GB2327433A - Foam stain receiver - Google Patents

Abstract

Foam stain receivers are reinforced by an external covering comprising a woven or non-woven fabric. The foam is protected against flaking when used as a stain receiver in a fabric stain removal operation.

Description

REINFORCED FOAM STAIN RECEIVER FIELD OF THE INVENTION The present invention relates to an improved foam stain receiver which is used to spot-clean fabrics.

BACKGROUND OF THE INVENTION Fabric cleaning and refreshment processes such as laundering and dry cleaning operations typically are used to clean entire garments. However, in some circumstances the user wishes only to clean localized areas of fabrics. Alternatively, the user may wish to spot-clean localized areas of stain before subjecting the entire fabric garment to an overall dry cleaning or laundering operation.

One problem associated with spot cleaning operations is the risk of damaging the fabric. Thus, when brisk brushing is used during the operation, the resulting shear forces can disrupt and abrade the fabrics, thereby leading to a worn appearance. Dyes may be discolored or partly removed in the spot-cleaned area. In some instances, the spot cleaning, itself, may leave "rings" or unsightly residues on the fabrics. Various means and special implements for avoiding or minimizing such problems are available to professional cleaners. However, for in-home use by relatively unskilled operators, there is a continuing search for simple, safe, yet effective methods for spot-cleaning fabrics.

It has been determined that certain absorbent foam materials (hereinafter, "FAM" foam) are especially useful in spot cleaning operations. In a typical operation, the FAM foam functions as a "stain receiver" by drawing the liquid cleaning composition through the stained/spotted area of the fabric. Thus, the stain/spot material which has been mobilized by the cleaning composition is captured in the FAM foam. Importantly, the FAM foam minimizes the tendency of the stain/spot to spread laterally on the fabric, thereby minimizing the formation of "rings" on the fabric.

In a preferred spot cleaning operation, a FAM foam stain receiver is positioned beneath a stained area of fabric. A cleaning composition is then applied to the stain and worked into the stain by mechanical action. Such mechanical action preferably comprises using compressional, mainly Z-directional force in the manner disclosed herein. Unfortunately, it has now been determined that the FAM foam used as the stain receiver is not sufficiently robust to withstand vigorous force.

Simply stated, the FAM stain receiver is sufficiently friable under mechanical force that it may begin to disintegrate, with the result that the FAM flakes off. This results in a messy appearance in the area where the spot cleaning process is being conducted. Moreover, the FAM flakes may be undesirably transferred to the fabric being spot-cleaned. Having thus discovered the problems associated with FAM foam when used in the present manner, the invention herein employs a coversheet to encase and reinforce the FAM stain receiver, thereby minimizing such problems.

BACKGROUND ART WO 97/00993A1, published January 9, 1997 to Weller, et al.; WO 97/00990A2, published January9,1997 to Tyerech, et al.; GB 2,302,553A, published January 22, 1997 to Telesca, et al.; GB 2,302,878A, published February 5, 1997 to Weller, et al.; and GB 2,302,879A, published February 5, 1997 to Sidoti, et al. all relate to in-dryer fabric cleaning. U.S. 4,532,722, issued to S. H.

Sax, August 6, 1985, relates to a fabric conditioning device for use in a laundry dryer. A peracid-containing dry cleaning composition is described in U.S.

4,013,575, issued to H. Castrantas, et al., March 22, 1977. Dry cleaning processes are disclosed in: U.S. 5,547,476 issued 8/20/96 to Siklosi & Roetker; U.S. 5,591,236 issued 1/7/97 to Roetker; U.S. 5,630,847 issued 5/20/97 to Roetker; U.S. 5,630,848 issued 5/20/97 to Young, et al.; U.S. 5,632,780 issued 5/27/97 to Siklosi; EP 429,172A1, published 29.05.91, Leigh, et al.; and in U.S. 5,238,587, issued 8/24/93, Smith, et al. Other references relating to dry cleaning compositions and processes, as well as wrinkle treatments for fabrics, include: GB 1,598,911; and U.S. Patents 4,126,563, 3,949,137, 3,593,544, 3,647,354; 3,432,253 and 1,747,324; and German applications 2,021,561 and 2,460,239, 0,208,989 and 4,007,362. Cleaning/prespotting compositions and methods are also disclosed, for example, in U.S. Patents 5,102,573; 5,041,230; 4,909,962; 4,115,061; 4,886,615; 4,139,475; 4,849,257; 5,112,358; 4,659,496; 4,806,254; 5,213,624; 4,130,392; and 4,395,261. Sheet substrates for use in a laundry dryer are disclosed in Canadian 1,005,204. U.S.

3,956,556 and 4,007,300 relate to perforated sheets for fabric conditioning in a clothes dryer. U.S. 4,692,277 discloses the use of 1,2-octanediol in liquid cleaners.

