NZ599042A

NZ599042A - Partial lamination of friction washing surface onto inside of laundry washing bag

Info

Publication number: NZ599042A
Application number: NZ59904212A
Authority: NZ
Inventors: Ashley Martin Newland; Nick Dobson
Original assignee: Calibre8 Pty Ltd
Priority date: 2012-03-26
Filing date: 2012-03-26
Publication date: 2013-07-26

Abstract

599042 A method of concurrently creating a frictional washing surface and joining the frictional washing surface to the surface of a housing material (20) for a sealable waterproof bag for washing one or more textile items. The method includes: i) applying a quantity of a polymer (22) to the surface of the housing material for the sealable bag; ii) positioning a tool (10) on the quantity of the polymer, the tool including a void region containing depressions and/or projections complementary to the shape of the frictional washing surface; and iii) heating the polymer and allowing it to form the shape of the frictional washing surface and concurrently join the frictional washing surface to the housing material for the sealable bag.

Description

Patent Form No. 5 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION TITLE: A METHOD OF FORMING A FRICTIONAL WASHING SURFACE We CALIBRE8 PTY LTD of Unit 8, 16 Abinger St, Richmond, VIC 5031, Australia, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: Title: A METHOD OF FORMING A FRICTIONAL WASHING SURFACE Field of the invention: The present invention relates to a method of concurrently creating a frictional washing surface and joining the frictional washing surface to the surface of a housing material for a sealable bag for washing one or more textile items.

Background Using sealable waterproof bags with frictional washing surfaces inside provides travellers with a convenient and lightweight device for washing clothing when they are away from home. Such bags provide an alternative to soaking clothes in a basin or paying to have their clothing washed. Such bags may also be used domestically instead of using a washing machine or for military or aid relief uses.

To wash their clothing, users add 2-4 litres of water, a small amount of cleaning material (e.g. shampoo, body wash, washing liquid or powder, etc.) and several items of dirty clothing. The bag is sealed and air may be expelled through a valve. A user then places the bag on a table or the floor and rubs the clothing against the inner frictional washing surface for 20-40 seconds. The clothing may then be removed and rinsed. Optionally, the bag may be provided with an external grip surface (backing the frictional washing surface) to prevent the bag from sliding and/or to prevent the frictional washing surface from bunching up (particularly if the frictional washing surface is flexible and/or has a minimal thickness between projections making up the frictional washing surface).

Such bags may have a volume of between about 2L and 40L or between 8L and 15L and may weigh between about 30g and 1500g, 30g and 500g, between about 80g and 400g, or between about 80g and 250g.

A particularly effective sealing mechanism that may be used to seal the bag is a roll-down seal (often including fabric webbing straps or rubber/plastic stiffeners that are brought together before rolling the straps or stiffeners down the bag 3-4 times and clipping the ends of the seal together). Other seals may be used such as waterproof zippers, fold-over seals, zip-lock seals, drawstrings, crimp seals, releasable glue/sticky seals, hydrophobic material seals, clamping seals, etc.

Creating and applying the frictional washing surface to the bag is a complex and involved process.

Typically, the frictional washing surface is produced by injection moulding and then must be adhered to the housing material of the bag. This involves complex and expensive tooling and several steps to arrive at the final product.

It is therefore desirable to provide an improved method for producing the sealable waterproof bags with the frictional washing surfaces for washing clothing.

Detailed Description The present invention provides a method of concurrently creating a frictional washing surface and joining the frictional washing surface to the surface of a housing material for a sealable waterproof bag for washing one or more textile items, the method including: i) applying a quantity of a polymer to the surface of the housing material for the sealable bag; ii) positioning a tool on the quantity of the polymer, the tool including a void region containing depressions and/or projections complementary to the shape of the frictional washing surface; and iii) heating the polymer to soften it and allow it to form the shape of the frictional washing surface and concurrently join the frictional washing surface to the housing material for the sealable bag. The housing material may be placed on a conductive surface to allow conductivity of the heat and/or a current and/or a frequency through the polymer and housing material (e.g. a conductive plate).

This method is much more time and cost efficient than previous methods, as the amount of tooling required and the time taken to produce the bag is reduced. Furthermore, the method eliminates a manufacturing step as the frictional washing surface is created concurrently to it being joined to the surface of the housing material for the bag. The housing material may already be constructed in the shape of the bag or may be a linear sheet that will be used to construct the bag.

Reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common general knowledge in any country.

Furthermore, it must be noted that, as used herein, the singular forms “a”, “an” and “the” include plural aspects unless the context already dictates otherwise.

The term ‘frictional washing surface’ as used herein is intended to mean a surface, which includes raised portions and/or depressed portions that increase the friction between the surface and one or more textile items (e.g. clothing, hosiery, linen, towels, etc.), which are rubbed along or across the surface.

As set out above, the tool includes a void region containing depressions and/or projections complementary to the shape of the frictional washing surface that is to be created. As can be appreciated, the configuration of the depressions and/or projections may vary depending on the pattern of the frictional washing surface that is desired. In some embodiments, the void volume may include depressions with depths between 0.5mm and 8mm, between 1mm and 5mm or between 1.5mm and 3mm. The tool may be positioned such that the quantity of polymer is received, at least in part, in the void region. As the polymer softens, the polymer is drawn up to fill the void region (including the depressions). This process may be aided by applying pressure on the tool during step iii) to help draw the polymer into the void region. Pressure may be applied, for example, using a hydraulic or pneumatic press. In some embodiments, the tool may include multiple voids each containing depressions and/or projections. As can be appreciated, depressions in the void will create projections in the resulting frictional washing surface. Projections in the voids may be used to create channels, fold lines, impressed logos, patterns or text in the resulting frictional washing surface.

