CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of U.S. patent application Ser. No. 12/400,497, filed Mar. 9, 2009, which is a non-provisional patent application of U.S. Provisional Patent Application Ser. No. 61/046,118, filed Apr. 18, 2008, each of which is incorporated herein by reference. 
     Priority of U.S. Provisional Patent Application Ser. No. 61/046,118, filed Apr. 18, 2008, incorporated herein by reference, is hereby claimed. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to continuous batch washers or tunnel washers. More particularly, the present invention relates to an improved method of washing textiles or fabric articles (e.g. clothing, linen, etc.) in a continuous batch tunnel washer wherein the textiles are moved sequentially from one module or zone to the next module or zone including initial pre-wash zones, a plurality of main wash and pre-rinse zones, and then transferred to an extractor that removes water. More particularly, the present invention relates to an improved method of washing textiles in a continuous batch tunnel washer wherein a counter flow of wash liquor from one module or zone to the next module or zone is stopped, allowing for a standing bath. Chemicals are then added to separate soil from the goods and suspend the soil in the wash liquor. After a period of time, counter flow is commenced again to remove the suspended soil. The pre-rinsed goods are spray rinsed during extraction of excess water so that soil is not redeposited eliminated graying of the goods. 
     2. General Background of the Invention 
     Currently, washing in a commercial environment is conducted with a continuous batch tunnel washer. Such continuous batch tunnel washers are known (e.g. U.S. Pat. No. 5,454,237) and are commercially available (www.milnor.com). Continuous batch washers have multiple sectors, zones, stages, or modules including pre-wash, wash, rinse and finishing zone. Commercial continuous batch washing machines utilize a constant counter flow of liquor and a centrifugal extractor or mechanical press for removing most of the liquor from the goods before the goods are dried. Some machines carry the liquid with the goods throughout the particular zone or zones. 
     Currently, a counter flow is used during the entire time that the fabric articles or textiles are in the main wash module zone. This practice dilutes the washing chemical and reduces its effectiveness. Additionally, while the bath liquor is being heated, this thermal energy is partially carried away by the counter flow thus wasting energy while a desired temperature value is achieved. 
     A final rinse with a continuous batch washer has been performed using a centrifugal extractor or mechanical press. In prior art systems, if a centrifugal extractor is used, it is typically necessary to rotate the extractor at a first low speed that is designed to remove soil laden water before a final extract. 
     Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples. 
     
       
         
               
               
               
             
           
               
                 TABLE 
               
               
                   
               
               
                 PAT. NO. 
                 TITLE 
                 ISSUE DATE 
               
               
                   
               
             
             
               
                 4,236,393 
                 Continuous tunnel batch washer 
                 Dec. 02, 1980 
               
               
                 4,485,509 
                 Continuous batch type washing 
                 Dec. 04, 1984 
               
               
                   
                 machine and method for operating 
                   
               
               
                   
                 same 
                   
               
               
                 4,522,046 
                 Continuous batch laundry system 
                 Jun. 11, 1985 
               
               
                 5,211,039 
                 Continuous batch type washing 
                 May 18, 1993 
               
               
                   
                 machine 
                   
               
               
                 5,454,237 
                 Continuous batch type washing 
                 Oct. 03,1995 
               
               
                   
                 machine 
               
               
                   
               
             
          
         
       
     