See also U.S. Patents 3,591,510; 3,737,387; 3,764,544; 3,882,038; 3,907,496; 4,097,397; 4,102,824; 4,336,024; 4,594,362; 4,606,842; 4,758,641; 4,797,310; 4,802,997; 4,943,392; 4,966,724; 4,983,317; 5,004,557; 5,062,973; 5,080,822; 5,173,200; EP 0 213 500; EPO 261 718; G.B. 1,397,475; WO91/09104; WO 91/13145; WO 93/25654 and Hunt, D.G. and N.H. Morris, "PnB and DPnB Glycol Ethers", HAPPI, April 1989, pp. 78-82.

SUMMARY OF THE INVENTION The present invention encompasses an absorbent stain receiver comprising FAM foam wholly or partially encased in a liquid-permeable coversheet.

In a preferred mode, the present invention encompasses a receiver wherein the coversheet comprises a woven or non-woven fabric.

In one convenient mode, the process herein is conducted using the following steps: 1. Place the stained area of the fabric over and in fluid-receiving contact with the reinforced FAM foam absorbent stain receiver article of this invention; 2. Apply enough composition, preferably from a bottle with a narrow spout which directs the composition onto the stain (without unnecessarily saturating the surrounding area of the fabric), to saturate the localized stained area - about 10 drops; more may be used for a larger stain.

3. Optionally, allow the composition penetrate the stain for 3-5 minutes. (This is a pre-treat or pre-hydration step for better cleaning results.) 4. Optionally, apply additional composition - about 10 drops; more may be used for larger stains.

5. Apply mechanical force to the stained area. This can be done, for example, by means of the spot removal devices shown in the Figures to work the stain completely out. Rock the device (i.e. force applied in the downward "Z" direction) firmly against the stain for 20-120 seconds, longer for tougher stains. Do not rub (i.e., force applied in the side-to-side "X-Y" direction) the stain with the device, since this can harm the fabric. Alternatively, use the tip of the bottle spout to mechanically manipulate the stain.

6. Remove the fabric from contact with the FAM stain receiver.

7. Optionally, blot the fabric between paper towels or other absorbent materials to remove excess cleaning composition.

In an alternate mode, the cleaning/refreshment composition can be applied to the stain (Step 2 and/or 4) by spraying, daubing or by padding the composition on from a carrier sheet, or by any other convenient means.

All percentages, ratios and proportions herein are by weight, unless otherwise specified. All documents cited are, in relevant part, incorporated herein by reference.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates the use of a cleaning device by using hand pressure to rock the device, thereby causing the protuberances which extend outwardly from the arcuate, convex head to impinge on the stained (207) fabric and to impart a cleaning force perpendicular to the stain. Undesirable side-to-side (shear) forces on the fabric are thus minimized or eliminated. The FAM-foam stain receiver (501) according to this invention is shown underlaying the stained area of fabric.

Figure 2 is a perspective of a spot cleaning device of the type used herein having a convex base (301) whose circumference is substantially circular.

Figure 3 is a perspective of a preferred arcuate cleaning device comprising cleaning protuberances (401), sponge layer (402), arcuate base (403), shaft (404) and bulbous hand grip (405).

DETAILED DESCRIPTION OF THE INVENTION The stain receiver used herein comprises Functional Absorbent Materials ("FAM's") which are in the form of water-absorbent foams having a controlled capillary size. The physical structure and resulting high capillarity of FAM-type foams provide very effective water absorption, while at the same time the chemical composition of the FAM typically renders it highly lipophilic. Thus, the FAM can essentially provide both hydrophilicity and lipophilicity simultaneously. (FAM foams can be treated to render them hydrophilic. Both the hydrophobic or hydrophilic FAM can be used herein.) The acquisition and absorbency of the FAM with respect to the liquid prespotting compositions herein is superior to most other types of absorbent materials.

For example, the FAM has a capacity of about 6 g (H2O) per gram of foam at a suction pressure of 100 cm of water. By contrast, cellulose wood fiber structures have substantially no capacity above about 80 cm of water. Since, in the present process the volume of liquid pre-spotter used is relatively low (a few milliliters is typical) the amount of FAM used can be small. This means that the pad of FAM which underlays the stained area of fabric can be quite thin and still be effective.

For pre-spotting, the stained area of the garment or fabric swatch is placed over a section of FAM, followed by treatment with the liquid cleaning solution, preferably in conjunction with force applied using the tip of the dispenser tube to provide mechanical agitation. The mechanical manipulation and the detergency effect of the solution serve to loosen the soil and transfer it through the fabric and into the FAM. While spot cleaning progresses, the suction effects of the FAM capillaries cause the cleaning solution and stain debris continue to be carried into the FAM, where the stain debris is largely retained. At the end of this step the stain as well as almost all of the cleaning solution is found to have been removed from the fabric being treated and transferred to the FAM. This leaves the fabric surface only damp, with a minimum residue of the cleaning solution/stain debris which can lead to undesirable rings on the fabrics.

