The present invention relates generally to a deodorizing substrate. More particularly, the present application involves a deodorizing substrate that is capable of removing undesired odors from an article. An associated method of manufacture is also provided.
The use of baking soda (sodium bicarbonate) as an odor absorbing agent is well known. Open boxes of baking soda have been used to control odor in refrigerators, cabinets and other enclosed spaces.
U.S. Pat. No. 5,046,604 to Forhetz et al. teaches an odor absorbing liner that uses pouches of odor absorbing particulates which are stitched between sheets in a quilt-type fashion. The odor absorbing particles are loose in the pouches and if substrate becomes torn, the particles can be released.
It is also know in the art to incorporate into a cellulose paper product sodium bicarbonate by adding the sodium bicarbonate into an aqueous suspension of paper making fibers as set forth in U.S. Pat. No. 7,462,260 to Spence et al. While the Spence et al. patent is directed to absorbing unpleasant odors inherent in the paper product when exposed to water, there is no teaching or suggestion of incorporating efficient sodium bicarbonate into a paper substrate that would allow the paper substrate to remove odors from adjacent articles in surrounding environment.
There remains room for variation and improvement in the art of deodorizing paper substrates that facilitate the deodorization of other articles.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figures in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention.
Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.
It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.
As used herein, terms “deodorizing substrate” and “deodorizing paper” refer to materials having a cellulosic content in which an effective deodorizing amount of sodium bicarbonate is present within the cellulosic fibers. The various embodiments described herein have been found useful for removing odors from articles and from the ambient environment. The substrates will work within a sealed environment for deodorizing an article. The substrates are also useful for removing odors from an article such as a shoe even when the shoe and deodorizing paper substrate are exposed to ambient conditions.
In accordance with one aspect of this invention, it has been found that applying a 10%-15% by volume of baking soda to a paper web, in an aqueous solution heated to about 110°-150° F., using a conventional paper size press can be used to form a paper substrate having between 3%-6% by weight of sodium bicarbonate present in the end paper substrate product. The 3%-6% loading levels are achieved using a single pass through a paper size press. Greater quantities of sodium bicarbonate up to about 12%-15% by weight can be achieved by using multiple passes through a size press, subsequent spraying of aqueous solutions and baking soda, or in combination with other application or production techniques as described herein.
The fiber content for the paper include a 83% softwood mix of Western North America species and 17% Maplewood hardwood fibers. The fibers were bleached to a brightness of 90. While the fiber content was useful for the development of a paper substrate having the indicated levels of baking soda incorporated therein, is believed that a wide variety of paper making fiber blends and content can be used including fiber content that may increase the ability of baking soda to be incorporated into the paper substrate.
Rolls of paper were manufactured having widths between 22 inches to 48 inches and basis weights ranging from 108# to 130# per 3000 square feet. Sodium bicarbonate was applied as an aqueous solution of 10% and 15% by volume at temperatures between 110° to 150° F. at the size press. For samples in which the cyclodextrin was added, 4% by volume loadings were used and also applied at the size press. Conventional sizing agents were also applied in the paper manufacturing process at loading levels of 2 pounds per ton. For samples where a 15% solution of baking soda was applied at the size press, the sizing agents were reduced by half.
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It is noted that 3%-6% levels of incorporation of sodium bicarbonate into the paper substrate may create a yellow discoloration and streaking to a bleached paper. While discoloration may be unsuitable for certain paper products, it has been found that the resulting paper substrate offers unexpected odor absorbing qualities. Further, the paper substrate lends itself to subsequent processing into a variety of useful particles adapted for use as a deodorizing article within a number of specialized environments.
The use of a size press to apply solutions or mixtures to a paper web are well known as set forth in U.S. Pat. Nos. 5,401,315, and 7,381,300 the disclosures of which are incorporated herein by reference for all purposes. As conventional within the art, a size press may be used to apply a coating to either one or both surfaces of a paper web. To the extent it is desirable to maximize the amount of sodium bicarbonate present in a resulting paper substrate, it is advantageous to coat both sides of a paper with the aqueous solution of sodium bicarbonate. As seen in reference to
Various basis weight papers may also be combined to form multi-ply sheets with one or more plies having been treated with sodium bicarbonate. The formation of multi-ply paper can be done using conventional ply forming techniques. Aqueous solutions of a poly-vinyl acetate adhesive have been found useful to laminate sheets of deodorizing paper. The use of an adhesive does not seem to impair the deodorizing capabilities of the paper. Multiple passes through a size press may also be used to increase the amount of sodium bicarbonate present within the paper substrate and additional amounts of sodium bicarbonate can be applied by spray application either during an on-line paper forming step or applied as a separate step during a converting process.
