WO2001032823A1

WO2001032823A1 - Fabric-treatment systems using a metallized bag

Info

Publication number: WO2001032823A1
Application number: PCT/US2000/029856
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 metallized devices, especially bags, which are comprised of a substrate on which a metal is applied. The metallized bags may include a metallic and/or silica coating or laminate as the exterior surface, interior surface and/or a metallic layer within the sides of the bag. These metallized bags 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

FABRIC-TREATMENT SYSTEMS USING A METALLIZED BAG

FIELD OF THE INVENTION

The present invention relates to metallized devices for use in cleaning, freshening or otherwise treating fabrics 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 metallized 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 dirt 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 from many different people are dry-cleaned with the same batch of solvent, which can result in malodorous residues left on the clothes cleaned therein.

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 used in these at-home methods for cleaning/freshening clothing do not have an exceptionally low heat resistance, do not reflect heat and are susceptible to problems with static electricity. Often these bags must be of a minimum thickness to prevent tearing and thermal degradation.

In addition, the at-home systems may utilize thermoplastic bags through which at least a small amount of the components of the cleaning/freshening composition can permeate to the atmosphere outside the bag, especially in cases where the dry-cleaning or freshening composition contains high amounts of organic solvent, fragrance, or volatile components. This is an inefficient waste of such components. And although the organic solvents may not be toxic, they may leave an undesirable residue in the dryer dram that ultimately comes into contact with clothing subsequently dried in the dryer.

SUMMARY OF THE INVENTION The present invention provides a novel dryer-safe device that is metallized. Preferably the metallized 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 layer and a metal. In general, the metal is in the form of a metallized 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.). 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 metallized layer. It is not necessary that the entire exterior or interior surface be metallized, although this may be preferred in certain embodiments of the invention. The invention also includes metallized devices where only a portion of the interior and/or exteior surface is metallized. For instance, the metallization may take the form of strips, dots, or the like, which are applied to the surfaces by any means known in the art. Alternatively, a metal layer may be included as a third layer, between the interior and exterior layers within the walls of the device.

In another embodiment the metallization is not in the form of a layer, but is mixed in with the materials forming a bag, and extruded, blown, etc. with the materials as the bag is formed. Thus, the composition of the bag comprises metal, and preferably in an mount sufficient to achieve one or more of the advantages referred to herein. This can be done using known mixing and extrusion techniques. For instance, metal in the form of ftakes, powder or liquid may be added to a hot mixture of thermoplastics. The bag may be formed in any shape desired, and'upon cooling, will be metallized. In one preferred embodiment utilizing the metallized 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 metallized bag with a cleaning/freshening composition. The metallized bags of the invention are advantageous in that they provide a dryer-safe device comprised of a material that is substantially air and moisture impervious, and is resistant to degradation, abrasion or tearing in conditions of tumbling. Other advantages of these bags are that they resist melting in elevated temperatures, exhibit improved heat resistance in general, reflect heat, permit thinner gauge of plastics to be used, can prevent static electricity buildup, and extend the useful life of the bag. If a cleaning/freshening composition includes a fragrance (especially a fragrance oil), the metallized bag may be advantageous by preventing or reducing permeation of the flagrance through the bag material. Similarly, if the cleaning/freshening composition includes organic solvent or volatile components, the metallized bag may be advantageous by preventing or reducing permeation or volatilization of such components through the bag material.

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 a metallized dryer-safe bag according to one embodiment of the invention, where a metal layer is applied to the exterior surface of the bag.

Figure 2 is a perspective view of a metallized dryer-safe bag of Figure 1, optionally with vents.

Figure 3 is a perspective view of a metallized dryer-safe bag according to another embodiment of the invention, where a metal layer is applied to the interior surface of the bag.

Figure 4 is a perspective view of a metallized dryer-safe bag according to another embodiment of the invention, where a metal layer is within the sides or walls of the bag. Figure 5 is a perspective view of a metallized dryer-safe bag according to an embodiment of the invention, where a metal layer is within the sides or walls of the bag, and a second metal layer is applied to the exterior surface of the bag.

Figure 6 is a perspective view of a metallized dryer-safe bag according to an embodiment of the invention, where a metal layer is within the sides or walls of the bag, and a second metal layer is applied to the interior surface 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. Metallized Bags

The metallized devices should be formed of at least two materials: (a) a substrate material and (b) at least one metal or silica. The substrate may be formed of any material that is capable of supporting the metal in the form of a layer, coating, film, lamination, etc., (collectively, "layer") with the material of the bag, 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.