The manufacture of FAM-type foams for use as the stain receiver herein forms no part of the present invention. The manufacture of FAM foam is very extensively described in the patent literature; see, for example: U.S. 5,260,345 to DesMarais, Stone, Thompson, Young, LaVon and Dyer, issued November 9, 1993; U.S. 5,268,224 to DesMarais, Stone, Thompson, Young, LaVon and Dyer, issued December 7s 1993; U.S. 5,147,345 to Young, LaVon and Taylor, issued September 15, 1992 and companion patent U.S. 5,318,554 issued June 7, 1994; U.S. 5,149,720 to DesMarais, Dick and Shiveley, issued September 22, 1992 and companion patents U.S. 5,198,472, issued March 30, 1993 and U.S. 5,250,576 issued October 5, 1993; U.S. 5,352,711 to DesMarais, issued October 4, 1994; PCT application 93/04115 published March 4, 1993, and U.S. 5,292,777 to DesMarais and Stone, issued March 8, 1994; U.S. 5,387,207 to Dyer, DesMarais, LaVon, Stone, Taylor and Young, issued February 7, 1995; U.S. 5,500,451 to Goldmanand Scheibel, issued March 19, 1996; and U.S. 5,550,167 to DesMarais, issued August 27, 1996, all incorporated herein by reference.

Stain receiver pads made of FAM foam can be used in either of two ways. In one mode, the uncompressed foam is used. Uncompressed FAM pads having a thickness in the range of about 0.3 mm to about 15 mm are useful. In another mode, the FAM foam can be used in a compressed state which swells as liquid pre-spotter with its load of stain material is imbibed. Compressed FAM foams having thicknesses in the range of about 0.02 inches (0.5 mm) to about 0.185 inches (4.7 mm) are suitable herein.

The preparation of FAM foam (also sometimes referred to in the literature as "HIPE", i.e., high internal phase emulsion) is described in the patents cited hereinabove. The following Example illustrates the preparation of a compressed foam for use herein.

Preparation of Emulsion and FAM Foams Therefrom A) Emulsion Preparation Anhydrous calcium chloride (36.32 kg) and potassium persulfate (189 g) are dissolved in 378 liters of water. This provides the water phase stream to be used in a continuous process for forming the emulsion.

To a monomer combination comprising distilled divinylbenzene (42.4% divinylbenzene and 57.6% ethyl styrene) (1980 g), 2-ethylhexyl acrylate (3300 g), and hexanedioldiacrylate (720 g) is added a diglycerol monooleate emulsifier (360 g), ditallow dimethyl ammonium methyl sulfate (60g), and Tinuvin 765 (15g). The diglycerol monooleate emulsifier (Grindsted Products; Brabrand, Denmark) comprises approximately 81% diglycerol monooleate, 1% other diglycerol monoesters, 3% polyols, and 15% other polyglycerol esters, imparts a minimum oil/water interfacial tension value of approximately 2.7 dyne/cm and has an oil/water critical aggregation concentration of approximately 2.8 wt. %. After mixing, this combination of materials is allowed to settle overnight. No visible residue is formed and all of the mixture is withdrawn and used as the oil phase in a continuous process for forming the emulsion.

Separate streams of the oil phase (250C) and water phase (53"-55"C) are fed to a dynamic mixing apparatus. Thorough mixing of the combined streams in the dynamic mixing apparatus is achieved by means of a pin impeller. The pin impeller comprises a cylindrical shaft of about 36.8 cm in length with a diameter of about 2.5 cm. The shaft holds 6 rows of pins, 3 rows having 33 pins and 3 rows having 32 pins, each having a diameter of 0.5 cm extending outwardly from the central axis of the shaft to a length of 2.5 cm. The pin impeller is mounted in a cylindrical sleeve which forms the dynamic mixing apparatus, and the pins have a clearance of 1.5 mm from the walls of the cylindrical sleeve.

A minor portion of the effluent exiting the dynamic mixing apparatus is withdrawn and enters a recirculation zone; see PCT U.S. 96/00082 published 18 July 96 and EPO 96/905110.1 filed 11 January 96. The Waukesha pump in the recirculation zone returns the minor portion to the entry point of the oil and water phase flow streams to the dynamic mixing zone.

The combined mixing and recirculation apparatus set-up is filled with oil phase and water phase at a ratio of 4 parts water to 1 part oil. The dynamic mixing apparatus is vented to allow air to escape while filling the apparatus completely.

The flow rates during filling are 7.6 g/sec oil phase and 30.3 cc/sec water phase.