In some embodiments, the void volume of the tool has a length by breadth area of greater than 2500 mm , 2 2 2 2 greater than 10,000 mm , greater than 25,000 mm , greater than 50,000 mm , or greater than 60,000 mm .

For example, the length and/or breadth of the void volume may be greater than 50 mm, greater than 100 mm, greater than 150 mm, greater than 200 mm, greater than 250 mm or greater than 300 mm. As can be appreciated, in some embodiments, the frictional washing surface may cover a surface area of the housing 2 2 2 material of greater than 2500 mm , greater than 10,000 mm , greater than 25,000 mm , greater than 50,000 mm , or greater than 60,000 mm .

The polymer that is applied to the surface of the housing material for the sealable bag may be in a solid, semi-solid or liquid state. For ease of application, the polymer may be used in a solid or semi-solid state as this may allow neater application and better positioning. In this regard, the polymer may be in the form of a sheet, a block, a mass, a ball, or any other shape. In some embodiments, the quantity of polymer may be provided as a single unit, multiple units or partially joined units. In some embodiments, a sheet of polymer may simplify the method as it may be cut to substantially match the shape of the tool (e.g. die cut) and may allow better formation of the frictional washing surface as the polymer would be more evenly distributed across the tool, thereby allowing better uptake of the polymer in the depressions of the tool’s void region.

Furthermore, using a sheet of polymer may reduce the amount of energy required to soften the polymer due to the distribution of the polymer. The term “sheet” is intended to include flat sheets, mesh sheets, patterned sheets, sheets of varying thickness, perforated sheets, etc. In some embodiments, a sheet with apertures may be prepared such that the polymer lines up with the recesses of the tool and the apertures line up with projections or flat sections of the void of the tool.

In embodiments wherein the polymer is provided as multiple units or partially joined units, the units may be arranged such that they are positioned in the vicinity of depressions in the void of the tool. In this regard, depending on the quantity of the polymer and the arrangement of the tool, a frictional washing surface with one or more discrete projections or one or more substantially discrete projections may be formed. This can reduce the amount of polymer required and thereby reduce the weight of the frictional washing surface.

In some embodiments, it may be beneficial to use a quantity of polymer and a tool that results in the creation of a thin base on the housing material that supports the projections of the frictional washing surface (e.g. a greater volume of polymer than the void volume). The thin base may provide additional strength and/or thickness to the portion of the housing that is likely to be under the most stress when in use and/or is likely to wear through quickest. A base may also be designed into the shape of the void and/or the inclusion of a peripheral lip on the tool.

The optimal quantity of polymer may be determined with respect to the volume of the void region of the tool. In some embodiments, the void volume of the tool may be between 2,000 mm and 400,000 mm , 3 3 3 3 between 5,000 mm and 200,000 mm , between 15,000 and 150,000 mm , between 35,000 mm and 85,000 3 3 3 mm or between 45,000 mm and 70,000 mm .

As can be appreciated, the void volume of the tool will vary depending on the area of the frictional washing surface to be created, the number of depressions and/or projections, the type of depressions and/or projections, and the dimensions of the depressions and/or projections. The frictional washing surface is not particularly limited and may include a relatively rigid washing surface or a flexible washing surface. For portability, a flexible washing surface may be beneficial.

In some embodiments, the washing surface may include a plurality of projections (e.g. ridges, knobs, or the like) and/or depressions (e.g. inundations, divots, channels, etc.). In some embodiments, the depressions may be inherently delineated by projections. The depressions and/or projections may be elongate, connected to other projections or depressions, discrete units, uniformly shaped, or irregularly shaped. In some embodiments, the depressions and/or projections or parts thereof may have a tapered profile. For example, the depressions and/or projections may include a semi-circular, circular segment, semi-ellipsoidal, ellipsoidal segment, pyramidal, triangular shaped, pentagonal shaped, or wave shaped cross-section.

Alternatively, the depressions and/or projections may include a quadrangular shaped cross-section. In some embodiments, the washing surface may include a plurality of differently shaped or sized depressions and/or projections. The depressions and/or projections may cover all or part of the washing surface. To minimise damage to the textiles, the washing surface may be a low abrasive surface (e.g. protrusions are preferably relatively blunt and/or composed of a resilient material).

Different shaped and sized depressions and/or projections may be suitable for different washing purposes.

For example, large well-defined depressions and/or projections may be used for durable (e.g. denim materials) and/or heavily soiled clothing while smaller or less pronounced depressions and/or projections may be used for delicates (e.g. ladies underwear or clothing made from delicate materials, such as silk). In some embodiments, the washing surface may include two or more regions, each with different sized, shaped and/or configured projections, depressions and/or holes. In this regard, different regions of the same washing surfaces may be used for different textiles.

