WO2007146201A1

WO2007146201A1 - Sodium bicarbonate vacuum bag inserts

Info

Publication number: WO2007146201A1
Application number: PCT/US2007/013641
Authority: WO
Inventors: Arnold Sepke
Original assignee: Electrolux Home Care Products, Ltd.
Priority date: 2006-06-09
Filing date: 2007-06-11
Publication date: 2007-12-21
Also published as: CN101528321A; GB0822198D0; GB2451412A; GB2451412B

Abstract

An odor neutralizer having a deodorizing sheet and one or more odor neutralizing agents associated with the deodorizing sheet. The deodorizing sheet is configured to have at least two generally facing surfaces having a space between them. The space extends along the sheet and forms an air passage through the odor neutralizer. In one variation, the deodorizing sheet may be folded along at least two folds, and the odor neutralizer further comprises a backing sheet to which the deodorizing sheet is attached at the at least two folds. In another variation, the odor neutralizer may have a housing that contains the deodorizing sheet, and the housing may have openings at each end of the air passage. In another variation, the deodorizing sheet may be formed in a generally spiral shape.

Description

SODIUM BICARBONATE VACUUM BAG INSERTS FIELD OF THE INVENTION

I The present invention relates to deodorizers, and in particular to deodorizing sheets, packets and other products. BACKGROUND OF THE INVENTION

' Many types of odor neutralizing and deodorizing devices are available for commercial and consumer cleaning needs. For example, aerosol sprays are well known in the art. In addition, some odor neutralizers comprise sodium bicarbonate to combat odors. One such neutralizer is described in U.S. Patent No. 4,624,366, which is incorporated herein by reference, which describes a container with porous sidewalls to allow an odor-absorbing chemical in the container to be exposed to odorous air. In another device, shown in U.S. Patent Application No. 11/417,167, which is incorporated herein by reference, sodium bicarbonate in various forms are described as being used to eliminate odors in conjunction with the operation of a vacuum cleaner.

A common problem with these and other odor neutralizing devices is that they are sometimes permanently attached to a device, such as a vacuum or vacuum bag, or are sometimes too bulky to be placed at the source of the odors. In view of this, there remains a need to provide improved or alternative methods and apparatuses for controlling odors in cleaning appliances.

SUMMARY OF THE INVENTION

, In one aspect, the present invention provides an odor neutralizer having a deodorizing sheet and one or more odor neutralizing agents associated with the deodorizing sheet. The deodorizing sheet is configured to have at least two generally facing surfaces having a space between them. The space extends along the sheet and forms an air passage through the odor neutralizer. In one variation, the deodorizing sheet may be folded along at least two folds, and the odor neutralizer further comprises a backing sheet to which the deodorizing sheet is attached at the at least two folds. In another variation, the odor neutralizer may have a housing that contains the deodorizing sheet, and the housing may have openings at each end of the air passage. In another variation, the deodorizing sheet may be formed in a generally spiral shape. i Other uses and variations on the foregoing will be apparent to one of ordinary skill in the art after studying the present disclosure and practicing the invention described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

¹ Figure 1 depicts a first embodiment of a chemical odor neutralizer of the present invention.

^! Figure 2 is a top plan view of the embodiment of Figure 1. Figure 3 is a side view of the embodiment of Figure 1.

, Figure 4 depicts a variation of the embodiment of Figure 1 having a peel-away liner and an adhesive strip.

, Figure 5 depicts a second embodiment of a chemical odor neutralizer of the present invention.

Figure 6 illustrates the embodiment of Figure 5 used in conjunction with a container typically associated with undesirable odors.

. Figure 7 depicts a third embodiment of a chemical odor neutralizer of the present invention and a possible use therefor.

Figure 8 A depicts a fourth embodiment of a chemical odor neutralizer of the present invention.

Figure 8B shows a variation of the embodiment of Figure 8 A. , Figure 8C shows another variation of the embodiment of Figure 8 A.

' Figure 8D illustrates a method of packaging the embodiment of Figure 8A or variations thereof.

Figure 9 A illustrates an embodiment of a chemically impregnated deodorizing sheet of the present invention.

Figure 9B illustrates an accompanying container for the embodiment of Figure 9A. Figure 9C illustrates the embodiment of Figure 9 A in the container of Figure 9B.

Figure 10 illustrates an embodiment of a chemically impregnated deodorizing sheet of the present invention used in conjunction with an animal bed. Figure 11 illustrates an embodiment of a chemically impregnated deodorizing sheet of the present invention used in conjunction with a vehicle cabin air filter. i Figure 12 is an embodiment of a method of manufacturing one embodiment of a chemically impregnated deodorizing sheet.

Figure 13 illustrates an example of a chemically impregnated sheet made from the process depicted in Figure 12.

Figure 14 is another embodiment of a method of manufacturing another embodiment of a chemically impregnated deodorizing sheet.

Figure 15 illustrates an example of an impregnated sheet made from the process depicted in Figure 14.

Figure 16 is an embodiment of a disk-shaped chemically impregnated article of the present invention.

Figure 17 illustrates an embodiment of a process that may be used to create the embodiment of Figure 16.