Once the apparatus set-up is filled the vent is closed. Agitation is then begun in the dynamic mixer, with the impeller turning at 1450 RPM and recirculation is begun at a rate of about 30 cc/sec. The flow rate of the water phase is then steadily increased to a rate of 151 cc/sec over a time period of about 1 min., and the oil phase flow rate is reduced to 3 g/sec over a time period of about 3 min. The recirculation rate is steadily increased to about 150 cc/sec during the latter time period. The back pressure created by the dynamic mixer and static mixing zone (TAH Industries Model Number 101-212) at this point is about 14.7 PSI (101.4 kPa), which represents the total back pressure of the system. The Waukesha pump speed is then steadily decreased to a yield a recirculation rate of about 75 cc/sec. The impeller speed in then steadily increased to 1550 RPM over a period of about 10 seconds.

The back pressure increases to about 16.3 PSI (112 kPa).

B) Polymerization of Emulsion The emulsion flowing from the static mixer is collected in a round polypropylene tub, 17 in. (43 cm) in diameter and 7.5 in (10 cm) high, with a concentric insert made of Celcon plastic. The insert is 5 in (12.7 cm) in diameter at its base and 4.75 in (12 cm) in diameter at its top and is 6.75 in (17.1 cm) high. The emulsion-containing tubs are kept in a room maintained at 65 "C. for 18 hours to bring about polymerization and form the foam.

C) Foam Washing and Dewatering The cured FAM foam is removed from the curing tubs. The foam at this point has residual water phase (containing dissolved emulsifiers, electrolyte, initiator residues, and initiator) about 45-55 times (45-55X) the weight of polymerized monomers. The foam is sliced with a sharp reciprocating saw blade into sheets which are 0.185 inches (0.47 cm) in thickness. These sheets are then subjected to compression in a series of 2 porous nip rolls equipped with vacuum which gradually reduce the residual water phase content of the foam to about 6 times (6X) the weight of the polymerized material. At this point, the sheets are then resaturated with a 1.5% CaC12 solution at 600C., are squeezed in a series of 3 porous nip rolls equipped with vacuum to a water phase content of about 4X. The CaCl2 content of the foam is between 8 and 10 %.

The foam remains compressed after the final nip at a thickness of about 0.025 in. (0.063 cm). The foam is then dried in air for about 16 hours. Such drying reduces the moisture content to about 9-17 % by weight of polymerized material.

At this point, the foam sheets are very drapeable. In this collapsed state, the density of the foam is about 0.14 g/cc. Optionally, a liquid-impermeable backing sheet (e.g., 1 mil. polypropylene) can be applied to the foam pad to prevent liquid strike-through when the pad is being used.

Reinforcing; Means - As noted above, for use as a stain receiver in the prespotting operation herein, a sheet of the FAM is placed beneath and in close contact with one-side of the stained area of a fabric. A portion of pre-spotting composition is dispensed onto the fabric and manipulated into the stain by mechanical means.

The excess pre-spotting composition and its load of stain material are thereby transferred into the underlying FAM pad. The reinforcement means herein minimizes flaking of the FAM pad during this mechanical manipulation. In a highly preferred mode, the reinforcing means comprises a liquid-permeable coversheet which enrobes the FAM foam sheet and which freely allows passage of the liquid cleaning composition herein through the coversheet and into the foam.

Typical materials used as reinforcing means are as follows.

1. Formed-film material with uniform or "dual" sized holes; see, for example, U.S. Patents 4,324,246; 4,342,314; 4,609,518; and EP 0,165,807 for the manufacture of formed films.

2. Poly-chiffon - 100% polyester woven fabric.

3. 18 grams/meter2 (gsm) spunbonded polyester sheet (Reemay).

4. 18 gsm carded polypropylene sheet.* 5. Women's nylon hosiery - 88% nylon, 12% Lycrat Spandex(E 6. Organza - 100% polyester woven fabric.

7. 14 gsm thermally bonded air laid woven made with bicomponent annular fiber - polypropylene inner core with polyethylene outer shell.

*Commercially used in disposable absorbent products such as diapers.

The FAM can be encased in the reinforcing means by any convenient process which essentially "wraps" the foam within at least one layer of the reinforcing sheet material. If desired, the FAM can be only partially encased such that only the uppermost part of the FAM which is directly impacted by mechanical force during the spot-cleaning operation is reinforced. Since the back of the FAM may be covered with a liquid impermeable backing sheet, such backing sheet will also provide reinforcement. However, and depending on the type of equipment which is available, it may be simpler to encase the entire FAM pad.

As noted, the reinforcing means can be applied to the foam pad in any convenient manner. Optionally, the reinforcing means can be held in place by means of adhesives, or the like. Preferably, the reinforcing means is applied in any manner that ensures it is in close contact with the FAM pad to provide optimum reinforcement.