     BRIEF SUMMARY OF THE INVENTION 
     The present invention improves the current art by reducing water consumption, improving rinsing capability, reducing the number of components required to perform the function of laundering fabric articles or textiles, and saving valuable floor space in the laundry. 
     The present invention reduces and/or combines zones, sectors, or modules and improves the method of processing the textiles. Rinsing is done in two zones, first in the continuous batch washer itself in an intermediate rinse zone after each main wash zone(s) and a pre-rinse in the last zone(s). A final rinse is then done in a mechanical water removal machine such as a centrifugal extractor or mechanical press. 
     When the goods are initially transferred into the main wash modules, the counter flow of wash liquor into the modules is stopped allowing for a standing bath. Chemicals are added to separate the soil from the goods and suspend the soil in the wash liquor. If needed, the wash liquor to the separate module bath is raised in temperature to facilitate the release of soil from the goods and activate the chemicals. 
     Once the soil has been released from the textiles, there is no more work for the chemicals to perform. At this time, the process can be described as “chemical equilibrium”. At this point, water by counter flow is commenced to remove the suspended soil. This rinsing is termed “intermediate rinse” in the wash zone(s) and a pre-rinse after the last wash zone. A final rinse can be performed in a centrifugal extractor or mechanical press. 
     The process of the present invention uses fresh water that can be supplied through an atomizing nozzle while the goods are being extracted. Because the free soil has already been removed in the pre-rinse zone, the spray rinse while extracting will not re-deposit soil on the linen thereby reducing or eliminating graying of the goods. It is not necessary to centrifuge (and drain at a low speed) the soil laden water before the final extract. With the present invention the process time is reduced. The amount of fresh water required compared with conventional processes is reduced. 
     The method of the present invention uses less water than in current art because the counter flow is stopped for part of the cycle. The spray rinse in the centrifugal extractor or mechanical press is more effective than the current practice of draining the free water from the linen and then refilling. 
     The method of the present invention preserves the washing effectiveness of current counter flow washers to wash heavy soil classifications because the amount of soil dilution is the same even though there are less zones, stages, or modules. The present invention provides a higher effective rinsing provided by the spray rinse in the centrifugal extractor because of the pre-rinse. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
         FIG. 1  is a schematic diagram showing the preferred embodiment of the apparatus of the present invention; 
         FIG. 2  is a schematic diagram showing the preferred embodiment of the apparatus of the present invention; 
         FIG. 3  is a schematic diagram showing the preferred embodiment of the apparatus of the present invention; 
         FIG. 4  is a schematic diagram of an alternate embodiment of the apparatus of the present invention; 
         FIG. 5  is a schematic diagram of the alternate embodiment of the apparatus of the present invention; 
         FIG. 6  is a partial perspective view of the alternate embodiment of the apparatus of the present invention; 
         FIG. 7  is a partial perspective view of the preferred embodiment of the apparatus of the present invention; 
         FIG. 8  is a fragmentary perspective view of the alternate embodiment of the apparatus of the present invention showing the starch dispensing nozzle tube; 
         FIG. 9  is a fragmentary perspective view of the alternate embodiment of the apparatus of the present invention showing the starch dispensing nozzle tube; and 
