IMPROVED APPARATUS AND METHOD

Abstract

An apparatus (10) for use in the treatment of at least one substrate with a multiplicity of solid particles comprising: a) a housing (20) in which a drum (40) is rotatably mounted; b) a door (60) moveable between an open position wherein the at least one substrate can be placed in the drum and a closed position wherein the apparatus is substantially sealed; c) a separator (100) mounted in the door, wherein the separator comprises a perforated portion; d) a flow pathway pipe (110) mounted on or in the housing, wherein the flow pathway pipe comprises an outlet (140); and e) pumping means (210) configured to pump treatment liquor and a multiplicity of solid particles from a first location through the flow pathway pipe and out of the outlet towards the separator; wherein the separator is arranged to direct the multiplicity of solid particles into the drum and wherein the separator is further arranged to direct a portion of the treatment liquor to a location other than the drum.

Claims

1. An apparatus for use in the treatment of at least one substrate with a multiplicity of solid particles comprising: a) a housing in which a drum is rotatably mounted; b) a door moveable between an open position wherein the at least one substrate can be placed in the drum and a closed position wherein the apparatus is substantially sealed; c) a separator mounted in the door, wherein the separator comprises a perforated portion; d) a flow pathway pipe mounted on or in the housing, wherein the flow pathway pipe comprises an outlet; and e) pumping means configured to pump treatment liquor and a multiplicity of solid particles from a first location through the flow pathway pipe and out of the outlet towards the separator; wherein the separator is arranged to direct the multiplicity of solid particles into the drum and wherein the separator is further arranged to direct a portion of the treatment liquor to a location other than the drum; and wherein the flow pathway pipe is not attached to the door.

2. The apparatus of claim 1 wherein the cross-sectional area of the outlet is smaller than the cross-sectional area of the flow pathway pipe.

3. The apparatus of claim 2, wherein the cross-sectional area of the outlet is from about 10 to about 99% of the cross-sectional area of the flow pathway pipe.

4. The apparatus of claim 1 or claim 2, wherein the perimeter of the outlet is located no more than about 12 mm from the perforated portion of the separator, preferably no more than about 10 mm from the perforated portion of the separator.

5. The apparatus of any of the preceding claims, wherein the perimeter of the outlet is essentially equidistant from the perforated portion of the separator.

6. The apparatus of any of the preceding claims, wherein the outlet has an elongate shape, preferably the elongate shape has a length, L, and a width, W, such that the ratio L:W of the elongate shape is greater than 2:1.

7. The apparatus of any of the preceding claims, wherein the velocity of the treatment liquor and the solid particles at the outlet is about 150 cm/s or more.

8. An apparatus for use in the treatment of at least one substrate with a multiplicity of solid particles comprising: (a) a housing in which a drum is rotatably mounted; (b) a door moveable between an open position wherein the at least one substrate can be placed in the drum and a closed position wherein the apparatus is substantially sealed; (c) a separator, wherein the separator comprises a perforated portion; (d) a flow pathway pipe mounted on or in the housing, wherein the flow pathway pipe comprises an outlet; and (e) pumping means configured to pump treatment liquor and a multiplicity of solid particles from a first location through a flow pathway pipe and out of the outlet towards the separator; wherein the separator is arranged to direct the multiplicity of solid particles into the drum and wherein the separator is further arranged to direct a portion of the treatment liquor to a location other than the drum; and wherein at least one of the following conditions is fulfilled: (i) the cross-sectional area of the outlet is smaller than the cross-sectional area of the flow pathway pipe; (ii) the outlet has an elongate shape; (iii) the perimeter of the outlet is located no more than 30 mm, preferably no more than 12 mm from the perforated portion of the separator; (iv) the perimeter of the outlet is essentially equidistant from the perforated portion of the separator; (v) the velocity of the treatment liquor and the solid particles at the outlet is about 150 cm/s or more.

9. The apparatus of claim 8 wherein in condition (iii) the perimeter of the outlet is located no more than 12 mm from the perforated portion of the separator.