In some embodiments, the washing surface may make up less than 50%, less than 40%, less than 30% or less than 20% of the total inner surface of the housing. Such percentages can assist in maintaining a high degree of flexibility of the housing when in use and minimise weight of the device. The depressions and/or projections may be uniformly distributed on the housing and/or may be concentrated around a mid-point of the length or width of the housing, or around the mid-point of the length of the housing when sealed.

In some embodiments, the depressions and/or projections may be provided in a parallel arrangement, hatched arrangement, perpendicular arrangement, zig zag arrangement, rippled arrangement, or other suitable arrangement. In some embodiments, the washing surface may include a path through the depressions and/or projections to allow residual water to effectively drain from the washing surface (e.g. the depressions and/or projections may be angled towards a direction of drainage and/or may include channels through the depressions and/or projections to provide a drainage pathway).

In some embodiments, the depressions and/or projections may be multidirectional (e.g. they may allow cleaning of textiles when rubbed in more than one direction). For example, parallel ridges may allow textiles to be cleaned by rubbing them back and forth against the ridges. However, knobs or other discrete projections may allow textiles to be cleaned when textiles are rubbed in more directions. If cleaning against the washing surface is only intended in one direction (or one reversible direction), the washing surface may be longer in that direction to allow better cleaning of the textiles for each stroke of the textiles against the washing surface. In some embodiments, the washing surface may resemble a traditional or modern washboard, which may be relatively rigid or composed of a flexible material.

As described above, different sized depressions and/or projections may be used, which may depend on the desired washing application and/or desired compactness (e.g. smaller depressions and/or projections may be used to keep the waterproof housing compact for ultra-light travellers). In some embodiments, the depressions and/or projections may have a height or depth of between 0.5mm and 10mm. Larger or smaller depressions and/or projections are also contemplated by the present invention. In some embodiments, the depressions and/or projections may have a height or depth of between 1mm and 6mm or between 1.5mm and 4mm. These heights or depths may still allow effective cleaning of clothing or other textiles by pressing and rubbing the clothing against the washing surface, while allowing the washing surface and housing to maintain a relatively compact size. In some embodiments, the washing surface may include different sized depressions and/or projections.

In some embodiments, the washing surface may include a base on which the depressions and/or projections are provided. The base may confer additional stability to the frictional washing surface, prevent depressions and/or projections from bunching up, and/or distribute pressure over a wider area, which may reduce wear on the housing or gripping surface (described below).

In some embodiments, the base may include one or more flex lines (straight or curved) to increase the flexibility of the washing surface, which can assist in folding or inverting the laundry device. For example, flex lines running perpendicular to the length or breadth of the housing may assist in folding the laundry device while flex lines that are not perpendicular or parallel to the length of the housing (e.g. flex lines at an acute angle to the length or breadth of the housing) may assist in inverting the housing and/or wringing out wet clothes in the housing. The flex lines may include thinner sections of the base, perforated base sections, high flex material sections (i.e. more flexible than the rest of the base), or splits within the base.

In some embodiments, the quantity of polymer may be equal to or greater than the volume of the void of the tool. This can have the benefit of allowing the softened polymer to be taken up into substantially all the void volume. Polymer quantities greater than the void volume of the tool may be useful in allowing the softened polymer to be taken up into more than 70%, more than 80%, more than 90%, more than 95% or substantially all the void volume and/or may provide a base for the fictional washing surface (e.g. as described above). The void of the tool may be calculated as the empty volume of the tool (e.g. the void volume would be the same as the volume of a material required to fill the tool).

As described above, the quantity of polymer may be provided as a sheet. In some embodiments, the sheet of polymer may have a thickness between 0.1 mm and 8 mm, between 0.2 mm and 4 mm, between 0.4 mm and 3 mm, or between 0.8 mm and 1.4 mm. In some embodiments, the thickness of the polymer sheet may be an average thickness of the sheet as sheets with varying thickness are also contemplated by the present invention. The required average thickness of the polymer in the form of a sheet may be determined with respect to the volume of the void region of the tool and the thickness of a base for the frictional washing surface that may be desired.

The polymer may be any polymer that is able to be softened by applying heat and/or a current and/or a frequency to the tool when positioned and subsequently polymerising by removing the heat and/or current and/or frequency and/or applying a polymerising agent. In some embodiments, the polymer may include a polymer selected from the group including: ABS, Acrylic, Aclar, APET, Barex 210, Barex 218, Cellulose acetate, Cellulose Acetate butyrate, Cellulose Nitrate, Cellulose triacetate, Ethyl Vinyl Alcohol (EVA),EVOH, Nylon (Polyamide), Pelathane, PET, PETG (polyester glycol), Pliofilm (rubber hydrochloride), Phenol-formeldehyde, Polyethylene, Polymethyl: Methylacrilate, Polyurethane, Polyurethane foam, Polyvinyl acetate, Polyvinyl chloride, Saran (polyvinylidene chloride), or derivatives or combinations of any of the foregoing. In some embodiments, the polymer may be a urethane polymer or a PVC polymer.

The tool may be composed of any suitable metal that is able to soften the polymer by applying heat and/or a current and/or a frequency to the tool. In some embodiments, the tool is a metallic tool. In some embodiments, the tool may be composed of aluminium, steel, titanium, copper, iron, or a composite or alloy including any one or more of the foregoing. In some embodiments, the tool is an aluminium tool.