         FIG. 10  is a fragmentary perspective view of the alternate embodiment of the apparatus of the present invention showing the starch dispensing nozzle tube. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1-3  shows a schematic diagram of the textile washing apparatus of the present invention, designated generally by the numeral  10 . Textile washing apparatus  10  provides a tunnel washer  11  having an inlet end portion  12  and an outlet end portion  13 . In  FIG. 1 , tunnel washer  11  provides a number of modules  14 - 18 . These modules  14 - 18  can include a first module  14  and a second module  15  which can be pre-wash modules. The plurality of modules  14 - 18  can also include modules  16 ,  17  and  18  which are main wash and pre-rinse modules. 
     The total number of modules  14 - 18  can be more or less than the five (5) shown in  FIG. 1 .  FIG. 2  shows an alternate arrangement that employs a tunnel washer  11  having eight (8) modules  14 - 18  and  35 - 37 .  FIG. 3  shows an alternate arrangement that employs a tunnel washer  11  having ten (10) modules  14 - 18  and  35 - 39 . In  FIG. 2 , the modules  14 ,  15  can be pre-wash modules. In  FIG. 3 , modules  14 ,  15 ,  16  can be pre-wash modules. In  FIG. 2 , the modules  16 ,  17 ,  18  and  35 ,  36 ,  37  can be main wash and pre-rinse modules. In  FIG. 3 , the modules  17 ,  18  and  35 ,  36 ,  37 ,  38 ,  39  can be main wash and pre-rinse modules. Instead of a two (2) or three (3) module pre-wash section (see  FIGS. 1 ,  2 ,  3 ), a single module  14  could be provided as an alternate option for the pre-wash section. 
     Inlet end portion  12  can provide a hopper  19  that enables the intake of textiles or fabric articles to be washed. Such fabric articles, textiles, goods to be washed can include clothing, linens, towels, and the like. An extractor  20  is positioned next to the outlet end portion  13  of tunnel washer  11 . Flow lines  21 ,  25 ,  26 ,  27 ,  27 A are provided for adding water and/or chemicals to tunnel washer  11  as will be described more fully hereinafter. 
     When the fabric articles, goods, linens are initially transferred into the main wash modules  16 ,  17 ,  18 , a counter flow of wash liquor into these modules  16 ,  17 ,  18  is reduced, preferably stopped allowing for a standing bath. Chemicals are then added as indicated by arrows  26 ,  27  to the modules  16 ,  17  and/or  18 . In  FIG. 2 , chemicals are added as indicated by arrows  26 ,  27 ,  27 A to the modules  16 ,  17 ,  18 ,  35 ,  36  and/or  37 . In  FIG. 3 , chemicals are added to the modules  16 - 18  and  35 - 39  as indicated by the arrows  26 ,  27 ,  27 A. In  FIGS. 1-3 , these chemicals separate the soil from the goods, linens, textiles and suspend the soil in the wash liquor. During this step of the method of the present invention, the wash liquor temperature can be elevated if needed to facilitate the release of soil from the goods, fabric articles or linens and activate the chemicals. 
     Once the maximum soil has been released from the textiles or fabric articles, there is no more work for the chemicals to perform. At this time, the process can be described as chemical equilibrium. The flow of water is stopped for a time period sufficient to release soil from the goods such as for example between about 20 seconds and one hundred twenty (120) seconds. However, this time interval can be between about ten (10) and three hundred (300) seconds. 
     After this time interval of having no counter flow, water by counter flow is commenced to remove the suspended soil. This rinsing can be termed pre-rinse. A final rinse is then performed in a centrifugal extractor or mechanical press  20 . The process of the present invention uses fresh water that can be supplied through an atomizing nozzle for example while the goods are being extracted using the extractor  20 . The process of the present invention uses fresh water in the extractor that can be supplied through an atomizing nozzle for example while the goods are being extracted at high speed (e.g. between about 200 and 1,000 g&#39;s) using the extractor  20 . 
     Flow line  21  transmits water to hopper  19  as indicated by arrow  22 . Flow line  21  also carries water to pre-wash module  15  as indicated by arrow  23 . Arrow  24  indicates a flow of water from module  14  to module  15  as part of the pre-wash. 
     In  FIG. 1 , flow line  25  adds water for counter flow pre-rinse to module  18 . Such water added via flow line  25  to module  18  flows in counter flow fashion from module  18  to module  17  to module  16  (see arrow  25 A). Arrows  26  and indicate chemical addition to modules  16  and  17  respectively. Chemicals to be added to modules  16  and  17  can include for example detergent, alkalaii, and/or oxidizing agents. 