10. The apparatus of claim 8 or claim 9 wherein all of conditions (i) to (v) are fulfilled.

11. The apparatus of any of claims 8 to 10, wherein the cross-sectional area of the outlet is from about 10 to about 99% of the cross-sectional area of the flow pathway pipe.

12. The apparatus of any of claims 8 to 11 wherein the perimeter of the outlet is located no more than about 10 mm from the perforated portion of the separator.

13. The apparatus of any of claims 8 to 12, wherein the elongate shape has a length, L, and a width, W, such that the ratio L:W of the elongate shape is greater than 2:1.

14. The apparatus of any of claims 8 to 13, wherein the separator is located in the door.

15. The apparatus of claim 14, wherein the flow pathway pipe is not attached to the door.

16. The apparatus of any of claims 8 to 13, wherein the separator is mounted in a location other than in the door.

17. The apparatus of any of the preceding claims, wherein the outlet is configured such that the path of the treatment liquor and multiplicity of solid particles leaving the outlet defines an angle of incidence, , on the surface of the perforated portion of the separator of from about 60 to about 150, preferably of from about 60 to about 120.

18. The apparatus of any of the preceding claims, wherein the perforated portion of the separator is curved.

19. The apparatus of any of the preceding claims, wherein the wetness of the solid particles directed by the separator towards the drum is 20 wt % or less, preferably 15 wt % or less, preferably 10 wt % or less.

20. The apparatus of any preceding claim, wherein said location other than the drum is said first location, preferably wherein said first location is a sump.

21. The apparatus of any preceding claim wherein the bore of the flow pathway pipe narrows as the flow pathway pipe approaches its outlet, and preferably wherein the flow pathway pipe comprises a main portion and a nozzle portion and said narrowing of the bore of the flow pathway pipe occurs in the nozzle portion thereof preferably such that the cross-sectional area of the main portion is substantially constant along its length.

22. The apparatus of any of the preceding claims, wherein the apparatus is a cleaning apparatus for use in the cleaning of at least one soiled substrate, wherein said treatment liquor is a wash liquor.

23. The apparatus of any of claims 1 to 21, wherein the apparatus is an apparatus for treating a substrate with a multiplicity of solid particles, wherein the substrate is an animal substrate selected from skins, hides, pelts, leather and fleeces, preferably wherein treating is colouring, tanning and associated tanning processes.

24. A method of treating at least one substrate comprising the treatment of the substrate with a multiplicity of solid particles using the apparatus of any of claims 1 to 23.

25. The method of claim 24 comprising the steps of: (a) loading the at least one substrate into the drum and closing the door; (b) introducing treatment liquor to moisten the substrate; (c) rotating the drum; (d) operating pumping means to pump treatment liquor and the multiplicity of solid particles from the first location through the flow pathway pipe towards the separator and introducing the multiplicity of solid particles into the drum via the separator.

26. The method of claim 25, further comprising the step of: (e) operating the apparatus for a treatment cycle wherein the treatment liquor and the multiplicity of solid particles are transferred from the drum into a lower portion of the housing as the drum rotates.

27. The method of claim 26, further comprising the steps of: (f) operating the pumping means so as to pump additional treatment liquor and solid particles from the first location to the separator and to recirculate the multiplicity of solid particles used in step (d) for re-use in the treatment operation; and (g) continuing with steps (c), (d), (e) and (f) as required to effect treatment of the at least one substrate.

28. The method of any of claims 24 to 27, wherein the method of treating is a method of cleaning at least one soiled substrate and wherein the treatment liquor is a wash liquor.

29. The method of any of claims 24 to 28, wherein the method of treating is a method of treating a substrate with a multiplicity of solid particles, wherein the substrate is an animal substrate selected from skins, hides, pelts, leather and fleeces, preferably wherein treating is colouring, tanning and associated tanning processes.