The heat and/or current and/or frequency applied to the tool may include high frequency welding (or radio frequency welding), vibration welding or ultrasonic welding. In some embodiments, applying heat and/or current and/or frequency may involve applying a radio frequency of approximately 27.12 MHz. The precise frequency and duration will depend on the type of polymer, the thickness and form of the polymer and the void volume of the tool (e.g. the depth of recesses and/or the height of projections). In some embodiments, a mechanical pressure may be applied to the tool to press it against the quantity of polymer and the housing material. In some embodiments, the combination of the weight of the tool and gravity may provide ample pressure between the tool and the quantity of polymer and the housing material. Methods and settings for applying heat and/or current and/or frequency suitable for the tool for different polymers include those described in Handbook of Plastics Joining (1997) by Plastics Designs Library (a division of William Andrew Ltd).

It will be appreciated that the heating current, heating time and pressure required will depend on a number of factors including, for example, the type of polymers, the thickness of the polymers, the surface area of the frictional washing surface to be formed, and the composition of the tool. In some embodiments, the optimal settings for the heating current, heating time and pressure may be determined by first testing with minimum power, minimum time (e.g. <1 or <2 seconds), and medium pressure. If the join is weak and/or the frictional washing surface is ill-formed, the time may be increased gradually up to 3 or 4 seconds. Then the power may be increased incrementally until a good join and well-formed frictional washing surface is obtained. To minimise burning or arcing, the heating current may be kept as low as possible consistent with good join and frictional washing surface formation.

In some embodiments, a radio frequency of approximately 27.12 MHz may be applied to the tool for 0.5-10 seconds or 0.5 to 5 seconds to soften the polymer.

As can be appreciated, the shape of the tool may be determined by the desired shape of the frictional washing surface. In some embodiments, the tool may include a peripheral lip to contain the softened polymer during step iii. In some embodiments, the peripheral lip may also be used to define the thickness of the base of the frictional washing suface (if there is one).

In some embodiments, the tool may include a channel adjacent to the periphery of the tool to take up excess softened polymer. In this regard, softened polymer is less likely to cross the periphery of the tool, which can look messy. The channel may be provided in conjunction with a peripheral lip or in the absence of a peripheral lip.

The housing material may include any suitable waterproof material. In some embodiments, the housing material may include a polymer selected from the group including: a silicone, ABS, Acrylic, Aclar, APET, Barex 210, Barex 218, Cellulose acetate, Cellulose Acetate butyrate, Cellulose Nitrate, Cellulose triacetate, Ethyl Vinyl Alcohol (EVA),EVOH, Nylon (Polyamide), Pelathane, PET, PETG (polyester glycol), Pliofilm (rubber hydrochloride), Phenol-formeldehyde, Polyethylene, Polymethyl: Methylacrilate, Polyurethane, Polyurethane foam, Polyvinyl acetate, Polyvinyl chloride, Saran (polyvinylidene chloride), or derivatives or combinations of any of the foregoing.

In some embodiments, the housing material may include synthetic or natural fibres. The fibres may be individual fibres or may be part of a woven fabric, a non-woven fabric, filaments, threads or yarns. The fibres, fabrics, filaments, threads or yarns may be coated, encapsulated or impregnated with a polymer (including, for example any of the aforementioned polymers). In some embodiments, the fibres may be included in the housing as an unorganised arrangement of fibres (e.g. mixed with or coated onto a liquid polymer or polymer layer), matted together or included as an organised arrangement of fibres, filaments, threads or yarns (e.g. a woven fabric, scrim or one or more layers or lines of unidirectional fibres). The term scrim, as used herein is intended to mean a base fabric component created by laying out fibres, filament or thread in a grid pattern and joining them at the intersections (e.g. by knitting, tying or adhering). In some embodiments, the housing material may include a fabric with a fabric or fibre denier between 0.5 and 600, between 1 and 300, between 25 and 220, or between 50 and 100, and/or the fibre is a microfibre with a denier less than 0.5.

As mentioned above, the use of fibres in the housing can increase the durability of the housing (e.g. increase the tear resistance, increase the puncture resistance, increase the wear resistance, reduce flex fatigue and/or reduce stretching or deformation of the housing). Other advantages of using fibres may include improved feel of the housing, and/or improved tactility of the contents in the bag, and/or reduced incidence or appearance of flex associated wear (e.g. creases or residual marks from bending or deforming the housing).

Fibres can also allow flexing of the housing with loss of strength compared to housings without fibres (e.g. blown plastic films). Each of these features can be important when users grip or press on the housing to press and rub clothing against the washing surface, which is the most effective way to use to the laundry device to clean clothing. Furthermore, the inclusion of fibres can reduce the quantity of polymer required in the housing to achieve a desired feel, tactility and/or durability (e.g. when compared to the use of blown films without fibres). Reducing the quantity of polymer can reduce the weight of the housing and/or improve the flexibility of the housing, which are important considerations for travellers. Furthermore, as some polymers such as PVC become relatively stiff at low temperatures, minimising the quantity of the polymer in the housing can reduce limitations of the material while retaining benefits.