     In  FIG. 2 , flow line  25  adds water for counter flow pre-rinse to module  37 . Such water added via flow line  25  to module  37  flows in counter flow fashion from module  38  to module  37 , then  36 , then  35 , then  18 , then to module  17  (see arrow  25 B). 
     In  FIG. 3 , flow line  25  adds water for counter flow pre-rinse to module  38 . Such water added via flow line  25  to module  38  flows in counter flow fashion from module  38  to module  37 , module  36 , module  35 , module  18 , and module (see arrow  25 C). 
     In  FIG. 1 , textiles or fabric articles that are pre-washed, washed, and then pre-rinsed in tunnel washer  11  are transferred from module  18  to extractor  20  as indicated schematically by arrow  28 . In  FIG. 2 , the textiles or fabric articles that are pre-washed, washed, and then pre-rinsed in tunnel washer  11  are transferred from module  37  to extractor  20  as indicated schematically by arrow  28 . In  FIG. 3 , textiles or fabric articles that are pre-washed, washed, intermediately rinsed and then pre-rinsed in tunnel washer  11  are transferred from module  39  to extractor  20  as indicated schematically by arrow  28 . 
     The method of the present invention thus conducts rinsing in two zones. Rinsing is first conducted in the tunnel washer  11  in a pre-rinse zone which occurs after the main wash. In  FIG. 1 , pre-wash zones can be  14 ,  5 . The pre-rinse zone and main wash zone can be modules  16 ,  17 ,  18 . In  FIG. 2 , the pre-wash zone can be modules  14  and  15  while the main wash and pre-rinse zones can be modules  16 ,  17 ,  18 , 35 ,  36  and  37 . In  FIG. 3 , the pre-wash zone can be modules  14  and  15  while the main wash and pre-rinse zones can be modules  16 ,  17 ,  18 , 35 ,  36 ,  37 ,  38  and  39 . The second rinse zone is the final rinse, which is conducted in the extractor  20  or other mechanical water removal machine such as a mechanical press. 
     Because the free soil has already been removed in the pre-rinse zone at modules  16 ,  17 ,  18  of  FIG. 1  (or  16 - 18 ,  35 - 37  of  FIG. 2  or  16 - 18 ,  35 - 39  of  FIG. 3 ) as part of the method of the present invention, the spray rinse while extracting will not redeposit soil on the linen thereby reducing or eliminating graying of the goods. With the present invention it is not necessary to centrifuge (and drain at a low speed) the soil laden water before the final extract at  20 . With the present invention, the process time is thus reduced. The amount of fresh water required compared with conventional processes is reduced. The spray rinse and the centrifugal extractor  20  or mechanical press is more effective than the current practice of draining the free water from the linen and then refilling the extractor  20 . 
     An additional benefit of the pre-rinse concept of the present invention is to permit the mechanical press or extractor to have more time extracting the free water. This result follows because the effect of the pre-rinse is to remove most of the suspended soil. The amount of fresh water required for final rinse is thus greatly reduced. The time for rinsing is reduced, allowing this saved cycle time for water removal. 
     The method of the present invention preserves the washing effectiveness of current counter flow washers  11  to wash heavy soil classifications because the amount of soil dilution is the same even though there are fewer zones or stages or modules. 
     The present invention provides a higher effective rinsing provided by the spray rinse  30  and the centrifugal extractor  20  because of the pre-rinse that is conducted in the modules  16 ,  17 ,  18  as discussed above. 
       FIGS. 4-10  show an alternate embodiment of the apparatus of the present invention, designated generally by the numeral  40 . The textile washing apparatus  40  of the alternate embodiment can provide the same tunnel washer  11  of the preferred embodiment having the modules  14 - 18 ,  35 - 39  provided in any one of the embodiments of  FIG. 1 ,  2  or  3 .  FIG. 4  shows the embodiment of  FIG. 1  having a specially configured starch spray arrangement. 
