IS CLAIMED IS:

1. A fabric-treatment system for containment and treating and/or freshening of one or more fabric articles in conditions of heat and tumbling in a rotary clothes dryer comprising: a fabric-treatment composition; and a heat-resistant bag comprising a nonwoven fabric, woven fabric, and/or paper material, which bag defines an opening and has an interior surface and an exterior surface, and has a fastening system for closing the opening, wherein at least one of the exterior surface or interior surface is at least partially covered with a polymer layer.