The fibres may include cellulose fibres, mineral fibres, polymer fibres, microfibres, vegetable fibres, wood fibres, or animal fibres. Examples of such fibres include: nylon fibres, polyester fibres (e.g. Dacron®, PET, PBT), ultra high molecular weight polyethylene fibres (e.g. Dyneema®, Spectra®, Pentex®, Certran®), liquid crystal polymer fibres (e.g. Vectran®, Zylon PBO®), aramid fibres (e.g. Kevlar® (including Kevlar®49 or Kevlar®Edge ), Technora®, Twaron®, Nomex®), carbon fibres, phenol-formaldehydes (PF), polyvinyl alcohol fibres (PVA), polyvinyl chloride fibres, polyolefin fibres (PP or PE), PBO Zylon fibres, PEN fibers (Polyethylene Napthalate), poly-urethane fibres, rayon fibres, cotton fibres, silk fibres, wool fibres, linen fibres, hemp fibres, coir fibres, and jute fibres.

In embodiments wherein the fibres, filaments, threads, yarns or fabrics are coated with a polymer, the polymer coat may be a thin coat (e.g. between 100nm and 500nm). In some embodiments, the polymer coat may be between 100nm and 50 m or between 100nm and 200 m, or between 100nm and 300 m, or between 50 m and 200 m. Thicker coatings may be used although some of the flexibility and/or weight advantages may be reduced. Thicker or thinner coatings are also contemplated by the present invention.

In some embodiments, the polymer used to coat, impregnate or encapsulate the fibres, filaments, threads, 2 2 2 2 yarns or fabrics may be used in a quantity of between 4g/m and 400g/m or between 15g/m and 300g/m , 2 2 2 2 or between 20g/m and 30g/m or between 30g/m and 80g/m . Higher or lower quantities are also contemplated by the present invention. In some embodiments, the fibres, filaments, thread, yarn or fabrics may be impregnated and coated with polymers. For example, a woven fabric may be impregnated with silicone and coated with a urethane on one or both sides.

In some embodiments, the polymer used to coat, impregnate or encapsulate the fibres, filaments, threads, yarns or fabrics may include a urethane (including, for example, silicone-modified polyurethanes), a silicone (including, for example, fluorosilicones), a PVC, a PVC substitute, a vinyl, an acrylic, a polytetrafluoroethylene, a polyester (e.g. PET, PEN, Mylar®), a polyamide, a polyimide (e.g. Kapton®, Upilex®, CP1®), a para-aramid, a flouroplymer (e.g. PVF, ECTFE, ETFE), a DWR, a latex coating, any other suitable polymer, or a combination of any of the foregoing. When used to coat fabrics, the polymer may be provided on the inner surface, outer surface or both surfaces of the fabrics. Specific examples of suitable coated or impregnated woven fabrics include urethane coated nylon, PVC coated nylon and silnylon.

Coating the fibres, filaments, threads, yarns or fabrics may include lamination.

In some embodiments, the fabric may include a specific weave pattern or process to increase durability and/or reduce weight. For example, the fabric may include a ripstop fabric, a Cordura® fabric, a Kodra fabric, an Oxford weave fabric or a Taffeta® fabric. In some embodiments, the fibres may be laid side-by- side to form a uni-directional layer of fibres, thereby reducing creep or crimp that may occur with some woven fabrics. Multiple layers may be used with the fibre layers being oriented in different directions (e.g. °, 45° or 90° to the first layer) to increase strength of the fabric in multiple directions. In some embodiments, the waterproof housing may include a CTF fabric (CUBIC TECH CORP) or Cuban fabric (plasma treated ultra high molecular weight polyethylene fibers and monofilament polyester film).

In some embodiments, the housing material may include a fabric with a fabric or fibre denier between 0.5 and 600, between 1 and 300, between 25 and 220, or between 50 and 100, and/or the fibre is a microfibre with a denier less than 0.5.

In some embodiments, the housing includes may include a nylon fabric, an acrylic fabric, a polyester fabric or vinyl fabric, the fabric coated on at least one side or impregnated with PVC, polyurethane, silicone or latex.

To facilitate effective joining of the frictional washing surface to the housing material, the housing material may include a polymer that has welding compatibility with the quantity of polymer applied to the housing material. In some embodiments, the polymers may be of a different type. In some embodiments, the polymers may be of the same type (e.g. both urethanes with different chemical compositions). In some embodiments, the polymers may be identical.

In some embodiments, the quantity of polymer may include one or more synthetic or natural fibres. Such fibres may provide the flexible washing surface with added durability and may include any of the fibres previously mentioned herein.

In some embodiments, the method may further include concurrently creating a grip surface on a surface of the housing material backing at least a portion of the position of the frictional washing surface, the method including the further step of iv): allowing some of the quantity of polymer to pass through the housing material to form the grip surface during step iii); or v) applying a second quantity of a polymer to the surface of the housing material backing at least a portion of the position of the frictional washing surface, wherein the second quantity of polymer is also joined to the housing material during step iii). Where two quantities of polymers are used, it will be appreciated that the polymers may be identical, of the same polymer type or polymers of different types.

Concurrently forming the gripping surface on the housing material may further reduce manufacturing steps, cost and time.

As for the operation of the bag, providing a grip surface can be advantageous in that it may allow the frictional washing surface to remain substantially in the same place during use (e.g. prevent the housing from sliding). If the washing surface moves as the textiles are rubbed against it and/or the projections/depressions bunch up (particularly if the frictional washing surface doesn’t include a base as described above), the laundry device will be less effective. The gripping surface may also be advantageous in that it can provide a barrier between the waterproof housing and the surface it is used on, thereby reducing abrasion and wear of the housing material.