¹ Figure 18 is a variation of the embodiment of Figure 16. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides methods and apparatuses for neutralizing odors in common household items, such as laundry hampers, refuse containers and liners, refrigerators and freezers, animal beds and other areas associated with pets, and an automobile. The methods and apparatuses preferably use sodium bicarbonate, a non-toxic and non-irritating substance having the chemical formula NaHCO₃, and often referred to as baking soda. Sodium bicarbonate is a known compound, and is generally provided as a white, powdered substance, but it is also known to form it into a solid form or liquid slurry. It is in widespread use as a cooking additive, for acid reduction, and as a mild abrasive for cleaning. Sodium bicarbonate also acts as a deodorizer by neutralizing the acidic or basic components of odors and turning them into nonvolatile salts. Various commercial products have been developed to use sodium bicarbonate in refrigerators and on carpets to reduce odors produced by foods, pets, smoke, and other sources. An example of a product that is used for deodorizing carpets is sold under the name ARM SC HAMMER CARPET AND ROOM DEODORIZER, which is available from Church & Dwight Co., Inc., of Princeton, New Jersey. The forgoing product is generally deposited by hand on a carpet, and removed with a conventional vacuum cleaner. The present invention provides a number of alternative methods and apparatuses for depositing and using sodium bicarbonate or other deodorants. j Referring to Figures 1 — 4, in a first exemplary and non-limiting embodiment, the present invention provides an odor neutralizer 100 in the form of an air-pervious bag or sachet 102 filled withisodium bicarbonate chemical neutralizer and/or other odor neutralizers or fragrances. The sachet 102 may be used wherever odors are present or are expected to be.

, The sachet 102 may be formed from an air-permeable woven or nonwoven fabric or mesh- like material that is folded over a quantity of sodium bicarbonate, then bonded to itself by adhesives, ultrasonic bonding or other joining methods. Alternatively, the sachet 102 may be formed as two separate sheets that are bonded together. In addition, a portion of the sachet 102 may be formed from an air-impervious material, and it is also envisioned that a removable air- impervious material may be provided over the air-permeable portion of the sachet 102 to seal the sachet 102 when it is not in use.

¹ As shown, the sachet 102 may be provided as a strip of sachets 102 that are connected end-to-end and separated by perforations 108 that may be torn to release one or more sachets 102 for use. Such interconnected sachets 102 may be provided to the customer on a roll or folded and boxed. The user may then tear off one or more sachets 102 at a time as needed. Of course, in other embodiments, the sachets 102 may be provided separately or connected to one another in other ways.

. As shown in Figure 4, the sachet 102 may also be provided with an adhesive 104 along the length of one side by which the sachet 104 can be held in place at an endless variety of locations. A peel away liner 106 protects and preserves the adhesive 104 until the sachet 102 is ready for use. Other fastener devices, such as hook-and-loop fasteners (which typically have two similar or dissimilar elements, such as hook element and a loop element, that resiliently lock together), rigid hooks, openings to fit over hooks, or the like, may be used instead of the adhesive 104 to provide the sachet 102 with a fastener that allows it to be mounted in various locations. While a sachet structure may be preferred in some embodiments, it will be appreciated that in other embodiments the sachet 102 may be replaced by a sheet that is impregnated with the sodium bicarbonate odor neutralizer. Such an impregnated sheet may be provided in any of the forms described above with respect to the sachet 102 (for example, as a connected roll with perforations between individual sheets), and sachets and sheets are generally interchangeable in embodiments of the present invention described herein.

Referring to Figures 5 and 6, in another embodiment, the present invention may provide an odor neutralizer 200 in the form of a sodium bicarbonate chemical odor neutralizer impregnated sheet 202 that is attached to a backing 204, such as a paperboard or cardboard panel. The sheet 202 of this and other embodiments may be a gas-porous nonwoven material, but also may be a gas-impervious material, such as a plastic film. An example of a suitable deodorizing sheet and methods for making such a sheet are described in detail herein with reference to Figures 12-18, and such a sheet 202 may be replaced by one or more sachets containing deodorizing compounds. The sheet 202 is attached to the backing 204 at multiple locations to form a pleated or accordion fold geometry. The sheet 202 may be attached to the backing 204 by any suitable means known in the art, such as, for example, adhesives, stitches, or ultrasonic bonding. Any number of attachment patterns may be used, and in one embodiment the attachments to the backing 204 are generally parallel to one another to form one or more continuous tunnels between the sheet 202 and the backing 204. The pleated geometry provides a sheet 202 having a relatively large surface area for its attachment area (that is, the area required to attach the odor neutralizer 200 to a surface for use). This large surface area may improve the effectiveness of the odor neutralizer 200, which is generally dependent upon the total surface area of the sheet 202 that is exposed to the offending odors.

The odor neutralizer 200 may be used by itself, in any location, or in conjunction with a container 206, such as a laundry hamper or refuse container. Where the odor neutralizer 200 is intended to be used by itself, it may include an adhesive or other fastener to allow it to be mounted in a variety of locations. For example, the backing 204 may include an adhesive that is protected by liner, as shown in Figure 4. Where the odor neutralizer is intended to be used in a specific location, such as a laundry hamper 206, the location may include a receptacle to receive the odor neutralizer 200. The receptacle may be built into the location, or a receptacle may be provided with the odor neutralizer 200 to be attached to the location and used with a succession of odor neutralizers 200 as they periodically expire. Where the receptacle is built into the location, the receptacle can either be a purpose-made structure that is intended for use with the odor neutralizer 200, or it may be a preexisting structure at the location. An example of a preexisting structure is an automobile or household air vent to which the backing 204 may be attached by one or more clips.