Compositions - The user of the present process can be provided with various compositions to use as spot removers. One problem associated with known fabric spot remover compositions is their tendency to leave visible residues on fabric surfaces. Such residues are problematic and are preferably to be avoided herein since the present process does not involve conventional immersion or rinse steps.

Accordingly, the pre-spotting compositions herein should, most preferably, be substantially free of various polyacrylate-based emulsifiers, polymeric anti-static agents, inorganic builder salts and other residue-forming materials, except at low levels of about 0.1%-0.3%, and preferably 0%, of the final compositions. Stated otherwise the compositions herein should be formulated so as to leave substantially no visible residue on fabrics being treated according to the practice of this invention.

Accordingly, in a preferred aspect of this invention there are provided liquid pre-spotting (i.e., spot-cleaning) compositions which are substantially free of materials which leave visible residues on the treated fabrics. This necessarily means that the preferred pre-spotting compositions are formulated to contain the highest level of volatile materials possible, preferably water, typically about 95%, preferably about 97.7%, a cleaning solvent such as BPP at a low, but effective, level, typically about 1 % to about 4%, preferably about 2%, and surfactant at levels of about 0.1 to about 0.7%. Advantageously, when thus formulated such compositions exist as aqueous solutions rather than as suspensions or emulsions. Thus, such compositions do not require use of additional emulsifiers, thickening agents, suspending agents, and the like, all of which can contribute to the formation of undesirable visible residues on the fabric.

Indeed, as an overall proposition, any of the chemical compositions which are used to provide the pre-spotting function herein comprise ingredients which are safe and effective for their intended use, and, as noted above, preferably do not leave unacceptable amounts of visible residues on the fabrics. While conventional laundry detergents are typically formulated to provide good cleaning on cotton and cotton/polyester blend fabrics, the compositions herein must be formulated to also safely and effectively clean and refresh fabrics such as wool, silk, rayon, rayon acetate, and the like. In addition, the compositions herein comprise ingredients which are specially selected and formulated to minimize dye removal or migration from the stain site of fugitive, unfixed dye from the fabrics being cleaned. In this regard, it is recognized that the solvents typically used in immersion dry cleaning processes can remove some portion of certain types of dyes from certain types of fabrics. However, such removal is tolerable in immersion processes since the dye is removed relatively uniformly across the surface of the fabric. In contrast, it has now been determined that high concentrations of certain types of cleaning ingredients at specific sites on fabric surfaces can result in unacceptable localized dye removal.

The preferred compositions herein are formulated to minimize or avoid this problem.

The dye removal attributes of the present compositions can be compared with art-disclosed cleaners using photographic or photometric measurements, or by means of a simple, but effective, visual grading test. Numerical score units can be assigned to assist in visual grading and to allow for statistical treatment of the data, if desired.

Thus, in one such test, a colored garment (typically, silk, which tends to be more susceptible to dye loss than most woolen or rayon fabrics) is treated by paddingon cleaner/refresher using an absorbent, white paper hand towel. Hand pressure is applied, and the amount of dye which is transferred onto the white towel is assessed visually. Numerical units ranging from: (1) "I think I see a little dye on the towel"; (2) "I know I see some dye on the towel"; (3) I see a lot of dye on the towel"; through (4) "I know I see quite a lot of dye on the towel" are assigned by panelists.

In addition to the foregoing considerations, the compositions used herein are preferably formulated such that they are easily dispensed and not so adhesive in nature that they render dispensing from the container to be unhandy or difficult.

However, and while not intending to be limiting of the present invention, the preferred compositions disclosed herein afford a spot-cleaning process which is both effective and aesthetically pleasing when used in the manner disclosed herein.

Aqueous Snot Stain Cleaning; Compositions (a) Water -The preferred, low residue compositions herein may comprise from about 90%, preferably from about 95.5% to about 99.9%, by weight, of water.

(b) Solvent - The compositions herein may comprise from about 0% to about 10%, by weight, of butoxy propoxy propanol (BPP) solvent or other solvents as disclosed herein. Preferred spot cleaners will comprise 1-4% BPP.

(c) Surfactant - The compositions herein may optionally comprise from about 0.05% to about 2%, by weight, of surfactants, such as MgAES and NH4AES, amine oxides, ethoxylated alcohols or alkyl phenols, alkyl sulfates, and mixtures thereof. The use of surfactants limited to the lower end of the range is preferred for some dyes and fabric types.

Typically, the weight ratio of BPP solvent:surfactant(s) is in the range of from about 10:1 to about 1:1. One preferred composition comprises 2% BPP/0.25% Neodol 23 6.5. Another preferred composition comprises 4% BPP/0.4% AS. A highly preferred composition comprises 2% BPP/ 0.3% MgAE1S/0.03% dodecyldimethylamine oxide.