Description

[0174] The disclosure is further illustrated by reference to the following drawings, wherein:

[0175] FIG. 1 shows an external perspective view of the cleaning apparatus according to the disclosure;

[0176] FIG. 2 shows a front view of the cleaning apparatus according to the disclosure;

[0177] FIG. 3 shows a cross-sectional view of the cleaning apparatus through section X-X of FIG. 2;

[0178] FIG. 4 shows a cut-away sectional perspective view of the cleaning apparatus with part of the front of the housing and part of the door removed;

[0179] FIG. 5 shows a cross-sectional front view of the cleaning apparatus according to the disclosure; and

[0180] FIG. 6A shows a cross-section view of the door shown in FIG. 3;

[0181] FIG. 6B shows a rear view of the door; and

[0182] FIG. 7 shows a schematic diagram of the way that wash liquor and the multiplicity of particles strike and leave the separator.

[0183] With reference to FIGS. 1 to 5, there is provided a cleaning apparatus (10) according to an aspect of the present disclosure comprising a housing (20). The housing (20) comprises an upper portion (20a) and a lower portion (20b). The housing (20) comprises a rotatably mounted drum (40). The drum (40) may be in the form of a rotatably mounted cylindrical cage. The drum is horizontally mounted in a casing or a tub (80) and is mounted in the upper portion (20a) of the housing. The tub (80) comprises a curved top portion (84) that circumferentially surrounds a portion of the drum (40). The tub (80) comprises a first sidewall (85) and a second sidewall (87) extending from the curved portion (84) to the base of the tub (86).

[0184] The drum (40) has perforated side walls (not shown). The perforations allow the ingress and egress of fluids and the solid particles. Alternatively, the drum may have perforations that 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 the solid particles used to clean the soiled substrate.

[0185] Rotation of the drum (40) is effected by use of drive means (90). The drive means (90) comprises electrical drive means in the form of an electric motor. The operation of the drive means (90) is effected by control means which may be operated by a user.

[0186] The base (86) of the tub (80) includes a sump (88). The sump (88) functions as a chamber for retaining the solid particles. The sump (88) can further contain water and/or one or more cleaning agents. The sump (88) comprises heating means (not shown) allowing its contents to be raised to a preferred temperature for use in the cleaning operation.

[0187] The unitary nature of the tub (80) enables the portion containing the drum (40) and the portion comprising the sump (88) to move together as one body in response to vibrations induced by rotation of the drum (40). The cleaning apparatus (10) comprises dampers (78) connected to the tub (80) to reduce the extent to which vibrations from the drum are transmitted to the housing (20).

[0188] The cleaning apparatus has a collar or hood (82) that projects out from the front face (22) of the housing (20) around part or all of the opening (200) of the housing through which the drum (40) is accessible. The collar or hood (82) may extend from or be an integral part of the tub (80).

[0189] The collar or hood (82) comprises an aperture (90). The apparatus has a flow pathway pipe (110) having an outlet (140) that defines a path between the sump (88) and a separator (100). The flow pathway pipe is configured so that it is mounted in the housing and passes through the aperture (90) of the collar or hood (82).

[0190] A pump (210) is arranged so that it is able to pump wash liquor and solid particles from the sump (88), along the flow pathway pipe (110) and onto the separator (100).

[0191] The apparatus comprises delivery means (160) through which wash liquor constituents (such as water and/or detergents) may be added to the drum without needing to travel via the flow pathway pipe (110).

[0192] The cleaning apparatus (10) comprises a door (60) to allow access to the interior of the drum (40). The door (60) is hingedly coupled or mounted to the front (22) of the housing (20). In an alternative arrangement (not shown) the door (60) may be hingedly coupled or mounted to a portion of the tub (80).

[0193] The door is moveable between an open and a closed position. When the door (60) is in a closed position (as shown in FIGS. 1, 2 and 3), the cleaning apparatus (10) is substantially sealed. When the door (60) is in an open position, the inside of the drum (40) is accessible. In the arrangement shown, when the door is in the closed position, the door abuts and makes a seal with the collar (82).

[0194] The door (60) comprises a separator (100). The separator comprises a perforated portion (105) and is adapted to receive wash liquor and a multiplicity of solid particles from the outlet (140) of the flow pathway pipe (110).