The polymer for the grip surface may include any of the polymers previously mentioned here or may include an elastomeric polymer. The polymer for the grip surface may be applied in the form of a sheet, a mesh, lattice, a blob, etc. In some embodiments, providing the grip surface as a sheet, a mesh, lattice that is approximately cut to the size of the tool may result in a neater looking product. In some embodiments, a sheet, mesh or lattice with large apertures may be advantageous as it will provide a latticed or gridded grip surface. When used on a smooth wet surface, the water may be at least partially displaced into the apertures of the grip surface thereby improving the ability of the gridded or latticed grip surface to grip the smooth surface.

Examples of suitable classes of elastomeric polymers may include anionic triblock copolymers, polyolefin- based thermoplastic elastomers, thermoplastic elastomers based on halogen-containing polyolefins, thermoplastic elastomers based on dynamically vulcanized elastomer- thermoplastic blends, thermoplastic polyether ester or polyester based elastomers, thermoplastic elastomers based on polyamides or polyimides, ionomeric thermoplastic elastomers, hydrogenated block copolymers in thermoplastic elastomer interpenetrating polymer networks, thermoplastic elastomers by carbocationic polymerization, polymer blends containing styrene/hydrogenated butadiene block copolymers, and polyacrylate- based thermoplastic elastomers.

In some embodiments, the elastomeric polymer may include, for example, a thermoplastic elastomer or thermoset elastomer. Thermoplastic elastomers include, for example, styrenic block copolymers, polyolefin blends, elastomeric alloys (TPE-v or TPV), thermoplastic polyurethanes, thermoplastic copolyesters and thermoplastic polyamides. The elastomers may include, for example, natural rubbers, butyl rubbers, EPDM rubbers, silicone rubbers (e.g. polydimethyl siloxane), polyisoprenes, polybutadienes, polyurethanes, ethylene/propylene/diene terpolymer elastomers, chloroprene rubbers, styrene-butadiene copolymers (random or block), styrene-isoprene copolymers (random or block), acrylonitrile-butadiene copolymers, acrylics, epoxies, polyvinyl chlorides, neoprenes, nitriles, Viton®, polyethylenes, polystyrenes, silicones, Hypalon®, mixtures thereof and copolymers thereof. The block copolymers may include, for example, linear, radial or star configurations and may be diblock (AB) or triblock (ABA) copolymers or mixtures thereof. Blends of these elastomers with each other or with modifying non-elastomers are also contemplated.

Commercially available elastomers include block polymers (e.g., polystyrene materials with elastomeric segments), available from KRATON Polymers Company of Houston, Texas, under the designation KRATON™. The elastomeric resin materials, such as those described above, may also have added to them any of a number of customary additives, including, for example, plasticizers, silica, tackifiers, fillers, antioxidants, UV absorbers, hindered amine light stabilizers (HALS), dyes or pigments, opacifying agents and the like.

In some embodiments, the grip surface may have a static or dynamic coefficient of friction greater than 0.5, greater than 0.75, greater than 1.0, greater than 1.25, greater than 1.50, greater than 2.0, greater than 2.5, or greater than 3.0. Methods for determining the coefficient of friction are as described in .

In some embodiments, the gripping surface may have a wet static or wet dynamic coefficient of friction greater than 0.5, greater than 0.75, greater than 1.0, greater than 1.25, greater than 1.50, greater than 2.0, greater than 2.5, or greater than 3.0. In some embodiments, the grip surface that is formed may have a coefficient of friction that is greater than the coefficient of friction of the non-grip portion of the housing material by at least 25%, at least 50%, at least 100%, at least 200%, at least 300%, at least 400%, at least 500%, at least 600%, at least 700% or at least 800%.

The present invention also provides for a sealable waterproof bag with an inner frictional washing surface for washing a textile item produced according to the method described herein.

The present invention also provides a tool with a void region containing depressions and/or projections complementary to the shape of the frictional washing surface, when used to produce the bag described herein using the method described herein.

Examples of specific embodiments of the invention Reference will now be made to the following examples which describe particular embodiments of the present invention. These examples should not be taken as limiting the scope of the claims.

Brief description of the figures Figure 1 shows a flow chart of the method according to an embodiment of the present invention. Figure 2 shows a perspective view drawing of a tool according to an embodiment of the present invention. Figure 3A and Figure 3B show perspective view drawings of the tool of Figure 2 being used according an embodiment of the present invention. Figure 3C shows a perspective drawing of the frictional washing surface formed using the tool from Figure 3A and Figure 3B. Figure 3D shows a perspective drawing of a sealable waterproof bag for washing one or more textile items constructed using the housing material including the frictional washing surface from Figure 3C. Figure 4 shows a perspective drawing of a finished sealable waterproof bag produced according to an embodiment of the present invention.

As shown in Figure 1; a quantity of polymer 22 is applied to housing material 20; tool 10 is positioned on polymer 22; heat and/or current and/or a high frequency is applied to soften polymer 22 and draw it into void 24 of tool 10 to form the shape of frictional washing surface 30; tool 10 is removed and polymer 22 is allowed to cool; and construction of sealable waterproof bag 40 may then be completed. Optionally, a second polymer 38 may be applied beneath housing material 20 to allow grip surface 48 to be formed on housing material 20 backing the frictional washing surface 30 that is formed. Also optionally, pressure may be applied on tool 10 to help draw polymer 22 into void 24.