Figure 6 illustrates the exemplary use of the embodiment of Figure 5 in the interior of a laundry hamper 206. Here, the hamper 206 comprises a pocket or clips (not shown) formed on an interior surface, such as the bottom of the container lid 208. In one example, the edges of the backing 204 extend past the edges of the impregnated sheet 202, and the pocket or clips hold and retain the odor neutralizer 200 by these extended edges. In another example, the odor neutralizer 200 is secured in place by clips that extend into and between the folds of the sheet 202 and secure the backing 204 at the exposed portions between the folds. Another variation to this embodiment comprises a backing 204 with adhesive, allowing the odor neutralizer 200 to be secured virtually anywhere.

Figure 7 illustrates another embodiment of an odor neutralizer 300 of the present invention. In this exemplary embodiment, the odor neutralizer 300 comprises a sodium bicarbonate impregnated sheet 302 or sachet that is inserted into a traditional garbage bag or trashcan liner 304. The sheet 302 may be attached to an interior surface of the liner 304 by any suitable means, such as adhesive attachment.

Referring to Figures 8 A - 8D, another exemplary embodiment of the present invention provides an odor neutralizer 400 in the form of a rolled sheet 402 or cylindrical column of material. In a preferred variation of this exemplary embodiment, the odor neutralizer comprises a sodium bicarbonate impregnated sheet 402 rolled to a generally spiral shape that forms a generally cylindrical overall shape. Preferably, one or more empty spaces 404 are provided between the turns 406 of the roll to provide a large exposed surface area of the odor-neutralizing sheet 402 in a compact volume. The spaces 404 may comprise one continuous space formed between facing adjacent portions of the sheet 402, or multiple separate spaces between the sheet layers. hi one exemplary embodiment, the sheet 402 may be formed from a rigid material that maintains a space 404 between the facing adjacent sheet surfaces, or the sheet 402 may be formed into a spiral shape then treated with adhesives or other materials to stiffen the sheet to hold it in this position. Alternatively, the sheet 402 may be joined to itself periodically to provide additional strength to hold the sheet in the desired spiral shape. In other embodiments, such as described below, additional supporting parts may be provided to hold the sheet 402 in shape.

Referring to specifically to Figures 8B and 8C, plastic end caps 408, 412 may be provided at the open ends of the cylindrical spiral sheet 400 to maintain the shape and spacing between the spiral turns 406. In these embodiments, the sheet 402 may be bonded or clipped to each end cap 408, 412 to help maintain the spacing and the shape of the device. Each end cap 408 comprises a plurality of openings that allow air to enter the internal space 404 created by the sheet 402, and thus increases the overall surface area of the sheet 402 that is exposed to odors. If needed, additional structural members, such as vertical supports 410, may also be provided to extend between the end caps 408, 412 to hold the structure together and in the proper shape. The end caps 408 may be shaped and sized simply to hold the sheet 402 in the desired shape, or they may be modified to adapt the odor neutralizer 400 for specific purposes or to provide specific benefits. For example, as shown in Figure 8C, the end caps 412 may be formed as square shapes that to allow the odor neutralizer 400 to lie on a flat surface without rolling. In other exemplary variations, the end caps 408, 412 may be shaped to connect to a tube in a vacuum cleaner or air cleaner exhaust that causes air flowing through the vacuum cleaner to pass through the open spaced 404, or an end cap 408, 412 may be formed with clips by which the odor neutralizer 400 can be attached to a household fan grille or to an air conditioning vent in a car.

While the shown embodiments illustrate the sheet 402 being formed as a cylindrical spiral, it will be understood that other spiral shapes may be used. For example, the sheet 402 may be formed with other labyrinthine overlapping patterns, with a simple accordion-like pleat, with square, rectangular or other rectilinear spiral patterns, and so on. Any of these overlapping shapes can, like the shown spiral shape, be formed with a space between some or all adjacent folds of the sheet. These overlapping shapes, or the shown spiral overlapping shape, are all expected to be suitable for use with the present invention.

As with other embodiments of the invention, the embodiment of Figures 8A-C can be packaged in any number of ways for distribution to customers. For example, in one embodiment, shown in Figure 8D, the odor neutralizer 400 may be packaged for use as a freezer or refrigerator odor neutralizer as a set of monthly refills. In such an embodiment, the odor neutralizer 400 may be marked 414 to indicate when it is intended to be used.

Referring now to Figures 9A - 9C, another embodiment of the present invention is a odor neutralizer 500 comprising a sodium bicarbonate impregnated sheet 502, provided with an accordion-folded or pleated geometry that fits within a box 504. The pleated sheet material 502 is shown in Figure 9A. It will be appreciated that the shown embodiment is exemplary, and in other embodiments, any number of pleats may be formed in the sheet 502, the sheet 502 may be replaced by sachets, and the pleated sheet 502 or satchets may instead by formed in a spiral shape, such as shown in Figure 8A₅ or in other overlapping shapes.