It is believed that when using a size press to apply the sodium bicarbonate, varying degrees of penetration of sodium bicarbonate into the thickness of the paper can be achieved depending upon the basis weight of the paper, paper thickness, moisture content of the paper fiber characteristics and the texture of the paper. It has been found that any conventional grade of baking soda may be used by the size press to apply the sodium bicarbonate. To the extent the sodium bicarbonate is dissolved, the initial particle size of the baking soda is not a critical factor other than the ease of dissolving the sodium bicarbonate within the aqueous solution. While the aqueous solution was frequently maintained at a temperature of 110° F. for safety reasons, increasing the temperature of an aqueous solution does increase the volume percent of baking soda that can be brought into the size press solution. Accordingly, the increased volume can be expected to increase both the amount of sodium bicarbonate applied in the sizing press step as well as the amount retained within the paper substrate.
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At the loading levels using a single pass of a size press which achieved a 6.12% by weight of sodium bicarbonate, the sodium bicarbonate substrates have been found highly resistant to the release of the sodium bicarbonate. Simple tests using paper substrates which are agitated by shaking or tapping the substrates against a hard surface released no discernable powder residue. Similarly, rubbing the sodium bicarbonate containing substrate against a dark fabric did not result in any visible transfer of residue from the substrate to the fabric. A similar analysis using hand sheets of paper having a 15% by weight of baking soda applied to the sheet exhibited similar properties of resistance to release of the sodium bicarbonate.
The sodium bicarbonate containing substrate has been found to have a synergistic effect on odor removal. Subjective smell tests have demonstrated that a given quantity of a sodium bicarbonate containing paper substrate is more effective at odor removal during a 65 hour interval than a similar amount of loose sodium bicarbonate.
It is further believed that the quantities of sodium bicarbonate which are incorporated within the various paper substrates described herein have additional functionality as an effective desiccant. The desiccant properties are believed to enhance the odor removal capabilities. Test results demonstrate that the sodium bicarbonate substrate will absorb significantly greater quantities of moisture than untreated control papers.
By way of an example, a hand sheet of a 175 gram per square meter of a creped paper having an addition of 15% sodium bicarbonate by weight, when exposed in a moist, odoriferous environment, had a weight change increase of 235% in comparison to a similar control paper exhibiting less than a 15% weight increase.
The desiccation properties are believed to further enhance the odor absorbing capabilities for many applications. Ambient moisture within an environment may serve as a vector for objectable odors. As such, as the sodium bicarbonate containing substrate attracts moistures, any odors contained within moisture are also drawn into the substrate, allowing the sodium bicarbonate to bind and neutralize such malodors. Further, by removing excess moisture, the low moisture conditions helps prevent bacteria from growing and producing odorous by-products.
Accordingly, the present invention envisions the inclusion of other desiccant materials besides sodium bicarbonate. The inclusion of other desiccants such as silica gel, dehydrated gels, clay, synthetic zeolite, calcium oxide and calcium sulfate can be utilized in the substrate to increase the odor absorbing qualities for the substrate by increasing the moisture absorbing qualities.
An additional advantage of the paper substrate containing sodium bicarbonate is the ability to also function as an anti-microbial product that also has a deodorizing function. Such a substrate is believed useful on low basis weight materials such as paper hand towels having a basis weight of between about 14 to 25 gsm. Incorporation of baking soda levels of between 3%-15% in a paper hand towel product provides a paper substrate that, following use, is resistant to the growth of bacteria. The pH buffering capabilities of baking soda within the paper are believed to alter the pH levels within a used paper towel product such that bacteria cannot grow on the substrate. As a result, potential contamination via soiled towels is greatly reduced. Further, to an extent the towels are placed into a waste receptacle such as a kitchen garbage can, the used towel will continue to have an odor absorbing ability to maintain a clean scent within the waste receptacle.
For many of the embodiments set forth herein, the sodium bicarbonate coated paper substrate can be formed of multiple paper plies. In some embodiments, all plies may contain sodium carbonate in comparable loading levels. It is also envisioned that the amount of sodium bicarbonate may vary with respect to the various plies depending upon the intended end use of the deodorizing substrate. For instance, for some applications it may be beneficial to have one or more plies which comprise a desiccant paper having silica gel or a similar material. Such papers, if included within a multiple-ply structure, would increase the desiccation properties of the overall structure and thereby increase the odor absorption ability of the deodorizing paper.