An embodiment of the present invention will now be described with respect to the drawings in Figure 2 and Figure 3.

Figure 2 shows tool 10 with void 24. Void 24 is provided on face 14 and includes recesses 12. Tool 10 also includes channel 16 that runs adjacent to the periphery of tool 10. Lip 18 is also shown. Ridge 26 is provided half way along tool 10 and text ridges or channels 28 may be provided with a depth or height of approximately 0.2-0.4mm. Tool 10 is made from aluminium and has approximate dimensions of 300 mm x 240 mm x 15 mm (length x breadth x depth). Recesses 12 have a depth of approximately 1.5-2 mm.

Figure 3 shows tool 10 in use concurrently creating a frictional washing surface 30 and joining the frictional washing surface 30 to the surface of housing material 20 for sealable waterproof bag 40. As shown in Figure 3A, polymer 22 in the form of a die cut sheet of urethane is laid onto housing material 20, an 80 denier woven nylon fabric coated with urethane on one side. Tool 10 is brought down onto polymer 22 (Figure 3B). Optionally, second polymer 38 may be place under housing material 20 to form a grip surface.

Once tool 10 is in place, a radio frequency of approximately 27.12 MHz is applied to tool 10 for 0.5 to 10 seconds as well as a downward pressure. The radio frequency and heat generated thereby acts to soften polymer 22. The effect of the softening of polymer 22 and the pressure applied by tool 10 draws polymer 22 into recesses 12 to form knobs 36. Excess softened polymer is taken up by channel 16 and inhibited from leaking outside the area under tool 10 by raised lip 18. Lip 18 may be considered raised in relation to the rest of face 14 and/or channel 16. Furthermore, the urethane coating of the housing material 20 is also softened and melds with polymer 22. Ridge 26 of tool 10 produces fold line 32 in frictional washing surface , which aids in folding. Once tool 10 is removed, cooling is allowed to occur with polymer 22 now in the shape of frictional surface 30, securely joined to housing material 20. Text ridges or channels 28 result in impressed or embossed text 34 on frictional washing surface 30.

Construction of sealable bag 40 using housing material 20 may then be completed by sewing or welding the required seams. Edges 50 are joined together and end housing piece 52 is attached to edge 54. As shown in Figure 4, sealable bag 40 may also include rolldown seal 42 including straps 43 and clips 44. Sealable bag 40 may also include valve 46. Optionally, sealable bag 40 may further include grip surface 48 on the outside of housing material 20, backing frictional washing surface 30. Grip surface 48 may be joined to housing material 20 at the same time as the frictional washing surface is created and joined to housing material 20. To do this, second polymer 38 for grip surface 48 such as a silicone or urethane sheet (not illustrated) is laid underneath housing material 20 before tool 10 is positioned on polymer 22. When the high frequency is applied to tool 10 to soften the polymer for frictional washing surface 30, second polymer 38 is also softened and able to join to the fabric of housing material 20 and/or polymer 22, which may seep through the fabric, to form grip surface 48.

Claims

The claims defining the invention are as follows:

1. A method of concurrently creating a frictional washing surface and joining the frictional washing surface to the surface of a housing material for a sealable waterproof bag for washing one or more textile items, the method including: 5 i) Applying a quantity of a polymer to the surface of the housing material for the sealable bag; ii) Positioning a tool on the quantity of the polymer, the tool including a void region containing depressions and/or projections complementary to the shape of the frictional washing surface; and 10 iii) Heating the polymer to soften it and allow it to form the shape of the frictional washing surface and concurrently join the frictional washing surface to the housing material for the sealable bag.

2. The method of claim 1, wherein heating the polymer to soften it involves applying heat and/or a 15 current and/or a frequency to the tool.

3. The method of claim 1 or claim 2, wherein the quantity of polymer is provided as a sheet of polymer.

4. The method of claim 3, wherein the sheet of polymer has an average thickness between 0.2 mm and 20 3 mm.

5. The method of claim 2 or claim 3, wherein the sheet of polymer has an average thickness between

0.8mm and 1.4mm. 25 6. The method of any one of claims 1 to 5, wherein the polymer is a polymer selected from the group including: ABS, Acrylic, Aclar, APET, Barex 210, Barex 218, Cellulose acetate, Cellulose Acetate butyrate, Cellulose Nitrate, Cellulose triacetate, Ethyl Vinyl Alcohol (EVA),EVOH, Nylon (Polyamide), Pelathane, PET, PETG (polyester glycol), Pliofilm (rubber hydrochloride), Phenol- formeldehyde, Polyethylene, Polymethyl: Methylacrilate, Polyurethane, Polyurethane foam, 30 Polyvinyl acetate, Polyvinyl chloride, Saran (polyvinylidene chloride), or derivatives or combinations of any of the foregoing.

7. The method of any one of claims 1 to 6, wherein the void volume of the tool is between 2,000 mm and 400,000 mm .

8. The method of any one of claims 1 to 7, wherein the quantity of polymer is equal to or greater than the volume of the void of the tool.