     In  FIG. 4 , a starch tank  41  contains starch that is to be injected into the linen, fabric articles, or clothing contained in extractor  20 . Starch for the table linen, clothing, fabric articles is pumped in the first phase of the cycle through a spray nozzle  60  (see  FIGS. 8-10 ). Controlled flow metering can be achieved for example using an inverter controlled flow metering device. The precise amount of starch is thus injected into the linen, fabric articles, clothing or the like while in extractor  20 . Excess starch can be removed in a separate tank indicated as starch recovery tank  52  in  FIG. 4 . Flow line  53  enables recovered starch in tank  52  to be transferred to starch tank  41 . 
     Starch tank  41  contains starch that is to be pumped via flow line  42  to nozzle  60  and then to extractor  20 . Fresh water tank  43  can also be used to pipe fresh water to extractor  20 , flowing through valve  45  to nozzle  60 . Valves  44 ,  45  and  46  are provided for controlling the flow of either starch or fresh water or a combination thereof to nozzle  60  as shown in  FIG. 4 . 
     Flow line  49  is a flow line that carries extracted water to tank  51  as it is purged from the fabric articles, clothing or linens contained in extractor  20 . Starch can be recovered via flow lines  49 ,  50  to starch recovery tank  52 . Valves  44 ,  47  are provided for valving the flow of starch from tank  41  to extractor  20  via flow line  42 . Valve  48  enables tank  41  to be emptied for cleaning or adding new starch. 
     In  FIGS. 8-10 , starch spray nozzle  60  is shown in more detail. The spray nozzle  60  can provide an elongated section of conduit or pipe  61 . Spray nozzle  60  has an influent end  62  and a discharge end portion  63 . Conduit  61  provides an open ended bore  64  for conveying starch from flow line  42  to nozzle  60 . Influent end  62  provides a connection  80  for attaching conduit  61  to flow line  42 . 
       FIGS. 5-7  illustrate the spray pattern  76  that strikes the wall of drum  57  of extractor  20  as emitted by nozzle  60 . In  FIGS. 6 and 7 , extractor  20  provides a drum  57  that provides a chamber  55  having an inlet  56 . Clothes, textiles, linens to be sprayed are discharged from tunnel washer  11  via chute  79  into the chamber  55  of extractor  20 . The extractor  20  is preferably movable between a loading and discharging position. The loading position is shown in  FIGS. 5 and 6 . In the loading position, clothes transfer from the tunnel washer  11  to the chamber  55  via chute  79 . Pumps  54  can be used to aid in the transfer of water from tank  43  or starch from tank  41  into chamber  55  via nozzle  60 . The spray nozzle  60  produces a spray pattern  76  that extends substantially across the cylindrical wall  58  of drum  57  as shown in  FIGS. 6 and 7 . Drum  57  thus provides an inlet  56  for enabling clothing, textiles, or other fabric articles to be added to the drum  57  interior  55  and a rear circular wall  59 . Notice in  FIGS. 6 and 7  that the spray pattern  76  extends generally from inlet  56  to circular wall  59 , thus extending substantially across cylindric wall  58  as shown in  FIGS. 6 and 7 . Arrow  77  in  FIG. 7  illustrates the width of spray pattern  76  which can be about 16 degrees as an example along cylindrical drum wall  58 . 
     A mounting plate  65  can be provided having one or more openings  66  for attaching (for example, bolting) spray nozzle  60  to extractor  20  or to a frame that supports extractor  20 . 
     The discharge end portion  63  of spray nozzle  60  provides a nozzle tip  67 . The nozzle tip  67  provides a nozzle outlet  70  formed by side plates  71 ,  72 , upper plate  73  and lower plate  74 . Atomizing water nozzle  68 ,  69  are provided next to nozzle outlet  70 . The atomizing water nozzle  68  is mounted to upper plate  73 . The atomizing water nozzle  69  is mounted to lower plate  74  as shown in  FIGS. 8-10 . Spray nozzle  60  can be equipped with aerating or atomizing nozzles  68 ,  69  to control the consistency of the starch in the nozzle  60 , thus preventing starch build-up which might eventually plug of the nozzle  60 . 
     As part of the method of the present invention, all starch flow lines  42 ,  60  can be purged with hot water from fresh water tank via flow line  75 . 
     The following is a list of parts and materials suitable for use in the present invention. 
     
