Air freshener
10723051 ยท 2020-07-28
Assignee
Inventors
- Frank M. Lesniak (Media, PA, US)
- Kyle Brandenburg (Middletown, DE, US)
- John R. Hickman (North Canton, OH, US)
Cpc classification
B29C45/0003
PERFORMING OPERATIONS; TRANSPORTING
A61L2209/15
HUMAN NECESSITIES
A01M29/12
HUMAN NECESSITIES
B29C45/0001
PERFORMING OPERATIONS; TRANSPORTING
B29C45/16
PERFORMING OPERATIONS; TRANSPORTING
A01M1/2055
HUMAN NECESSITIES
B29C45/2737
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C45/16
PERFORMING OPERATIONS; TRANSPORTING
A61L9/04
HUMAN NECESSITIES
A01M29/12
HUMAN NECESSITIES
B29C45/27
PERFORMING OPERATIONS; TRANSPORTING
B29C45/18
PERFORMING OPERATIONS; TRANSPORTING
B29C45/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An air freshener has a rigidifying core defining a central axis, and an outer portion or sleeve contacting the core that is formed from one or more fragrance loaded polymers. Together, the core and outer portion are shaped to surround a first axis perpendicular to the central axis. The air freshener is made by injection molding a first shot of at least one polymer material to form the core, and injection molding a second shot of at least one polymer material incorporating one or more fragrance materials over or onto or into at least a portion of the core. The second shot of polymer material may be stretched about the portion of the core during injection molding, and may flow into a first hole formed in the core at or near the core distal end, and fills a second hole formed in the core at or near the core proximal end.
Claims
1. An air freshener, comprising: a core defining a proximal end, a distal end, a length between the proximal end and distal end, an upstanding inner wall, and a central axis along the length of said core of the air freshener, wherein the air freshener encircles an axis that is substantially perpendicular to the central axis; an I-beam strengthening section along the length of said core, with a first hole through the I-beam strengthening section at or near the distal end of the core, and with a second hole through the I-beam strengthening section at or near the proximal end of the core, said I-beam strengthening section comprising a flange spaced apart from the upstanding inner wall of the core by a web, said web defining a first trough between the upstanding inner wall of the core and the flange on one side of said web and defining a second trough opposite and below the first trough on an opposite side of said web between the upstanding inner wall of the core and the flange; a fragranced polymer covering the I-beam strengthening section, said fragranced polymer comprising at least one polymer incorporating one or more fragrance materials.
2. The air freshener of claim 1, wherein the upstanding inner wall begins at or near the proximal end and terminates at or near the distal end.
3. The air freshener of claim 1, wherein the I-beam strengthening section defines an apex and a reinforcement is provided at the apex.
4. The air freshener of claim 1, wherein the fragranced polymer is disposed over and around the flange and web of the I-beam strengthening section.
5. The air freshener of claim 1, wherein the fragranced polymer is disposed over the flange of the I-beam strengthening section, through the first hole and through the second hole.
6. The air freshener of claim 1, wherein the central axis is curved along at least a portion thereof.
7. The air freshener of claim 1, wherein the fragranced polymer is over-molded over the flange of the I-beam strengthening section.
8. The air freshener of claim 7, wherein the fragranced polymer forms a convexly curved outer sleeve of the air freshener.
9. The air freshener of claim 1, wherein the core has an interior section defining a plurality of ribbed channels that are disposed in a spaced apart relation in an array between a first side of the upstanding inner wall and an exterior wall.
10. The air freshener of claim 1, wherein the fragranced polymer comprises a polymer selected from the group consisting of: polyvinylchloride, polyethylene, low density polyethylene (LDPE), high density polyethylene (HDPE), thermoplastic elastomer (TPE), polypropylene, ethylene vinyl acetate, ethylene vinyl acetate copolymer, acetate, butyrate, propionate, silicone, copolymers thereof, and mixtures thereof.
11. The air freshener of claim 10, wherein the one or more fragrance materials comprise a fragrance material selected from the group consisting of: natural and synthetic fragrance oils, and mixtures thereof.
12. The air freshener of claim 1, wherein the core comprises a polymer selected from the group consisting of: polyvinylchloride, polyethylene, polyethylene terephthalate (PET), polyoxymethylene, polyamide (nylon), low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene, ethylene vinyl acetate, acrylonitrile butadiene styrene (ABS), styrene-acrylonitrile (SAN), rubber, thermoplastic elastomer (TPE), silicone, copolymers thereof, and mixtures thereof.