9. The method of any one of claims 1 to 8, wherein the tool includes a peripheral lip to contain the 5 softened polymer during step iii.

10. The method of any one of claims 1 to 9, wherein the tool includes a channel adjacent to the periphery to take up excess softened polymer. 10

11. The method of any one of claims 1 to 10, wherein the tool includes one of more ridges to form fold lines in the frictional washing surface.

12. The method of any one of claims 1 to 11, wherein the tool is composed of aluminium, steel, titanium, copper, iron, or a composite or alloy including any one or more of the foregoing.

13. The method of any one of claims 1 to 12, wherein step iii) includes applying a current/frequency of 27.12 mHz.

14. The method of any one of claims 1 to 13, wherein the housing material includes a polymer selected 20 from the group including: ABS, Acrylic, Aclar, APET, Barex 210, Barex 218, Cellulose acetate, Cellulose Acetate butyrate, Cellulose Nitrate, Cellulose triacetate, Ethyl Vinyl Alcohol (EVA),EVOH, Nylon (Polyamide), Pelathane, PET, PETG (polyester glycol), Pliofilm (rubber hydrochloride), Phenol-formeldehyde, Polyethylene, Polymethyl: Methylacrilate, Polyurethane, Polyurethane foam, Polyvinyl acetate, Polyvinyl chloride, Saran (polyvinylidene chloride), or 25 derivatives or combinations of any of the foregoing.

15. The method of any one of claims 1 to 14, wherein the housing material includes synthetic of natural fibres. 30

16. The method of claim 15, wherein the fibres are part of a woven fabric, a non-woven fabric, filament, thread or yarn.

17. The method of claim 15 or claim 16, wherein the fibres or fabric are coated, encapsulated or impregnated with a polymer.

18. The method of claim 17, wherein the polymer includes a polymer selected from the group including: silicone, ABS, Acrylic, Aclar, APET, Barex 210, Barex 218, Cellulose acetate, Cellulose Acetate butyrate, Cellulose Nitrate, Cellulose triacetate, Ethyl Vinyl Alcohol (EVA),EVOH, Nylon (Polyamide), Pelathane, PET, PETG (polyester glycol), Pliofilm (rubber hydrochloride), Phenol- 5 formeldehyde, Polyethylene, Polymethyl: Methylacrilate, Polyurethane, Polyurethane foam, Polyvinyl acetate, Polyvinyl chloride, Saran (polyvinylidene chloride), or derivatives or combinations of any of the foregoing.

19. The method of any one of claims 1 to 18, wherein the housing material includes a fabric with a 10 fabric or fibre denier between 0.5 and 600, between 1 and 300, between 25 and 220, or between 50 and 100, and/or the fibre is a microfibre with a denier less than 0.5.

20. The method of any one of claims 1 to 19, wherein the housing includes a ripstop fabric, a Cordura fabric, a Kodra fabric, an Oxford weave fabric, a Taffeta fabric, a CTF fabric or a Cuban fabric.

21. The method of any one of claims 1 to 20, wherein the housing includes a nylon fabric, an acrylic fabric, a polyester fabric or vinyl fabric, the fabric coated on at least one side or impregnated with PVC, polyurethane, silicone or latex. 20

22. The method of any one of claims 1 to 21, wherein the housing material includes a polymer that has welding compatibility with the polymer of the sheet.

23. The method of any one of claims 1 to 22, wherein the housing material includes the same polymer type as the polymer of the sheet.

24. The method of any one of claims 1 to 23, wherein the quantity of polymer includes one or more synthetic or natural fibres.

25. The method of any one of claims 1 to 24, further including concurrently creating a grip surface on a 30 surface of the housing material backing at least a portion of the position of the frictional washing surface, the method including the further step of: iv) allowing some of the quantity of polymer to pass through the housing material to form the grip surface during step iii); v) or applying a second quantity of a polymer to the surface of the housing material 35 backing at least a portion of the position of the frictional washing surface, wherein the second quantity of polymer is also joined to the housing material during step iii).

26. The method of claim 25, wherein the grip surface has a coefficient of friction greater than 0.5, greater than 0.75, greater than 1.0, greater than 1.25, greater than 1.50, greater than 2.0, greater than 2.5, or greater than 3.0.

27. The laundry device of claim 25 or claim 26, wherein the second polymer includes a polymer selected from the group including: ABS, Acrylic, Aclar, APET, Barex 210, Barex 218, Cellulose acetate, Cellulose Acetate butyrate, Cellulose Nitrate, Cellulose triacetate, Ethyl Vinyl Alcohol (EVA),EVOH, Nylon (Polyamide), Pelathane, PET, PETG (polyester glycol), Pliofilm (rubber 10 hydrochloride), Phenol-formeldehyde, Polyethylene, Polymethyl: Methylacrilate, Polyurethane, Polyurethane foam, Polyvinyl acetate, Polyvinyl chloride, Saran (polyvinylidene chloride), or derivatives or combinations of any of the foregoing.

28. A sealable waterproof bag with an inner frictional washing surface for washing a textile item 15 produced according to any one of claims 1 to 27.

29. A tool with a void region containing depressions and/or projections complementary to the shape of the frictional washing surface, when used to produce the bag of claim 28 using the method of any one of claims 1 to 27.