[0195] Referring in particular to FIGS. 6A and 6B, the door (60) comprises a ring (66). The door has an outer portion (62) and an inner portion (64). The outer portion (62) and the inner portion (64) are mounted in the ring (66). The outer portion (62) and the inner portion (64) of the door (60) may be transparent material, such as glass, which facilitates viewing of the inside of the drum during operation of the machine.

[0196] The door comprises a separator (100). In the arrangement shown in FIGS. 6A and 6B, the separator (100) is curved and is mounted between the outer portion (62) and the inner portion (64) of the door. The ring (66) is adapted to hold the separator (100) in position between the outer portion (62) and the inner portion (64) of the door (60).

[0197] The inner portion (64) of the door (60) comprises a door outlet (68). Material from the wash liquor/solid particle mixture that does not pass through the separator (100), travels down the slope of the separator (100) and through the door outlet (68), in the direction shown by the arrow A, and is able to pass into the drum. Having a door arranged with an inner portion reduces there being any snagging of the soiled substrate being cleaned on the separator (100) but requires the door outlet (68) in order for the solid particles to enter the drum (40).

[0198] The ring (66) of the door comprises a drain channel (70) located at the bottom of the door (60). The channel (70) is arranged such that material that has passed through the separator, such as wash liquor, is able to exit the door through the drain channel (70) in the direction shown by the arrow B and flows into the sump (88).

[0199] Referring to FIG. 7, preferably, the flow pathway pipe (110) is oriented so that the wash liquor and multiplicity of solid particles leaves the outlet (140) at an angle from horizontal. On striking the perforated portion of the curved separator (100), the wash liquor passing through the perforated portion travels down in direction D. The multiplicity of solid particles travel down along the curve of the separator in direction E. As the solid particles travel down along the curve of the separator, more wash liquor passes through the perforated portion in direction D. At the end of the separator, the solid particles are directed in a path F towards the drum. The angle is the angle above horizontal taken at a tangent at the end of the trailing edge of the curved separator. Preferably, angle is about 15 to 35, more preferably about 20 to 30. Preferably, angle is about 0 to 35, preferably about 0 to 30, preferably about 5 to 25, preferably about 10 to 20. Preferably, angle is about 15 to 35, more preferably about 20 to 30.

[0200] In use, wash liquor combined with a multiplicity of solid particles is transported from the sump (88) to the separator (100) using the pump (210). The wash liquor and the solid particulate material are pumped along the flow pathway pipe (110) and out through the outlet (140) onto the perforated portion (105) of the separator (100). Wash liquor is permitted to pass through the perforated portion (105) of the separator. However, as the solid particles are too large to exit via the apertures in the perforated portion, the solid particles are deflected by the surface of the separator (100) towards the door outlet (68). In this manner, separation of at least a portion of the wash liquor from the multiplicity of solid particles can be achieved.

[0201] In a typical wash cycle using the cleaning apparatus (10), soiled substrates (not shown) are first placed into the drum (40). An appropriate amount of wash liquor (water, together with any additional cleaning agent) is then added to the drum (40) via the delivery means (160). The water may be pre-mixed with the cleaning agent prior to its introduction into the drum (40). However, typically, water is added first in order to suitably wet or moisten the substrate before further introducing any cleaning agent.

[0202] The water and the cleaning agent may be heated by a heater (not shown). Following the introduction of water and any optional cleaning agents, the wash cycle commences by rotation of the drum (40). The solid particles and wash liquor residing in the sump (88), which optionally can be heated to a desired temperature using a heater (not shown), are then pumped via the flow pathway pipe (140) to the separator (100) in the door (60). Solid particles are propelled from the separator (100) through the door outlet (68) and into the centre of the washload in the drum (40).