13. The air freshener of claim 1, wherein the proximal end terminates at a face surface, and the distal end terminates at a second face surface, and wherein the face surface of the proximal end and the second face surface of the distal end are juxtaposed in substantially facing relation to one another.
14. The air freshener of claim 13, wherein the face surface of the proximal end and the second face surface of the distal end are spaced apart from one another when the air freshener is in closed configuration.
15. The air freshener of claim 1, wherein the proximal end terminates at a face surface and the distal end terminates at a second face surface, and wherein the face surface of the proximal end and the second face surface of the distal end slidably interlock.
Description
DESCRIPTION OF THE FIGURES
(1) Numerous other objects, features and advantages of the invention shall become apparent upon reading the following detailed description taken in conjunction with the accompanying drawings, in which:
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
(25) With reference to the drawings in which like numerals designate similar elements, a first embodiment of an air freshener 10 is shown in
(26) In a preferred embodiment, the proximal end 14 and distal end 16 of the air freshener 10 have generally planar face surfaces 36, 38 that are juxtaposed in slightly spaced apart, facing relationship. However, all or some portions of the planar faces 36, 38 of each of the proximal end 14 and distal end 16 may abut or contact one another when the air freshener 10 is in its closed configuration. The air freshener 10 may form a clip, such that in its closed configuration it can be clipped to a receiving structure or mounting structure.
(27) Referring to
(28) The upstanding inner wall 18 of the air freshener 10 of the embodiment of
(29) The air freshener 10 defines a central axis along its length. Where the air freshener 10 is curved, such central axis is curved, and the air freshener 10 may form a curved shape, such as in the configuration of a tear drop as shown in
(30) The I-beam strength section 22 of the core 12 may have a reinforcement 44 at the apex 42 of the curved I-beam strength section 22. As shown in
(31) In this embodiment, an outer portion or sleeve 50 of fragranced polymer or fragranced polymer mixture is molded over (or over-molded over) a portion of the core 12. As shown in
(32) Alternatively, the I-beam strength section 22 may terminate at each end without having straps 26 and without forming the holes 30, 32. The outer portion or sleeve material (fragranced polymer or polymer mixture) may be over-molded over the core 12, in the same manner, but without locking around straps or into holes. In such embodiment, the sleeve material functions also to indicate when fragrance has depleted from the air freshener 10. The sleeve material shrinks as fragrance dissipates from the sleeve material polymer. Such shrinkage will be evident first at the proximal and distal ends of the air freshener, where the sleeve material may begin to pull away from such ends. In such embodiment, it is preferable that fragranced polymer outer portion 50 comprises a polymer or mixture of polymers different from that comprising the core 12, and the polymer materials do not chemically bind to one another and are not otherwise adhered to one another to permit the desired shrinkage or slippage.
(33) The core 12 may be molded from a polymer containing at least one resin selected from the group consisting of: polyvinylchlorides (PVC), polyethylenes (PE), polyethylene terephthalates (PET), polyoxymethylene (Delrin), polyamides (nylon), low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylenes, ethylene vinyl acetate, acrylonitrile butadiene styrene (ABS), and styrene-acrylonitrile (SAN), rubber, thermoplastic elastomer (TPE), silicone, copolymers thereof and mixtures thereof. The resin composition may be mixed, blended or compounded together optionally with additives known in the art and with one or more fragrance materials to form an injection-moldable mixture before injection molding. A preferred amount of resin to form the core is from 2 g to 100 g, more preferably 3 g to 20 g.
(34) The outer portion or sleeve 50 may be a different polymer resin from that selected for the body or core 12. The sleeve 50 may be over molded over the core 12 in a multiple shot molding process. In a multiple shot molding process, the core 12 is formed in a first molding step and the sleeve 50 is formed over the core 12 in a second or subsequent molding step. The core 12 and sleeve 50 may be molded by injection molding, particularly by valve gated hot runner injection molding as described in more detail below.