(d) Optionals - The compositions herein may comprise minor amounts of various optional ingredients, including bleach stabilizers, perfumes, preservatives, and the like. If used, such optional ingredients will typically comprise from about 0.05% to about 2%, by weight, of the compositions, having due regard for residues on the cleaned fabrics.

(e) Bleach - The compositions herein may also optionally comprise from about 0.25% to about 7%, by weight, of hydrogen peroxide. Preferred spot cleaners will comprise 0.5 to about 3% hydrogen peroxide. It will be appreciated that peroxide sources other than H2O2 can be used herein. Thus, various per-acids, per-salts, per-bleaches and the like known from the detergency art can be used. However, such materials are expensive, difficult to formulate in liquid products, can leave residues on fabrics and offer no special advantages over H2O2 when used in the present manner.

(f) Chelator - Compositions which contain H2O2 will also typically contain a chelating agent. The chelating agent is selected from those which, themselves, are stable in aqueous H2O2 and which stabilize the H2O2 by chelating vagrant metal ions. Such chelating agents are typically already present at low, peroxide-stabilizing amounts (0.01 1%) in commercial sources of hydrogen peroxide. A variety of phosphonate chelators are known in stabilizing H202. The amino phosphonates are especially useful for this purpose. Various amino phosphonates are available as under the REQUESTS trade name from the Monsanto Company, St. Louis, Missouri. Representative, but non-limiting, examples include ethylenediamine tetrakis (methylene phosphonic) acid, diethylenetriamine penta(methylene phosphonic) acid, and the water-soluble salts thereof. Amino tris(methylene phosphonic) acid or its water-soluble salts (as DEQUEST 200) is a preferred chelator.

The pH range of the compositions helps provide stability to the hydrogen peroxide and is typically in the acid-slightly basic range from about 3 to about 8, preferably about 6.

Organic Solvent - The preferred cleaning solvent herein is butoxy propoxy propanol (BPP) which is available in commercial quantities as a mixture of isomers in about equal amounts. The isomers, and mixtures thereof, are useful herein. The isomer structures are as follows:

While the spot cleaning compositions herein function quite well with only the BPP, water and surfactant, they may also optionally contain other ingredients to further enhance their stability. Hydrotropes such as sodium toluene sulfonate and sodium cumene sulfonate, short-chain alcohols such as ethanol and isopropanol, and the like, can be present in the compositions. If used, such ingredients will typically comprise from about 0.05% to about 5%, by weight, of the stabilized compositions herein.

Surfactants - Nonionics such as the ethoxylated C10-C16 alcohols, e.g., NEODOL 23-6.5, can be used in the compositions. The alkyl sulfate surfactants which may be used herein as cleaners and to stabilize aqueous compositions are the Cg-C18 primary ("AS"; preferred C10-C14, sodium salts), as well as branched-chain and random C1 0-C20 alkyl sulfates, and C1 0-C18 secondary (2,3) alkyl sulfates of the formula CH3(CH2)x(CHOSO3 Me) CH3 and CH3 (CH2),(CHOS03-M+ CH2CH3 where x and (y + 1) are integers of at least about 7, preferably at least about 9, and M is a water-solubilizing cation, especially sodium, as well as unsaturated sulfates such as oleyl sulfate. Alkyl ethoxy sulfate (AES) surfactants used herein are conventionally depicted as having the formula R(EO)XSO3Z, wherein R is C10-C16 alkyl, EO is -CH2CH2-O-, x is 1-10 and can include mixtures which are conventionally reported as averages, e.g., (EO)2 5, (EO)6 5 and the like, and Z is a cation such as sodium ammonium or magnesium (MgAES). The C1 2- C16 alkyl dimethyl amine oxide surfactants can also be used. A preferred mixture comprises MgAE1S/C12 dimethyl amine oxide at a weight ratio of about 10:1.

Other surfactants which improve phase stability and which optionally can be used herein include the polyhydroxy fatty acid amides, e.g., C12-C14 N-methyl glucamide. AS stabilized compositions preferably comprise 0.1%-0.5%, by weight, of the compositions herein. MgAES and amine oxides, if used, can comprise 0.01%-2%, by weight, of the compositions. The other surfactants can be used at similar levels.

Other Optionals - In addition to the water, the preferred BPP solvent, the optional H2O2 and the surfactants disclosed above, liquid compositions used herein may comprise various optional ingredients, such as perfumes, preservatives, brighteners, salts for viscosity control, pH adjusters or buffers, and the like. The following illustrates preferred ranges for cleaning compositions for use herein, but is not intended to be limiting thereof.

h redient % (wt.) Formula Range BPP (Solvent) 0.05-5 Surfactant 0-2 Perfume 0.01-1.5 Water Balance pH range from about 6 to about 8.