The box 504, encloses the sheet 502 (or sheets), and the sheet 502 maybe secured to the box by adhesives, fasteners, being captured in place, or by other means. The box 504 may also help preserve the sheet 502 in its desired shape. The box 504 may be square, as shown, or may have any other suitable profile shape. In the shown non-limiting embodiment, the box 504 is capable of fully-enclosing the sheet 502 to package and preserve the deodorizing sheet 502 before it is ready to be used. The box 504 has one or more walls 506 that can be opened to expose the sheet 502 to odorous air. Preferably, the box 504 has two opposing end walls 506 that are positioned at the ends of the pleated sheet 502, so that air can pass through the box 504 and across the entire surface area of the sheet 502. These end walls 506 may be provided as recloseable doors, tear-away walls, removable lids, or in other forms, as will be appreciated by those of ordinary skill in the art in view of the disclosures herein. The end walls 506 may also simply comprise openable grates or punch-out holes that extend through the outer wall of the box 504.

As with previous embodiments, the odor neutralizer 500 may be provided to the customer as individual packages, or as a set of replaceable packages, as shown in Figure 8D.

Referring now to Figure 10, another exemplary embodiment of the present invention may provide a deodorizing sheet or pad 600 that is intended to be used with an animal enclosure 604, such as a doghouse or cage, or a pet bed 602. Such a deodorizing sheet 600 may be sewn into a pet bed 602, inserted into a pocket in the pet bed 602, attached to the pet bed 602 by one or more fasteners, or simply placed under the pet bed 602 or under a pet bed cover 606. Alternatively, the deodorizing sheet 600 may be placed in or mounted in the animal enclosure 604. Thus, in this embodiment, the odor neutralizer sheet 600 may be placed close to a source of unwanted pet odors to help neutralize such odors at their source.

Referring now to Figure 11, another embodiment of the present invention provides a deodorizing sheet or pad 700 that may be used in conjunction with a vehicle cabin. For example, the invention may provide a pad 700 that comprises the cabin filter for a vehicle 702, or may be separate from, but usable with, the cabin filter for a vehicle. If separate from the filter, the pad 700 is held in close proximity to the filter, but preferably does not inhibit the flow of air through the filter. A variation of this embodiment provides sodium bicarbonate adhered to, painted, or printed on a conventional filter medium of any type. In this embodiment, the sodium bicarbonate is printed on the filter medium in strips or other patterns so that it does not unduly inhibit the airflow through the filter. Alternatively, the present invention may provide an odor neutralizer, such as those described previously herein, that may be mounted in the vehicle cabin separately from the vehicle air filter.

An exemplary embodiment for producing an impregnated sheet for use with the present invention is depicted in Figures 12 and 13. The exemplary sheet 1134 produced by this process comprises first and second sheets 1120, 1130 and a dry deodorizing mixture 1126. The deodorizing mixture 1126 comprises a blend of deodorant, adhesive, and other useful compounds, if desired. In a preferred embodiment, the deodorizing mixture 1126 is a deodorizer comprising of 91.5 wt. % (weight percentage) sodium bicarbonate, such as ARM & HAMMER™ baking soda (with grades 2 and 5 being particularly useful), 5.0 wt. % 11P23 hot melt adhesive manufactured by EMS Griltech of Sumter, SC ("GRILTEX™ hotmelt" — a heat-resistant, polymer-containing, solvent-free binder), and 3.5% wt. % MOLSIV™ Adsorbents Smell Rite® Zeolite manufactured by UOP L.L.C. of Des Plaines, IL (a synthetic sodium aluminum silicate with a zeolite structure that has been treated to be adsorptive of odoriferous compounds, and has organophilic micropores that attract and trap odor molecules). The deodorizing mixture 1126 may be mixed in a pre-cleaned ribbon mixer or other suitable high shear powder mixer for sufficient time to fully blend the chemicals.

Other useful compounds that may be used with the present invention include, but are not limited to, activated carbons, activated charcoal, diatomaceous earths, cyclodextrin, quaternary ammonium salts, silane quaternary ammonium salts, clays, fragrance oils, and the like. Suitable mixtures include, for example, about 50-100 wt. % (weight percentage) of sodium bicarbonate, about 0-10 wt. % of zeolites, about 0-20 wt. % of activated carbon, about 0-5 wt. % of quaternary ammonium salts, about 0-5 wt. % of silane quaternary ammonium salts and about 0-2 wt. % of fragrance oils. In a preferred embodiment, the adhesive may be provided as about 2-6 wt. % of the deodorant composition, but may alternatively be provided as about 5-15 wt. %, and more preferably about 5-10 wt. % to better adhere the deodorizing particles to the sheets and adhere the sheets to one another.