(35) The fragranced polymer or outer portion or sleeve 50 may be molded from at least one resin selected from the group consisting of: polyvinylchlorides (PVC), polyethylenes (PE), high density polyethylenes (HDPE), low density polyethylene (LDPE), polyvinylchoride (PVC), polypropylenes, ethylene vinyl acetate copolymers (EVA), such as ELVAX EVA ethylene vinyl acetate copolymer, thermoplastic elastomers (TPE), polypropylenes, acetate, butyrate and propionate, silicone, copolymers thereof, and mixtures thereof. The resin composition may be mixed, blended or compounded together with one or more fragrance materials and optionally with other additives known to those in the art to form an injection-moldable mixture before injection molding. A preferred amount of resin to form the fragranced polymer or outer portion or sleeve is from 2 g to 100 g, more preferably 3 to 20 g.
(36) A fragrance material may be any material that has a smell or odor. Most conventional fragrance materials are highly volatile essential oils. Even those which are less volatile contain highly volatile top note fractions which preferably are retained in the composition during processing to obtain desired fragrance power and olfactory impact by the resultant molded article. A fragrance material or a combination of fragrance materials that is compatible with the selected resin composition is preferred. The fragrance material may be a synthetically formed material or may be a naturally derived oil such as, but not limited to, the oil of Bergamot, Bitter Orange, Caraway, Cedar Leaf, Cedar Wood, Champacc, Cinnamon, Frankincense, Geranium, Lavender, Mimosa, Orange, Orignaum, Patchouli, Rosewood, Sandalwood, Vanilla, Violet, White Cedar, Ylang Ylang, Limonene, menthol, eucalyptus, camphor or the like. The particular essential oil or combination of oils to be used depends upon the particular fragrance desired for emission by the product formed.
(37) Alternatively or additionally, the fragrance material may comprise or act as a volatile insecticide and/or insecticidal synergist or attractant or repellant, such as pyrethrum, octenol, linalool, mint oil, or a bacteriostat or pheromone. Alternatively or additionally, the fragrance material may comprise or act as a vaporous remedy for respiratory conditions, such as a vapor to relieve symptoms of colds and allergies.
(38) Available fragrance materials are catalogued and described in references and databases known to persons skilled in the art. For example, a database is maintained by the Research Institute for Fragrance Materials at www.rifm.org. Fragrance material suppliers include Takasago International Corp. (Rockleigh, N.J.) and Symrise (Teterboro, N.J.). Exemplary synthetic fragrance materials are described in U.S. Pat. Nos. 4,411,829; 4,314,915 and 4,434,306. Preferred amounts of fragrance loading in resin are from about 5% to about 45% by weight of the resin.
(39) Colorants (such as pigments known for use with thermoplastic and thermoset resins) may be incorporated into the polymers to improve aesthetics. Examples of suitable colorants also include any water-based colorant such as food coloring, and Reactint polymeric colorant from Milliken Chemical (Spartanburg, S.C.).
(40) Other additives may be incorporated into the polymers as desired, including one or more plasticizers, one or more stabilizers, and optionally one or more lubricants.
(41) Preferably, the outer portion or sleeve 50 comprises a fragranced polymer that is loaded with a suitable amount of fragrance oil(s). More frequently, the polymer(s) forming the core 12 will not include fragrance oil(s). When the air freshener 10 is installed over a retaining structure, the core will contact the retaining structure surfaces. Preferably, when viewed in cross section, the core 12 comprises more than 180 of the exterior periphery of the air freshener 10. As such, only the core will contact the retaining structure surfaces. Then, such core 12 without fragrance oil(s) will not leach or dissipate fragrance oils onto the retaining structure surfaces. In some embodiments, however, the core 12 also may comprise a fragranced polymer that is loaded with a suitable amount of the same or different fragrance oil(s).
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(43) When the distal end of the valve member 106 is pressed against the seat portion 98 of the first hot runner block 88 as shown in
(44) The two molds 82 and 84 are closed and clamped together by a mold clamping device (not shown). Air pressure is supplied to a lower chamber of the cylinder chamber 86 of the fixed mold 82 so as to move the valve member 106 to the first hot runner-opening position which is somewhat above the illustrated position of the valve member. By doing so, the first hot runner 96 communicates with the cavity C. A first polymer shot 114 is then injected from the first sprue 94. The first polymer shot resin 114 passes through the first sprue 94, the first hot runner 96, and the gate G, and flows into the cavity C. The injection molding is carried out at a temperature above the Vicat softening temperature of the resin, and generally above 100 C., and under pressures commonly used in injection molding.