Other solvents or co-solvents which can optionally be used herein include various glycol ethers, including materials marketed under trademarks such as Carbitol, methyl Carbitol, butyl Carbitol, propyl Carbitol, and hexyl Cellosolve, and especially methoxy propoxy propanol (MPP), ethoxy propoxy propanol (EPP), propoxy propoxy propanol (PPP), and all isomers and mixtures, respectively, of MPP, EPP, and BPP, as well as butoxy propanol (BP), and the like, and mixtures thereof. If used, such solvents or co-solvents will typically comprise from about 0.5% to about 2.5%, by weight, of the aqueous compositions herein. Non-aqueous (less than 50% water) compositions which optionally can be used in the pre-spotting step, can comprise the same solvents.

Dispenser - In one mode, the dispenser used herein comprises a container for the liquid pre-spotting composition, said container having a dispensing means which comprises a spout, preferably in the form of a hollow tube, which is connected to said container and is in communication with the interior of the container. In-use, a portion of the liquid composition within the interior of said container flows from the container through said spout, out the distal tip of said spout, and onto the stain which is being treated. The user manipulates the composition by daubing, smearing, pressing, or the like, using the distal tip to work the composition into the stain. A circular, rubbing motion is typical. By this means, the composition can be focused on the stained area. As the stain is loosened by the combined use of the aforesaid mechanical manipulation and the pre-spotting composition, the stain residues and the pre-spotting composition are transferred away from the fabric and into the underlying stain receiver. The fabric is then preferably re-positioned so that a fresh area of stain receiver underlies other stained areas, and the process is repeated until the prespotting operation is completed. The fabrics can then be used, as desired, or otherwise laundered or dry-cleaned.

Stain Removal Device - In another mode, a preferred embodiment of the arcuate device shown in Figure 3, the length of the arcuate base member (403) with its convex, generally rectangular configuration is about 2 inches (5 cm); its width is about 1.25 inches (3.2 cm); and its thickness is about 5/16 inch (0.8 cm). The width of shaft (404) at its mid-point is about 1 inch (2.54 cm) and its thickness at its midpoint is about 0.75 inch (1.9 cm). The length of the shaft (404) extending perpendicularly outward from the rear of the arcuate base to the base of bulb (405) is about 1.25 inches (3.2 cm). The bulb (405) which serves as a hand (or palm) rest has a circumference at its widest point of about 5.75 inches (14.6cm). The combination of shaft and bulb thus comprise the hand grip for the device. The overall height of the device measured from the center of the top of the bulb (405) to the center point of the front face of the convex base is about 3 inches (7.6 cm). The dimensions of the sponge layer (402) and protuberances (401) are as given above.

The following Examples further illustrate the stain removal operation of the present invention, but are not intended to be limiting thereof.

EXAMPLE I The spot cleaning operation herein for removing stain from a localized area on a fabric is conducted by: (a) underlaying the area containing said stain with the absorbent, FAM stain receiver reinforced with non-woven spun-bonded polyester fabric, basis weight ca. 18 grams/meter2; (b) applying a liquid cleaner (pre-spotter) composition to said stain from a container having a dispenser spout; and (c) rubbing or pressing said cleaning composition into said stain using the distal tip of said spout, whereby said stain is transferred into the reinforced FAM stain receiver.

In this mode, the face of the distal tip of said spout can be concave, convex, flat, or the like. The combination of container plus spout is referred to herein conjointly as the "dispenser".

A typical dispenser herein has the following dimensions, which are not to be considered limiting thereof. The volume of the bottle used on the dispenser is typically 2 oz. - 4 oz. (fluid ounces; 59 mls to 118 mls). The larger size container bottle can be high density polyethylene. Low density polyethylene is preferably used for the smaller bottle since it is easier to squeeze. The overall length of the spout is about 0.747 inches (1.89 cm). The spout is of a generally conical shape, with a diameter at its proximal base (where it joins with the container bottle) of about 0.596 inches (151 cm) and at its distal of 0.182 inches (4.6 mm). The diameter of the channel within the spout through which the pre-spotting fluid flows is approximately 0.062 inches (1.57 mm). In this embodiment, the channel runs from the container bottle for a distance of about 0.474 inches (1.2 cm) and then expands slightly as it communicates with the concavity to form the exit orifice at the distal end of the spout.

A composition for use herein with the aforesaid dispenser and the reinforced FAM-foam stain receiver is as follows.