The first non-woven sheet 1120 preferably comprises a non-woven polyester sheet with a thickness of 1.88 mm. Such a sheet is sold as style PN 232 by the Precision Custom Coatings Company of Totowa, NJ. Other suitable sheet materials may have a thickness of about 0.05 to 6.00 mm and a basis weight of about 25 to 200 gsm (grams per square meter). More preferably, the first sheet 1120 is about 0.50 to 4.00 mm thick, or even more preferably about 1.00 to 3.00 mm thick. Suitable alternative materials include, for example, natural fibers, other synthetic fibers, or open cell foams. The sheet is provided as a roll 1121 (as shown), as separate sheets, or manufactured from raw materials on the manufacturing line itself. When provided in a roll 1121, the sheet 1120 may be passed through a sheet spreader 1122, which pulls the sheet 1120 laterally, to make the sheet taut. The sheet 1120 then passes under a sifter 1124, or other type of deposition device, such as a vibratory feeder, which deposits the sodium bicarbonate deodorizing mixture 1126 onto the sheet 1120. It has been found that a portion of the mixture 1126 sinks down into the thickness of the sheet 1120, but much of it remains at or near the sheet's surface.

The sheet 1120, with the deodorizing mixture 1126 sifted onto it, then passes through a curing oven 1128. Heating lamps, hot air, or any other suitable heat source may be used in the oven 1128. The oven 1128 heats the surface of the sheet 1120 to melt the hot melt adhesive in the mixture 1126 and thereby bind the sacrificial deodorizing elements of the deodorizing mixture 1126 to the sheet 1120. A suitable temperature for the process is a sheet surface temperature of about 100°F-300°F, and more preferably about 270⁰F or 280°F-300°F. The foregoing temperatures have been found to be suitable to bind the deodorizing compounds in place without damaging them or the sheet 1120, and without unduly coating the deodorizing compounds with adhesive. It will be understood that the temperature and length of time in the oven can be adjusted to obtain the most favorable coating of the hot melt adhesive on the deodorant components and the sheet 1120. Too much heat may result in damage to the sheet 1120 or deodorants, or may cause excessive coating of the deodorant by the adhesive. Too little heat may result in insufficient binding of the deodorant. Preferably, the sheet 1120 is exposed to the heat just long enough to obtain a surface temperature of about 270⁰F or 280⁰F to 300⁰F, but this target temperature may vary depending on the type of sheet material or amount or composition of the deodorizing mixture 1126. This target temperature can be varied by any suitable means, such as varying the line speed, oven length, oven temperature, and so on, as will be appreciated by those of ordinary skill in the art.

After the first sheet 1120 emerges from the oven 1128, a second sheet 1130 is laid on the first sheet 1120 to overlie the deodorizing mixture 1126. The second sheet 1130 is provided to help capture the deodorizing mixture 1126 in place and reduce the dustiness of the finished product 1134 but is air permeable to allow airflow to the deodorizing mixture 1126. In the preferred embodiment, the second sheet 1130 comprises a PES (polyethersulfone) and rayon scrim with a thickness of about 0.203 mm. The Precision Custom Coatings Company of Totowa, NJ, sells such a sheet as style PC 858. This second sheet 1130 is unwound from a roll 1135 and pressed onto the first sheet 1120 and deodorizing mixture 1126 after it emerges from the oven 1128, and while it is still warm. Rollers 1132 compress the two sheets together at a pressure of about 50-200 pounds per. square inch of pressure, and more preferably about 80 pounds per square inch. By applying the second sheet 1130 immediately downstream of the oven 1128, it can be held in place by the still-warm hot melt adhesive, an no additional adhesive is required. Of course, a separate adhesive may be used to supplement the hot melt adhesive, or if it is desired to apply the second sheet 1130 at a location where the hot melt adhesive in the deodorizing mixture 1126 is not longer warm.

As the adhesive cools, it adheres the two sheets 1120, 1130 and the deodorizing mixture 1126 together. The finished product 1134 is about 0.50-5.00 mm thick, and more preferably about 2 mm thick (with potential for significant variation caused by the handling process and due to variations in the sheets' starting thickness and processing), with 3 layers: the first sheet 1120, the deodorizing mixture 1126, and the second sheet 1130. Figure 13 depicts these 3 layers. It will be appreciated that, while Figure 13 shows the layers as being discrete, some intermingling may occur in practice, and up to 100% diffusion (i.e., uniform diffusion) of the deodorizing mixture 1126 into the first and/or second sheet 1120, 1130 may be accomplished and used with the invention, if desired. To obtain such high penetration, however, other manufacturing methods may be necessary. Examples of other suitable methods for impregnating a material to form sodium bicarbonate sheet are disclosed in U.S. Pat. Nos. 6,099,101, and 6,302,946, which are incorporated herein by reference.

The process ends with the final product 1134 being rolled onto a final roll 1135. This product 1134 may now be cut into various shapes and sizes and utilized as described herein, preferably, but not necessarily, with the second sheet 1130 facing inwards into the bag filter. The finished product 1134 is preferably cut with an ultrasonic, thermal, or other self-sealing process. A self-sealing process binds the layers of the sheet together at the cut, and thus ensures minimal loss of the deodorizing mix 1126 after cutting. If a self-sealing method is not employed, then the amount of deodorizing mix 1126 may be increased, preferably by about 5% to 10% to account for the losses that may occur in the manufacturing process, and/or the amount of adhesive may optionally be increased to about 5-15 wt. %, and more preferably to about 5-10 wt. % to ensure sealing of the sheets and adherence of the deodorizing composition.