[0203] During the course of agitation by rotation of the drum (40), water including any cleaning agents falls through the perforations in the drum (40) and into the sump (88). Some solid particles may also fall through perforations in the drum (40) and into the sump (88). Lifters (not shown) disposed on the inner circumferential surface of the drum (40) can collect the solid particles as the drum (40) rotates and transfer the solid particles to the sump (88). On transfer to the sump (88), the solid particles and water plus any cleaning agents travel down the sloping walls (85) and (87) of the tub to the base of the sump (88). The pump (210) again pumps wash liquor in combination with the solid particles upwardly via the flow pathway pipe (110) and to the separator (100) in the door (60). Consequently, additional solid particles can be entered into the drum (40) during the wash cycle. Furthermore, solid particles used in the cleaning operation and returned to the sump (88) can be reintroduced into the drum (40) and can therefore be re-used in either a single wash cycle or subsequent wash cycles. Wash liquor pumped from the sump (88) through the separatior (100) with the solid particles which does not enter the drum (40) can be returned to the sump (88) via the drain (70) in the door (60).

[0204] The cleaning apparatus (10) can perform a wash cycle in a manner similar to a standard washing machine, for example, with the drum (40) rotating at from about 30 to about 40 rpm for several revolutions in one direction, then rotating a similar number of rotations in the opposite direction.

[0205] This sequence can be repeated for up to about 60 minutes. During this period, solid particles can be introduced and reintroduced to the drum (40) from the sump (88) via the separator (100) in the manner as described above.

[0206] The conditions employed in the use of the cleaning apparatus allow for 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. Typical procedures and conditions for wash cycles require that fabrics are generally treated according to the disclosed method at, for example, temperatures of from about 5 to about 95 C. for a duration of from about 5 to about 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. The total duration of the entire cycle is typically in the region of about 1 hour. The operating temperatures for the method of the invention are preferably in the range of from about 10 to about 60 C., or from about 15 to about 40 C.

[0207] Features described herein in conjunction with a particular aspect or example of the disclosure are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. As used herein, the words a or an are not limited to the singular but are understood to include a plurality, unless the context requires otherwise.

EXAMPLES

Example 1

[0208] A cleaning apparatus according to the disclosure was used in which a separator was located in the door. The separator was curved. The direction of curvature of the separator was such that solid particles following the direction of the curve were led towards the drum. The cleaning apparatus was of a size suitable for washing 35 lb (15.9 kg) of substrate. A 1:1 by weight mixture of wash liquor and polymeric beads was pumped from the sump towards the separator. The beads were ellipsoid shaped having a longest dimension of about 4 mm. The cross-sectional area of the flow pathway pipe at the pump was 3168 mm.sup.2, which reduced along its length to 2028 mm.sup.2. The cross-sectional area of the outlet was 2033 mm.sup.2. The cross-section of the flow pathway pipe was circular and the outlet had an elongate shape. The beads that had passed through the separator into the drum were collected and bead wetness was assessed by capturing the solid particles directed to the drum by the separator, weighing them and then separating off the remaining water in the solid particles, as described herein. The bead wetness was 12.7 wt %.

Example 2

[0209] Example 1 was repeated but the cross-sectional area of the outlet was reduced to 1869 mm.sup.2. The outlet remained in an elongate shape. The bead wetness of the beads collected from the drum was 10.3 wt %. Thus, reducing the cross-sectional area of the outlet leads to improved bead and wash liquor separation, resulting in drier beads being directed to the drum.

Example 3

[0210] A cleaning apparatus according to the disclosure was used in which a separator was located in the door. The separator was curved. The direction of curvature of the separator was such that solid particles following the direction of the curve were led towards the drum. The cleaning apparatus was of a size suitable for washing 35 lb (15.9 kg) of substrate. A 1:1 by weight mixture of wash liquor and polymeric beads was pumped from the sump towards the separator. The beads were ellipsoid shaped having a longest dimension of about 4 mm. The cross-sectional area of the flow pathway pipe at the pump was 3168 mm.sup.2, which reduced along its length to 2028 mm.sup.2. The cross-sectional area of the outlet was 2033 mm.sup.2. The cross-section of the flow pathway pipe was circular and the outlet had an elongate shape. The velocity of the beads and the wash liquor at the point of exiting the outlet was measured and was found to be 250.4 cm/s.

Example 4

[0211] Example 3 was repeated but the cross-sectional area of the outlet was reduced to 1869 mm.sup.2. The outlet remained in an elongate shape. The velocity of the beads and the wash liquor at the point of exiting the outlet was measured and was found to be 272.4 cm/s.