It is believed that the loading levels set forth herein of sodium bicarbonate within a paper substrate are novel and offer enhanced attributes not found or suggested within any prior combination of sodium bicarbonate and paper. As noted, the preferred levels of sodium bicarbonate present within the substrate may create a discoloration to a bleached paper. For many paper uses, such discoloration would be unacceptable for certain consumer end products. However, as set forth herein, the ability of paper to serve as a carrier for an odor reducing amount of sodium bicarbonate has great utility as a deodorizer.
While the application of sodium bicarbonate to the size press is one useful technique for forming the deodorizing substrate, is believed that other processes and methods can be used to provide an equivalent structure. For instance, incorporation of baking soda into a paper making slurry is possible as set forth in U.S. Pat. No. 7,462,260, assigned to Kimberly Clark Worldwide and which is incorporated herein by reference. The loading levels disclosed in the reference are believed to be significantly less than the amounts utilized in the present invention.
It is also possible to dispense sodium bicarbonate as a solution slurry to a paper web followed by subsequent drying and or optional crepeing steps. One such system is disclosed in U.S. Pat. No. 6,701,637 to Lindsay et al. and which is incorporated herein by reference.
Particles of baking soda can be applied as a powder coating unto a paper web having a coated substrate. As set forth in U.S. Pat. No. 6,355,330 to Koslow et al. and which is incorporated herein by reference, a pressure roller can be used to embed particulates into a softened coating surface present on the paper. While not a preferred method, it is believed that an equivalent substrate can be provided by such a method. Applicant's process of applying baking soda at the size press does not require any type of binder material to be utilized. Accordingly, Applicant's binder free application of sodium bicarbonate within deodorizing substrates and which avoids the undesired shedding or release of baking soda from the finished product is an improvement within the art.
The deodorizing substrates 10 or 12 seen in
The present invention provides for a deodorizing substrate. The deodorizing substrate 10 includes a plurality of deodorizing particles 20 that function to absorb, neutralize, or otherwise remove odiferous molecules associated with an item to improve the smell of the item. The deodorizing substrate 10 can be incorporated into a variety of deodorizing articles for use in specific environments.
Evaluation of the commercial grade papers having baking soda incorporated therein has indicated that the papers remain printable and can be scored and folded to various configurations without any perceived degradation of the standard paper qualities.
The deodorizing substrate 10 includes a plurality of deodorizing particles 20. The deodorizing particles 20 may be made of a variety of different materials. For example, in one exemplary embodiment the deodorizing particles 20 are made of sodium bicarbonate. Sodium bicarbonate is sometimes known as sodium hydrogen carbonate, sodium acid carbonate, baking soda, and bicarbonate of soda. In other exemplary embodiments, the deodorizing particles 20 can be potassium bicarbonate. In yet other arrangements, the deodorizing particles 20 may be cyclodextrin and/or zeolite. In still further embodiments, the deodorizing particles 20 may be a combination of sodium bicarbonate and potassium bicarbonate. The deodorizing particles 20 may be from 0.5-600 microns in size, from 6-150 microns, or from 25-50 microns with the majority being 40 microns in accordance with different exemplary embodiments. As noted earlier in the application, where the particulates are selected from sodium bicarbonate and applied to paper from a heated aqueous solution, the resulting coating layer does not form discrete particles.
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It has been found that when a two ply laminated shoe insert 300 incorporated therein a deodorizing amount of sodium bicarbonate 20 between the ranges of about 3% to about 6%, the insert is effective at deodorizing a shoe within 24 hours. The shoe insert 300 may optionally include a cyclodextrin 24 to further assist with deodorizing capabilities.
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A deodorizing substrate 10 or a deodorizing sheet of paper 12 as seen in reference to
It is readily understood and appreciated by those having ordinary skill in the art that to maintain the deodorizing properties of the paper base deodorizing substrates and products described herein are best packaged and stored in some type of air tight packaging until used. Air tight packaging prevent the loss of deodorizing capabilities brought about by exposure to the ambient environment.
While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.
This application claims the benefit of U.S. Application Ser. No. 61/311,664 filed on Mar. 8, 2010 and entitled, “Lint and Clothes Storage Apparatus and Process”. U.S. Application Ser. No. 61/311,664 is incorporated by reference herein in its entirety for all purposes.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US11/27583 | 3/8/2011 | WO | 00 | 9/6/2012 |
Number | Date | Country | |
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61311664 | Mar 2010 | US |