The size of the finished sodium bicarbonate impregnated sheet will vary, depending on the amount of dirt that is expected to accumulate in the particular application in which the sheet is used. Larger sheets generally would be used when greater amounts of dirt are expected to accumulate. Deodorizing sheets made from the previously described process have been found to be effective in reducing the odor released from a vacuum cleaner when cut to sizes ranging from 16 in² to 40 in² and when used to replace a standard filter used in a bagless vacuum dustcup. Smaller sheets, as small as 2 in² or even smaller, may be effective in small handheld vacuums, and much larger sheets may be used in large-capacity shop vacuums and central vacuums. It is believed that in applications in which the sheet is used within a dirt container (as opposed to being outside the actual dirt container, as in the case of sheets used, for example, with post-motor filters) there is a directly proportional relationship between the size of the dirt container and the size of the sheet necessary to provide effective odor prevention.

A preferred embodiment, such as one that is preferred to be used with the embodiments of Figures 5 - 11, has approximately 10 ounces of deodorizing mixture 1126 per square yard of sheet, or 10 oz/yd². The amount of deodorizing mixture 1126 per square yard of sheet is determined by the following equation: _τ J I _j2 \ Spread Rateioz I min)

Loadioz yd J = ^-_{7 ;} v^— - - -. — r ^v ' Fabric Speed{yd I min)* Fabric Width{yd)

"Load" represents the amount of deodorizing mixture per square yard of sheet with 10 oz/yd² being the preferred amount. "Spread Rate," expressed in oz/min, represents the rate the deodorizing mixture 1126 is spread onto the non- woven sheet 1120. "Sheet Speed" is the linear speed the sheet 1120 passes under the sifter 1124, and is expressed in yd/min. Finally, "Sheet Width" is the lateral width of the sheet as expressed in yards. Given the equation above, one skilled in the art can determine the parameters required to deposit 10 oz of mixture 1126 onto 1 square yard of sheet. One embodiment provides a spread rate of 40 oz/min, which would require a sheet speed of 4 yds/min for a 1 yd wide sheet.

Referring now to Figures 14 and 15, another process to manufacture a chemically impregnated sheet that may be used with embodiments of the present invention is described. This embodiment starts with a roll 1241 of non-woven sheet 1240. The sheet 1240 first passes under a sifter 1224, which deposits an even layer of deodorizing mixture 1226 on the sheet 1240. In this embodiment, the deodorizing mixture 1226 includes sodium bicarbonate, a water soluble adhesive, and any other useful deodorants or fragrances, if desired. The sheet 1240 and deodorizing mixture 1226, then pass over a rotating cam 1244. The cam 1244 continuously rotates through 360° about an axis that is parallel to the plane of the sheet and perpendicular to the path of the sheet. The cam 1244 has one or more eccentric lobes that strike the sheet 1240 and impart vibrations thereto to work the mixture 1226 into the sheet 1240 fibers. The cam 1244 of Figure 15 has two lobes, and is shown in two different positions representing the two extremes through which the cam 1244 rotates. When the cam 1244 is in a first position, it is in light contact or out of contact with the sheet 1244. When the cam 1244 rotates to a second position, shown in phantom lines, it presses against and displaces the sheet 1240. Thus, as the cam 1244 rotates, it pushes the sheet up and down and generally creates a first order standing wave with stationary nodes located at the sheet rolls 1241, 1251 at each end of the process. Other embodiments may include more cams, cams having a varied number of lobes, cams with lobes of varying dimension, cams placed on top of the sheet, and cams with constant or variable rotational speeds. Pinch rollers may also be provided to isolate the vertical displacement caused by the cam 1244.

After the deodorizing mixture 1226 is applied to the sheet 1240 and agitated into the sheet 1240 by the cam 1244, the sheet 1240 and mixture 1226 pass under a hot water vapor mist 1246 or a warm water spray. The water or water vapor mist 1246 emulsifies the adhesive so that the adhesive bonds the sodium bicarbonate to the fibers of the non- woven sheet 1240. After being impregnated with sodium bicarbonate in this manner, the sheet 1240 passes into an oven (as shown above) or under a fan 1248, which may also have an air heating element, to evaporate excess moisture and dry the impregnated material. As the adhesive cools and dries, it bonds the deodorizing elements of the mixture 1226 to the sheet 1240 and creates an impregnated sheet designated as 1250. Sheet 1250 is collected onto a final roll 1251, and may now be cut into various shapes and sizes and utilized as described herein. A cross-section of the sheet 1250 is illustrated in Figure 15 with the mix 1226 dispersed within the sheet 1240.

It should be noted that in the foregoing embodiment, the hot water vapor step 1246, may be omitted if the operation of the cam 1244 is suitable to obtain the desired penetration of the mixture 1246 in the sheet 1240.

It will be understood that the foregoing embodiments are exemplary only, and variations of these embodiments and other embodiments will be apparent to those of ordinary skill in the art in light of the teachings provided herein. In addition, it may be possible to mix the steps of the two processes described herein. As an example, the rotating cam 1244 of Figures 14 and 15 may also be used with the embodiments of Figures 12 and 13. It will be understood that the foregoing depictions of manufacturing systems and procedures are not intended to be exclusive of other features and steps. For example, either of the foregoing embodiments may include additional features such as loose powder recovery systems, vacuum assisted particle penetration devices that draw a vacuum on one side of the sheet to pull the particles deeper into the sheet, accumulators, and so on.