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 PARTS LIST 
               
             
          
           
               
                   
                 Part  
                   
               
               
                   
                 Number 
                 Description 
               
               
                   
                   
               
               
                   
                 10 
                 textile washing apparatus 
               
               
                   
                 11 
                 tunnel washer 
               
               
                   
                 12 
                 inlet end portion 
               
               
                   
                 13 
                 outlet end portion 
               
               
                   
                 14 
                 module 
               
               
                   
                 15 
                 module 
               
               
                   
                 16 
                 module 
               
               
                   
                 17 
                 module 
               
               
                   
                 18 
                 module 
               
               
                   
                 19 
                 hopper 
               
               
                   
                 20 
                 extractor 
               
               
                   
                 21 
                 flow line 
               
               
                   
                 22 
                 arrow 
               
               
                   
                 23 
                 arrow 
               
               
                   
                 24 
                 arrow 
               
               
                   
                 25 
                 flow line 
               
               
                   
                 25A 
                 arrow 
               
               
                   
                 25B 
                 arrow 
               
               
                   
                 25C 
                 arrow 
               
               
                   
                 26 
                 arrow-chemical addition 
               
               
                   
                 27 
                 arrow-chemical addition 
               
               
                   
                 27A 
                 arrow-chemical addition 
               
               
                   
                 28 
                 arrow-textile transfer 
               
               
                   
                 29 
                 spray rinse flow line 
               
               
                   
                 30 
                 arrow 
               
               
                   
                 31 
                 extractor water 
               
               
                   
                 32 
                 flow line 
               
               
                   
                 33 
                 outlet valve 
               
               
                   
                 34 
                 arrow 
               
               
                   
                 35 
                 module 
               
               
                   
                 36 
                 module 
               
               
                   
                 37 
                 module 
               
               
                   
                 38 
                 module 
               
               
                   
                 39 
                 module 
               
               
                   
                 40 
                 textile washing apparatus 
               
               
                   
                 41 
                 starch tank 
               
               
                   
                 42 
                 flow line 
               
               
                   
                 43 
                 fresh water tank 
               
               
                   
                 44 
                 valve 
               
               
                   
                 45 
                 valve 
               
               
                   
                 46 
                 valve 
               
               
                   
                 47 
                 valve 
               
               
                   
                 48 
                 valve 
               
               
                   
                 49 
                 flow line 
               
               
                   
                 50 
                 flow line 
               
               
                   
                 51 
                 extracted water tank 
               
               
                   
                 52 
                 starch recovery tank 
               
               
                   
                 53 
                 flow line 
               
               
                   
                 54 
                 pump 
               
               
                   
                 55 
                 chamber 
               
               
                   
                 56 
                 inlet 
               
               
                   
                 57 
                 drum 
               
               
                   
                 58 
                 cylindrical drum wall 
               
               
                   
                 59 
                 circular drum wall 
               
               
                   
                 60 
                 spray nozzle 
               
               
                   
                 61 
                 conduit 
               
               
                   
                 62 
                 influent end 
               
               
                   
                 63 
                 discharge end 
               
               
                   
                 64 
                 bore 
               
               
                   
                 65 
                 mounting plate 
               
               
                   
                 66 
                 opening 
               
               
                   
                 67 
                 nozzle tip 
               
               
                   
                 68 
                 atomizing water nozzle 
               
               
                   
                 69 
                 atomizing water nozzle 
               
               
                   
                 70 
                 nozzle outlet 
               
               
                   
                 71 
                 side plate 
               
               
                   
                 72 
                 side plate 
               
               
                   
                 73 
                 upper plate 
               
               
                   
                 74 
                 lower plate 
               
               
                   
                 75 
                 flow line 
               
               
                   
                 76 
                 spray pattern 
               
               
                   
                 77 
                 arrow 
               
               
                   
                 78 
                 drum moving mechanism 
               
               
                   
                 79 
                 chute 
               
               
                   
                   
               
             
          
         
       
     
     All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
     The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
A method of washing fabric articles in a tunnel washer includes moving the fabric articles from the intake of the washer to the discharge of the washer through first and second sectors that are a pre-wash zone. In the pre-wash zone, liquid is counter flowed in the wash interior along a flow path that is generally opposite the direction of travel of the fabric articles. The fabric articles are transferred to a main wash zone, and a washing chemical is added to the main wash zone. At about the same time, counter flow is reduced or stopped. The main wash zone can be heated as an option. After a period of time (for example, between about 20 and 120 seconds) counter flow is resumed or increased. In the wash zone, this is considered an intermediate rinse. After the wash zone(s), the increased counter flow after chemical treatment amounts to a pre-rinse. This pre-rinse ensures that the fabric articles are substantially free of soil or the majority of any soil and substantially free of chemicals when they are transferred to an extractor for final removal of excess water. A final rinse (second rinse) is conducted during extraction of excess water.