Suitable materials for forming the substrate include, but are not limited to, nonporous plastic film, non-woven fabric, and the like. For example, the bag can be formed from polyethylene, polypropylene, polyamide, nylon, cloth, paper, or a multiple or layered complex comprising such materials. Nylon is particularly useful in increasing heat resistance of the device in a dryer of other environment of elevated temperature. Further, it is sometimes preferred that the device be formed by the co-extrusion of materials with the desired properties. For instance, for certain embodiments it is preferred that the substrate comprises high molecular weight polymers. Those having a molecular weight of at least 10,000 and typically in the range between of 15,000-500,000, for example, would be particularly suitable for embodiments of the invention involving fabric-treatment within a hot air rotary dryer. The metallic coating, laminate or layer may comprise any metal that is compatible with the substrate and is flexible theron. For instance, the metal maybe selected from the group consisting of aluminum, cobalt, chromium, iron, nickel, zinc, tin, copper, and mixtures thereof, where aluminum is the preferred choice. Preferably, the metallic coating/laminate/film has a thickness between about 300 Angstroms and about 500 Angstroms, but is preferably not thicker than about 1 mi. However, the metallic layer may be of any thickness, according to the desired end-use, and may even be applied in a multi-ply manner, which may further increase the thickness.

Alternatively, the coating may be a silica coating. The silica coating may be applied by any means known in the art, and may be in place of or in addition to a metal layer. The advantages of silica are that is may be less expensive to procure and use, has ready availability, any may be more compatible with the substrate than some metals.

A metallic layer or silica layer can be applied to the substrate material by known processes such as vacuum metallization coating (continuous or semi-continuous), evaporation, vapor deposition, electrodeposition, chemical reaction, electron beam, sputtering (magnetion sputtering, reactive sputtering, drode sputtering, triode sputtering, etc.), doctor blade application, plasma treatment, lamination using an adhesive, direct metal deposition and by spraying. See C.A.Baer, Vacuum Metallizing Plastic Film, Vacuum

Equipment/ America, Inc., pages 9-76 (1996); Hanlon et al., Handbook of Package Engineering, (3~& edition) pages 116-122 (1996); Hung, et al., Functionalization and Metallization of Fluoropolymer Surfaces Through Reduction, Journal of Applied Polymer Science, Vol. 55, pages 549-559 (1995); U.S Patent Nos. 5,685,970, 5,631,066, 5,716,502. The contents of these references are incorporated in their entirety by reference. The metal coating or laminate may also be applied by any other suitable method known in the art.

One preferred material making up the bag is polyethylene terephthalate. In one preferred embodiment, the bag is made up of at least one layer of polyethylene terephthalate and at least one layer of polyester. A metallic layer may be formed between a polyethylene terephthalate layer and a polyester layer. The layers may be bonded together by any conventional means, for instance, adhesive bonding and lamination. This has the advantage protecting the metallized layer and creating a very strong device. Methods for construction of sandwich metallized film or plastics are known in the art such as U.S. Patent No. 4,403,004.

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). Optionally, the bag may be co- extruded into a tubular shape (or other desired shape). Multiple tubular layers may also be formed.

In a first embodiment, the metallized device is a bag having a metallic layer as the exterior surface. Preferably, but not necessarily, the metallic layer can be applied to the exterior surface of a bag substrate material via a three- layer process. For instance, first a resin coating is applied to the plastic or base bag material. Then a metallic coating is applied and then a topcoat is applied over the metallic coating. Both the resin coating and the topcoat may include acrylics, polyurethanes or epoxy-type coating materials, and may be the same of different from each other.

In a second embodiment, the system uses a metallized bag much like the bag described in the first embodiment but having the metallic layer as the interior surface of the bag rather than the exterior surface.

As an alternative embodiment, silica (SiO2) coating may be applied to the exterior and/or interior of the bag to comprise an interior and/or exterior surface of the bag in similar fashion as a metallic coating. Also, the silica may be within the sides of the bag. Optionally, the silica may be in addition to a metallized layer.

In another embodiment, a bag has a metallic layer within the sides or walls of the bag. For instance, preferably the metallic layer is between about 300 to about 500 Angstroms in thickness, and preferably is not thicker than 1 ml. However, as noted above, the layer may be of any desired thickness or multi-ply, as determined by someone of ordinary skill in this art.

One embodiment is shown in Figures 1-3, where comprises an interior surface 2 and an exterior surface 4. The bag 1 also defines an opening 8, which in one embodiment, is between top edges 5. An optional closure mechanism 3 is present for closing the opening 8.

In Figure 1, the exterior surface 4 is a substrate that is coated with a metallic coating 6, wherein the coating becomes the exterior surface. In Figures 2 and 3, the interior surface 2 is a substrate that is coated with a metallic coating, wherein the coating becomes the interior surface of the bag. Optionally, but not shown, both the interior and exterior surfaces can be coated with a metallic coating.

In another embodiment shown in Figure 4, the bag comprises a metallic layer 6a within the sides 2a and 4a or walls of the bag, that is, between the interior surface 2a and exterior surface 4a of the bag. Figure 5 shows a metallic layer 6a within the sides 2a and 4a or walls, and another metallic layer on exterior layer 6. Conversely, Figure 6 shows a metallic layer 6a within the sides 2a and 4a or walls, and another metallic layer on interior 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, hook and loop, magnetic strips, Velcro®, 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 the opening 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.