Referring now to Figures 16-18, another embodiment of a chemically impregnated sheet that maybe used with embodiments of the invention is depicted as disk 1300. Disk 1300 is circular and formed from open cell foam, non- woven high loft fabric 1301, or other materials, and can be used in the same way as other sodium bicarbonate-impregnated sheets described herein.

To manufacture this embodiment, the disk 1300 is spun horizontally at a high rotational speed, while a sodium bicarbonate slurry 1302 is added to the disk center 1304, which is located at the vertical axis of rotation. The resulting centrifugal force slings the slurry away from the center 1304, as shown by the arrows, and distributes the slurry 1302 throughout the disk 1300. After the slurry 1302 is sufficiently distributed, the disk 1300 may be further spun to sling out excess water and assist with drying. Additional or alternative methods of drying the disk 1300 may include subjecting the disk 1300 to a heat source, forced-air convection, or a combination thereof.

The sodium bicarbonate and disk fabric 1301 may be colored differently to provide a distinctive and unique appearance. For example, the sodium bicarbonate may be dyed yellow, and the disk fabric 1301 colored white.

Referring to Figure IS, a variation of the embodiment of Figure 16, also may include activated carbon 1311. The activated carbon 1311 preferably is provided in a slurry 1312 and applied around the perimeter of the disk to create a distinctive and unique appearance. Alternatively, the activated carbon 1311 may be added to the sodium bicarbonate slurry 1302, or may be diffused, as described above, in a separate sheet disk and adhered to disk 1300.

Slurries 1302, 1312 may also be provided with a hot melt adhesive, similar to the hot melt adhesive contained in mix 1126. If a hot melt adhesive is provided, then it will also be necessary to subject disks 1300, 1310 to a heat source, such as a forced-air convection oven, to activate the adhesive. This heating process would be similar to the oven process 1148 shown and described in Figure 12 and accompanying text. Alternatively, the slurry may be heated before being applied.

Other methods will be readily apparent to those of ordinary skill in the art in view of the present disclosure, and such other methods are included within the scope of the invention. Non- limiting examples of such variations include forming the sodium bicarbonate sheet as a layered non-woven material having powdered sodium bicarbonate distributed between or within the layers, or coating a sheet with sodium bicarbonate on its exterior surfaces. Example 1

Tests were conducted using Eureka Model 402 vacuum cleaners. The Eureka Model 402 vacuum cleaners were bagless and contained a cone shaped filter within the dust cup. A control filter was compared to a treated filter. The control filter was a standard untreated filter. The treated filter contained the deodorizing device of the present invention.

The deodorizing device included the deodorizing composition disposed between two nonwoven gas porous materials. The deodorizing composition contained about 91.5% sodium bicarbonate, 3.5% zeolite and 5% adhesive (GRILTEX™) and was coated on a 6.25 in. x 6.25 in. size filter at a coating level of 8.7 oz/yd² , (0.19 g/in²). The first nonwoven material was a moldable polyester having a fabric weight of 3.2 oz/yd¹ (108.5 g/m²); tensile strength in the machine direction of 25 lbs; tensile strength in the cross-machine direction of about 75 lbs; and thickness of 74 mils (1.88 mm). The first nonwoven material served as the bottom layer of the deodorizing device and was a heavier sponge-like nonwoven material than the top layer. A suitable example of the first nonwoven material was obtained under the trade designation PN232 available from Precision Custom Coatings LLC, Totowa, NJ.

The second nonwoven material used herein was a hydrophilic PES/rayon having a fabric weight of 0.75 oz/yd² (25.4 g/m²); tensile strength in the machine direction of 10.8 lbs; tensile strength in the cross-machine direction of 0.5 lbs; and thickness of 8 mils (0.203 mm). The second nonwoven material served as the top layer of the deodorizing device. The second nonwoven material was a "scrim" that minimized dustiness of the product and allowed for good air flow. A suitable example of the second nonwoven material was obtained under the trade designation PC757, available from Precision Custom Coatings LLC, Totowa, NJ.

Each of the filtered dust cups was filled with soil that was enhanced to emit a noticeable household odor. The soil consisted of 50 grams of damp vacuum cleaner dust, 2.5 grams of cat urine (provided by Martin Creek Kennels, of Williford, AR), and 1.25 grams of Limburger cheese. The cat urine provided a strong, characteristic pet odor and the Limburger cheese imitated human body odor and strong kitchen odors.

The Eureka Model 402 machines were equally loaded with soils and allowed to sit for 4 hours, and then placed inside cleaned new 30 gallon plastic garbage cans. The cans were used to contain the air emitted from the exhaust of the vacuum. The plastic lids on the garbage cans had sniffing ports cut into them through which panelists could sample the air therein.

After the 4 hour gestation time, the lids were sealed and the vacuums were activated for 5 seconds. The air ejected in this 5 second period represents the most odorous air, usually encountered at machine startup. It was captured in the cans for panelists to sample.

Twenty panelists rated the two cans on a 0 to 6 scale for malodor. A rating of 0 represented the least odor, a rating of 6 represented the most odor. The following table shows the result from two separate trials:

In the test, the difference between the heated and control was statistically different at the 99% confidence level.