Example 5

[0212] A cleaning apparatus according to the disclosure was used in which a separator was located in the door. The separator was curved. The direction of curvature of the separator was such that solid particles following the direction of the curve were led towards the drum. The cleaning apparatus was of a size suitable for washing 35 lb (15.9 kg) of substrate. A 1:1 by weight mixture of wash liquor and polymeric beads was pumped from the sump towards the separator at a pumping speed of 38 Hz. The beads were ellipsoid shaped having a longest dimension of about 4 mm. The cross-section of the flow pathway pipe was circular. The cross section of the outlet was circular and was cut normal to the pipe. The beads that had passed through the separator into the drum were collected and bead wetness was assessed. The results of the bead wetness are shown in Table 1.

Example 6

[0213] Example 5 was repeated but at a pumping speed of 50 Hz. The results of the bead wetness are shown in Table 1.

Example 7

[0214] Example 5 was repeated but the outlet was shaped so that each point on the perimeter of the outlet was equidistant from the perforated portion of the separator. The pumping speed was 35 Hz. The beads that had passed through the separator into the drum were collected and bead wetness was assessed. The results of the bead wetness are shown in Table 1.

Example 8

[0215] Example 7 was repeated but at a pumping speed of 50 Hz. The results of the bead wetness are shown in Table 1.

TABLE-US-00001 TABLE 1 Example 5 Example 6 Example 7 Example 8 Distance Not equidistant Not equidistant Equidistant Equidistant of outlet perimeter from separator Pumping 38 50 35 50 speed (Hz) Bead 28.5 22 16.2 14.75 wetness wt %

[0216] Examples 9 to 17

[0217] A cleaning apparatus according to the disclosure was used in which a separator was located in the door. The separator was curved. The direction of curvature of the separator was such that solid particles following the direction of the curve were led towards the drum. The cleaning apparatus was of a size suitable for washing 35 lb (15.9 kg) of substrate. A 1:1 by weight mixture of wash liquor and polymeric beads was pumped from the sump towards the separator at different distances between the perimeter of the outlet and the separator, and different relative orientations of the flow pathway pipe outlet and curved separator. The beads were ellipsoid shaped having a longest dimension of about 4 mm. In each case, the flow pathway pipe was circular and the end face of the outlet was circular. The outlets were either straight cut, thereby having a circular perimeter, or else were shaped to correspond to the curvature of the separator. In each case, the beads that had passed through the separator into the drum were collected and bead wetness was assessed by capturing the solid particles directed to the drum by the separator, weighing them and then separating off the remaining water in the solid particles, as described herein. The results are shown in Table 2. As shown in FIG. 7, angle is the angle below horizontal that the wash liquor and multiplicity of solid particles leave the outlet. The angle is the angle above horizontal taken at a tangent at the end of the trailing edge of the curved separator.

TABLE-US-00002 TABLE 2 Distance of Arrangement Pumping Outlet perimeter of of perimeter Bead speed shaped or outlet from of outlet to wetness Example () () (Hz) straight cut separator (mm) separator (wt %) 9 20 20 35 Straight cut 0 at top edge; Not 28.5 9.6 at lower equidistant edge 10 20 20 35 Straight cut 0 at top edge; Not 28.0 9.6 at lower equidistant edge 11 20 20 40 Straight cut 0 at top edge; Not 24.0 9.6 at lower equidistant edge 12 20 30 40 Straight cut 0 at top edge; Not 24.0 9.6 at lower equidistant edge 13 30 20 50 Straight cut 0 at top edge; Not 20.0 18.7 at lower equidistant edge 14 30 20 40 Shaped 6 Equidistant 18.0 15 30 20 50 Shaped 6 Equidistant 16.5 16 30 20 50 Shaped 6 Equidistant 16.5 17 20 30 50 Shaped 12 Equidistant 23.0

[0218] Examples 9 to 17 illustrate that having all points on the perimeter of the outlet equidistant from the separator improves bead wetness reduction. Also, reducing the gap between the outlet and the separator advantageously reduces bead wetness.