INGREDIENT % (wot) (Nonionic) Hydrogen peroxide 1.000 Amino tris(methylene phosphonic acid)* 0.040 Butoxypropoxypropanol (BPP) 2.000 Neodol 23 6.5 0.250 Kathon preservative 0.0003 Water 96.710 pH target =7; range = 6 - 8 * Stabilizer for hydrogen peroxide EXAMPLE II Examples of preferred, high water content, low residue compositions for use herein are as follows. The compositions are listed as "nonionic" or anionic", depending on the type of surfactant used therein. These compositions are used in the manner disclosed herein with the reinforced FAM-foam to spot-clean fabrics and garments.

INGREDIENT Nonionic Composition Anionic Composition (%) (%) Hydrogen peroxide 1.000 1.000 Amino tris(methylene phosphonic acid)* 0.040 0.0400 Butoxypropoxypropanol (BPP) 2.000 2.000 Neodol 23 6.5 0.250 NH4 Coconut E1S ---- 0.285 Dodecyldimethylamine oxide ---- 0.031 Magnesium chloride ---- 0.018 Magnesium sulfate ---- 0.019 Hydrotrope, perfume, other minors, ---- 0.101 Kathon preservative 0.0003 0.0003 Water (deionized or distilled) 96.710 96.507 Target pH** 6.0 6.0 *Stabilizer for hydrogen peroxide **Range pH 6-8 Preferably, to minimize the potential for dye damage as disclosed hereinabove, such compositions comprise the anionic or nonionic surfactant in an amount (by weight of composition) which is less than the amount of H202.

Preferably, the weight ratio of surfactant:H202 is in the range of about 1:10 to about 1:1.5, most preferably about 1:4 to about 1:3.

EXAMPLE m A liquid pre-spotting composition is formulated by admixing the following ingredients.

Ingredient % (wt.) BPP 4.0 C12-C14 AS, Na salt 0.25 H2O2 1.0 Water and minors* Balance *Includes preservatives such as KATHONs at levels of 0.00001%-1%, by weight.

The fabric to be treated is laid flat on the absorbent, FAM-foam stain receiver reinforced with women's nylon hosiery material and 0.5 ml-4 ml of the composition is applied directly to the stain and worked in by means of the distal tip of the dispenser using a circular motion.

Other useful compositions which can be used in this manner are as follows: Ingredient Percent (wt.) (Range; wt.) BPP 4.0 0.1-4.0% C12-C14 AS 0.4 0.1 - 0.S% Nonionic Surfactant (optional)* 0.1 0 - 0.5% H2O2 0.25 0.25-7.0 Water (distilled or deionized) Balance 95-99.8% Target pH =5.0-7.0, preferably 6.0.

*The optional nonionic surfactants in the compositions herein are preferably C12- C14 N-methyl glucamides or ethoxylated C12-C16 alcohols (EO 1-10).

EXAMPLE IV Examples of preferred, high water content compositions for use with the reinforced FAM in the spot removal process step herein are as follows. The compositions are listed as "nonionic" or "anionic", depending on the type of surfactant used therein.

Ingredient Nonionic (%) Anionic (%) Butoxypropoxypropanol (BPP) 2.00 2.00 NEODOL 23 6.5 0.250 NH4CoconutE1S* --- 0.285 Dodecyldimethylamine oxide --- 0.031 MgC12 --- 0.018 MgSO4 --- 0.019 Hydrotrope, perfume, other minors --- 0.101 KATHON preservative 0.0003 0.0003 Water 97.750 97.547 *Ammonium salt of C12-C14 (coconut alkyl) ethoxy (EO-1) sulfate.

In a highly preferred mode, the liquid Nonionic or Anionic composition is applied to the stained area from a dispenser in the manner of Example I to remove stain from fabrics. In the mode of the present Example, a sheet of organza fabric is laid over and in contact with the stained area such that the dispenser spout rubs on the organza rather than directly on the fabric being treated. This minimizes abrasion damage on the fabric being treated. The organza is a commercially-available polyester material: basis weight 26.33 grams/meter2; caliper at 0.1 psi 1.02 mm; caliper at 2 psi 0.76 mm; opacity % 54.1; 24 vertical x 25 horizontal threads per quarter inch.

Claims (3)

WHAT IS CLAIMED IS:

1. An absorbent stain receiver characterized by FAM foam wholly or partially encased in a liquid-permeable coversheet.

2. A receiver according to Claim 1 wherein the coversheet comprises a woven or non-woven fabric.

3. A process for cleaning stained areas on fabrics characterized by the steps of: (a) placing the stained area of the fabric over and in contact with a reinforced FAM stain receiver article; (b) applying enough cleaning composition to saturate the localized stained area; (c) optionally, allowing the composition penetrate the stain for 3-5 minutes; (d) optionally, applying additional composition; (e) applying mechanical force to the stained area; (f) removing the fabric from contact with the stain receiver article; and (g) optionally, blotting the fabric between paper towels or other absorbent materials to remove excess cleaning composition.