Example 2

Odor levels were measured in a sensory panel comparing a control sample to two treated samples. The odor studied in this test was 100 grams of damp vacuum cleaner dust. The tests were conducted by disposing the odors inside a 2 quart enclosed space.

The control sample had only the odor in the container. The two treated samples had the odors in the container and the deodorizing devices of the present invention where 7.4 grams of the deodorizing composition were loaded between two 6.25 in. square pieces of nonwoven material. The first "treated" sample contained 88% sodium bicarbonate, 7% Smellrite@, and 5% GRILTEX™ hotmelt on the nonwoven material. The second "treated" sample contained 91.5% sodium bicarbonate, 3.5% zeolite and 5% adhesive on the nonwoven material.

Eighteen panelists smelled the odor inside the 2-quart enclosed space and rated the smells on a 0 to 6 scale for malodor. A rating of 0 represented the least odor, a rating of 6 represented the most odor. The following table shows the result from the present test:

There was no statistically significant difference between the two samples and both of the treated samples had a statistically significant lower odor source than the control.

It should be understood that the foregoing embodiments are exemplary only, and other embodiments will be apparent to those of ordinary skill in the art in light of the teachings provided herein. Furthermore, while the foregoing description illustrates the use of various embodiments of odor neutralizers in various different uses, it will be understood that the embodiments and features of the embodiments may be used with one another and in different applications. Other variations will be apparent to those of ordinary skill in the art in view of the present disclosure and with practice of the invention.

Claims

We claim:

1. An odor neutralizer comprising: a deodorizing sheet; and one or more odor neutralizing agents associated with the deodorizing sheet; wherein the deodorizing sheet is configured to have at least two generally facing surfaces having a space between them, the space extending continuously along the sheet and forming an air passage through the odor neutralizer.

2. The odor neutralizer of claim 1, wherein the deodorizing sheet is folded along at least two folds, and the odor neutralizer further comprises a backing sheet to which the deodorizing sheet is attached at the at least two folds.

3. The odor neutralizer of claim 1, wherein the odor neutralizer further comprises a housing that contains the deodorizing sheet, the housing having a first opening located at one end of the air passage, and a second opening located at another end of the air passage.

4. The odor neutralizer of claim 1, wherein deodorizing sheet is formed in a generally spiral shape in which the sheet surface overlaps itself one or more times.

5. An odor neutralizer comprising: a backing sheet; a deodorizing sheet comprising one or more odor neutralizing agents, the deodorizing sheet being folded at two or more folds to form a plurality of pleats having a space between adjacent pleats, at least one of the spaces extending continuously along the sheet and forming an air passage through the odor neutralizer; and wherein the deodorizing sheet is attached to the backing sheet at at least two folds.

6. The odor neutralizer of claim 5, wherein the backing sheet comprises a fastener.

7. The odor neutralizer of claim 5, wherein the fastener comprises an adhesive or an element of a hook-and-loop fastener.

8. An odor neutralizer comprising: a deodorizing sheet comprising one or more odor neutralizing agents, the deodorizing sheet being folded at two or more folds to form a plurality of pleats having a space between adjacent pleats, at least one of the spaces extending continuously along the sheet and forming an air passage through the odor neutralizer; and a housing containing the deodorizing sheet and having a first opening at one end of the air passage, and a second opening located at another end of the air passage.

9. The odor neutralizer of claim 8, wherein the housing further comprises a first removable cover over the first opening, and a second removable cover over the second opening.

10. An odor neutralizer comprising: a deodorizing sheet comprising one or more odor neutralizing agents, the deodorizing sheet being formed in a generally spiral shape in which the sheet surface overlaps itself one or more times and has at least one space between overlapping portions of the sheet, at least one the spaces extending continuously along the sheet and forming an air passage through the odor neutralizer.

11. The odor neutralizer of claim 10, wherein the generally spiral shape has a generally cylindrical profile.

12. The odor neutralizer of claim 10, wherein the generally spiral shape has a generally rectilinear profile.

13. The odor neutralizer of claim 10, further comprising a first end cap attached to one end of the sheet adjacent a first end of the air passage, and a second end cap attached to the sheet adjacent a second end of the air passage, and wherein the first and second end caps each comprise at least one opening through which air moving along the air passage can pass.

14. The odor neutralizer of claim 13, wherein the first and second end caps contribute to maintain the sheet in the generally spiral shape.

15. The odor neutralizer of any of the foregoing claims, wherein the deodorizing sheet comprises a gas-porous fabric material.

16. The odor neutralizer of any of the foregoing claims, wherein the deodorizing sheet comprises one or more non-woven sheets, and the one or more odor neutralizing agents are impregnated in the one or more non-woven sheets.

17. The odor neutralizer of any of the foregoing claims, wherein the deodorizing sheet comprises one or more sachets containing the one or more odor neutralizing agents.

IS. The odor neutralizer of any of the foregoing claims, wherein the one or more odor neutralizing agents comprise sodium bicarbonate. 19. The odor neutralizer of any of the foregoing claims, wherein the one or more odor neutralizing agents consist of sodium bicarbonate.