A single metallic or silica layer is sufficient when used alone. However, the metallized bags may optionally have a second metallic or silica layer on the oppposite surface and/or within the walls of the device. One advantage to this structure is that it further ensures elimination of permeation of vapors and chemicals, and further increases heat resistance and tear resistance of the bag. In one embodiment, the bag is formed of a metallized material that is capable of reducing (or virtually eliminating) the amount of vapor, chemicals and air that would pass through a non-metallized material. This can be accomplished by forming a bag that is metallized with a metal 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 a layer of metal within the material of the bag, or a combination of both.

In a further embodiment, the metal layer does not cover the entire substrate, but covers only a portion or portions of the substrate. That is, the metal layer need not completely cover the interior and/or exterior surface, or be throughout the whole wall/side of the device. For instance, the metal 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.

Alternatively, or in addition to the metal layer, metal may be part of the substrate composition itself. For instance, metal may be mixed into the hot mixture prior to forming the substrate material. The metal may be in the form of flakes, powder, liquid, etc., and may be admixed using methods known in the art. The substrate-metal mixture may then be extruded, blown, etc., using methods known in the art, to form the substrate in the shape desired. 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, 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 bag may comprise a nonwoven or woven fabric or paper material, wherein the exterior surface is coated with a polymer coating selected from the group consisting of water- or solvent-based polymer emulsion or solution, plastic lamination, or mixtures thereof. In this embodiment, a metallic coating may be coated on top of the polymer coating, under the polymer coating, and/or a metallic layer may be put within the fabric or paper material. This latter construction may require at least two layers of fabric or paper material, in between which the metallic layer is sandwiched. Preferably, the fabric and paper materials are strong enough to support a polymer coating and metallic coating, and withstand the high temperatures and tumbling of a rotary dryer without substantial damage. Examples of suitable fabric or paper materials include, but are not limited to, polyester, acetate, fleece, recycled paper, cardboard, etc.

The polymer may include one or more of polyurethane, vinyl acetate, acrylic, acrylic copolymer, polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl chloride polyvinylidine dichloride, polyesters, epoxy resins, melamine formaldehyde, styrene butadine, 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.

The metallized 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. In another construction, the metallized 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 metallized 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 metallized 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 metallized 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 plastic 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 thermally stable 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 to form the absorbent interior surface of the bag may be 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 imparting 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 plastic film, the innermost film being absoφtive, 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. Such bags may be formed by co-extruding one or more multiple layers of plastic layers simultaneously during the blowing of the bag. 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 in^. and most preferably from about 1120 in^ to about

1560 π_2- 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 Metallized Bags

One utilization of the metallized 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 metallized 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 dram 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 metallized 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 metallized bag should include at least two components: (a) a substrate material, and (b) at least one metal or silica. The metal or silica 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 addition, or alternatively, the metal may be included as a component within the substrate itself.

In one embodiment, the metallic layer is thick enough so as to reduce or eliminate permeation of organic solvent, fragrance or other ingredients from inside the bag to air outside the exterior surface of the bag, and preferably be thick enough to increase heat resistance and tear resistance of the bag. For instance, the metallic coating thickness may be between about 300 Angstroms and about 500 Angstroms, although a thinner or thicker layer may also be effective.

For use with the fabric-treatment systems, the substrate material of the metallized bags may be formed from any flexible material that can support the metallic layer. Preferably, the substrate exhibits sufficient thermal stability for use in the rotary hot air dryer. In addition, it is prefeπed 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 metallized 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 metallized bag. Another advantage is the reduced or eliminated 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. For instance, these bags are especially useful where the fabric-treatment composition contains ester materials that tend to act as plasticizers. 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 metal component 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 generally 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 fatty acid condensates, anti-creasing agents, 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.

If the cleaning/freshening composition includes a fragrance (especially a fragrance oil), the metallized bag may be advantageous by preventing or reducing permeation of the fragrance through the bag material.

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 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 ¥-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 prefeπed 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 prefeπed 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 aπay 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 aπay of fibers in the non-woven material imparting excellent strength in all directions. Some examples of prefeπed non-woven cloth material useful as substrates in the present invention include 100% rayon sheets, 100% polypropylene sheets, blended sheets, (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 prefeπed size of sheets range from about 4" X 14", particularly from about 5" X 12" to about 9" X 10". In conjunction therewith, the prefeπed 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 metallized 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 metallized 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 absoφtive 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 absoφtive 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 absoφtive 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 absoφtive surface need not contain the composition at all. In that case, the absoφtive 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 metallized 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 incoφorated 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) a fabric-treatment composition; and b) a bag comprising a substrate and one or both of a metal and silica, the bag defining an opening and including sides each having an interior surface and an exterior surface, and further including a fastening system for closing the opening.