(45) When a predetermined amount of resin 114 has been injected, air pressure is supplied to an upper chamber of the cylinder chamber 86 so as to move the valve member 106 to the first hot runner-closing position. By doing so, the injection of the first polymer shot resin 114 is terminated. Slightly before, or simultaneously with, the end of the injection of the first polymer shot resin 114, a second shot polymer resin 120 is injected from the second sprue 100. The second shot polymer resin 120 passes through the second sprue 100, the second hot runner 102, and the gate C, and finally flows into the cavity C. After a predetermined amount of the second shot resin 120 has been injected, the process is finished. Accordingly, a molded product 130 having a core of second polymer and a sleeve of first polymer can be produced. Since the second shot polymer resin 120 can be injected successively after the injection of the first shot polymer resin 114, or vice versa, the resin flow never stops, and therefore, hesitation marks are not likely to develop on the surface of the molded product.
(46) The I-beam strengthening section 22 of the core 12 of the preferred embodiment air freshener 10 allows the second shot forming the outer portion or sleeve 50 to slide between the two attached ends to reduce internal stresses and reduce total part warpage.
(47) The gating locations 46 on the first shot polymer resin forming the core and the gating location 48 on the second shot polymer resin forming the sleeve are intended to use molecular orientation to help reduce total part warpage by better dimensional control as the air freshener 10 is injection molded.
(48) Referring next to
(49) In the preferred embodiments, the air freshener 10, 60 of the invention may generally have a thickness of about 1 cm, and a length of about 8 to 10 cm (as measured from the ends to the apex of the curved or rounded clip). The I-beam strength section has a length traversing the length of the core, and generally about 16 to 20 cm. The width of the I portion of the I-beam strength section is about 3 to 5 mm. The upstanding inner wall has a thickness of about 1 to 2 mm. The depth of the first trough is about 5 to 8 mm. The depth of the second trough is about 4 to 6 mm. The depth of the third trough is about 4 to 6 mm. The length of the straps is about 1 to 2 mm, the holes defined between the ends and the straps and the I-beam strength section have lengths of about 5 mm and heights of about 1 to 2 mm.
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(51) As shown in
(52) Twisting, flexing or pulling apart of the ends 14, 16 of the air freshener 10A, 60 is enhanced where the core and the fragranced polymer are formed of different polymers that do not chemically bind or adhere to one another. Some slippage between the polymers of the core and the fragranced polymer permits optimum bending to an open configuration and recovery or return to a closed configuration or substantially closed configuration.
(53) In one embodiment shown in
(54) In another embodiment according to the invention shown in
(55) In still another embodiment according to the invention shown in
(56) Referring to
(57) Alternatively, an air freshener according to the invention may be installed on a belt or on a belt loop or other clothing item and worn as a personal air freshening device. Such embodiment has particular appeal where the fragrance material comprises a volatile insecticide, or where the fragrance material comprises a cold or allergy vapor remedy.
EXAMPLE
(58) An example air freshener is formed as a clip of the embodiment of
(59) Air fresheners may be tested for fragrance character and fragrance strength using a fragrance panel test known in the fragrance industry. A sample air freshener product is suspended in a room with dimensions of 25 feet by 16 feet by 9 feet. A panel of at least four persons ranks the strength and character of the aroma emitted by the various air freshener products on a scale of 0 to 5, with 5 being the strongest and 5 being the closest in character to the fragrance oil. The fragrance power and fragrance character are observed over a four-week period. The fragrance power values are averaged, and the fragrance character values are averaged. Products that receive average rankings of 3 and above for the entire testing period are satisfactory for use as continuous action room air fresheners.
(60) Air fresheners may be tested for suitability and durability for use as air fresheners. For example, the air fresheners may be frozen for at least 12 hours and thawed over a repeated number of cycles (such as 3 cycles) to determine whether fragrance material exudes from the polymer upon thawing. Air fresheners may be heated to an elevated temperature of at least 120 F. and held for 4 weeks at such temperature, in packaging and outside of packaging, to determine whether fragrance exudes and whether fragrance strength and fragrance character degrade. Air fresheners may be exposed to ultraviolet light testing for at least 4 weeks to determine effect of light on product color and fragrance character.
(61) While preferred embodiments of the invention have been described and illustrated here, various changes, substitutions and modifications to the described embodiments will become apparent to those of ordinary skill in the art without thereby departing from the scope and spirit of the invention.