Mat for dispensing volatile materials

Details Mat for dispensing volatile materials Mat for dispensing volatile materials

1999-05-07

2001-10-30

Copenheaver, Blaine (Department: 1772)

Fabric (woven, knitted, or nonwoven textile or cloth, etc.)

Coated or impregnated woven, knit, or nonwoven fabric which...

Coating or impregnation functions biologically

C428S308400, C392S386000, C392S390000, C392S391000

Reexamination Certificate

active

06309986

ABSTRACT:

CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
This invention relates to dispensing volatile materials such as pest control materials, including but not limited to insecticides and insect repellents, and fragrances. More particularly, it relates to volatile material-containing mats that are employed in conjunction with electrical, gas, flammable liquid, or wax-fueled heaters or other sources of heat. One type of electrical heater used for this purpose is sold by S.C. Johnson & Son, Inc. under the trademark FUYI VAPE™.
It is known in the art to impregnate a solid, porous cellulosic mat with a volatile material or to place a volatile material in a pan-like metal structure. These mats and pans are placed on heaters to cause the volatile material to vaporize into the atmosphere.
A problem with the metal pan-like structures is that for typical heaters they can cause a volatile material to be exposed to too much heat. This can cause the volatile to be used up too fast or be deteriorated or destroyed through thermal degradation.
The mats have similar problems and also have problems with respect to their being exposed to differing temperatures across a heater surface. Low-cost existing heaters often have hotter regions at certain points along their burner surface. The mats therefore can have uneven and inefficient vaporization.
The above problems are of increased concern for extended longevity products intended to be used for a week or more. Merely adding additional volatile to increase product capacity and longevity does not work well because prolonged exposure of volatiles to too high temperatures can degrade or destroy the volatile and because, with hot temperatures, a disproportionate amount of the volatile can be driven off initially, with an insufficient amount surviving to be released in useful amounts at a later time.
Another design consideration is that existing heaters, for safety and other reasons, often only accept slab-like inserts having a small cross-sectional shape, necessary to fit into a small heater loading port or opening. Thus, any solution to the extended longevity problem preferably takes into account size restrictions imposed by existing heaters.
Yet another critical design consideration is cost. Mats of this type are often used in countries that have very modest average annual incomes. To have much practical application in those countries, the mats must be inexpensive.
As such, it can be seen that a need exists for an improved volatile dispensing device.
BRIEF SUMMARY OF THE INVENTION
In one aspect, the invention provides a mat for dispensing volatile vapors when the mat is heated. The mat has a carrier layer having a solid carrier material with a volatile material placed therein, the carrier material being constructed and arranged so as to emit the volatile material when heated. There is also a first metal layer secured to a side of the carrier layer. Preferably the first metal layer is secured adhesively, although crimping, riveting, and other ways to attach two layers can be used and would fall within the spirit and scope of the invention. Unless a contrary result is specified, all layers secured to each other, as described herein, can be secured by any of these or equivalent ways of doing so, although adhesive attachment is generally preferred. When a side of the metal layer opposite the carrier material is heated, the metal layer distributes heat along itself and transmits heat to the carrier.
The volatile material is preferably an insecticide, insect repellent, developmental controller, or other insect control material. Alternatively, the volatile material may be a fragrance, deodorizer, or other air quality modifying material. The carrier material is preferably a cellulosic material.
In a second embodiment, the mat also has a non-metallic layer secured to a side of the first metal layer opposite the carrier layer. The non-metallic layer provides a temperature step down from the temperature of the heater to that experienced by the volatile material. Preferably, there is also a second metal layer secured to a side of the non-metallic layer opposite the first metal layer. This embodiment provides further temperature step down and distribution.
In still another embodiment the last layer most distant from the volatile material is a non-metallic layer, which then contacts the heater. This embodiment is particularly desirable for heaters that have poor temperature control.
In yet another embodiment the mat has a non-metallic layer with leg portions extending therefrom, preferably extending downwardly, away from the volatile material, and the mat also has a second metal layer adhesively secured to the legs opposite the first metal layer. By this arrangement, a cavity is provided between a portion of the non-metallic layer and the second metal layer. This embodiment is particularly desirable with respect to heaters that occasionally provide temperature spikes.
The mats of the present invention spread heat more uniformly across their surface, as well as reduce excess temperatures that may be developed from poorly controlled heaters or heaters designed for use with less temperature sensitive volatiles.
These and still other features and advantages of the present invention will be apparent from the description which follows. The following description is of the preferred embodiments. The claims should be looked to in order to understand the full scope of the invention.


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Patent Abstracts of Japan, Publication No. 63122603.
Database WPI, XP002147906.

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