Patent Application
20220025573
Not applicable.
The invention relates to a toy product, preferably a plush toy product, with antimicrobial properties that permit it to resist odors and stains even after repeated washings and a method for manufacturing the same.
Plush toy products are a staple of the toy industry and have been marketed and used by children for generations. One of the inherent problems with any toy product, particularly one that has a plush outer surface, is that it can become a collector of various bacteria and viruses which can then be spread to the users.
The parents of children, particularly during a pandemic, are particularly sensitive to this problem. Therefore, there is a need for such a plush toy product that has antimicrobial properties that permit it to resist odors and stains. Since these products are frequently washed or cleaned by the parents of the users, the plush product must be able to maintain its antimicrobial properties after repeated washings.
Manufacturers of toy products, particularly plush toy products, have attempted to address this problem in the past although most, if not all, have been unsuccessful. Some manufacturers have attempted to simply apply an antimicrobial agent to the finished products which quickly wore off during use and after an initial washing because it was not embedded in the matrix of the products. Other attempts failed because they were either ineffective to prevent microbial growth or, worse yet, because they were considered unsafe to the children who would be playing with the toy product. To be considered effective and safe, these products needed to pass both efficacy and safety tests.
Examples of such prior art attempts include, for example, WO0002636 (A1) for Sanitary Finished Stuffed/Plush Toy and its Manufacturing Method in which a finished stuffed/plush) toy is treated with an antibacterial chemical alter fabrication rather than during the manufacturing process.
See also JP2008065705A for Deodorant Stuffed Toy where, again, the antimicrobial agent is sprayed onto the finished toy product after manufacture and CN102500110A for Antibacterial Fabric for Plush Toy where, again, the antimicrobial agent is not introduced during the manufacturing process.
In U.S. Pat. No. 6,240,879 for an Amusement Articles Possessing Microbe-Inhibiting Properties, a pet toy product including microbe-inhibiting properties is taught and identifies a host of different microbe-inhibiting agents, many of which are banned by the FDA due, no doubt, to the fact that the intended use of the product is for domestic animals, not children.
The toy product of the present invention incorporates an antimicrobial agent that is introduced during the manufacturing process, to render the resultant product fresh, hypoallergenic, and resistant to stains and odors during use, even after repeated washings.
In a preferred embodiment, the toy product is a stuffed plush animal in which some or all of the yarn/fabric used in fabricating the toy product is treated with an antimicrobial agent during the knitting of the yarn to create the plush. While several different antimicrobial agents may be used, a preferred antimicrobial agent is a solution selected from the group consisting of silver nitrate, pyrithione zinc, 3-(trimethoxysilyl) propyl dimethyl octadecyl ammonium chloride, cupric ion, zinc oxide, dimethyl distearylammonium chloride, and polyhexamethylene guanidine hydrochloride and phosphate.
According to the method of the present invention, the antimicrobial agent is preferably introduced into a water tank after the weaving and dying step and prior to the creation of the plush fabric used for the top product.
The toy product of the present invention, preferably in the form of a stuffed plush animal, is made from a super soft, plush material that is treated with an antimicrobial agent during the manufacturing process to render it safe, stain-resistant, and washable up to as many as 10 to 20 industrial washings without losing its antimicrobial properties. Such a product is safe for both humans and pets. The product can similarly be used for other toys, gifts, and novelty products including, blankets, pillows, decorative pillows, travel products, seasonal products, pet toys, and baby products.
To achieve its antimicrobial properties, the yarns or fabric used in fabricating the plush animal are woven, dyed, and then treated with the antimicrobial agent followed by exposure to elevated temperatures to cure or otherwise set the antimicrobial agent. Polyester is the best material for accepting the antimicrobial treatment although cotton, acrylic, and nylon also have a good acceptance level. The resultant fabric can then be knitted or woven to form the plush toy. While the antimicrobial agent may be introduced during the dying process, it has been found that it is more commercially effective to add such antimicrobial agent after the dying process. Alternatively, the antimicrobial agent can be sprayed or coated on the fabric or yarn. The spraying process can be treated by brush, ordinary hand pressure sprinkler, air pressure spray gun, special spray machine, etc., and it does not need high-temperature baking and natural air drying at normal temperature.
The antimicrobial agents used herein are added in varying concentrations depending upon the specific antimicrobial agent selected. In almost all instances, they are diluted with water to achieve their desired effect. The specific antimicrobial agents used are generally effective in concentrations between 0.2% and 10%.
While several different antimicrobial agents may be used, it has been found that antimicrobial agents, including silver nitrate, silver chloride, and/or alkyl dimethyl benzyl ammonium chloride are particularly effective antimicrobial agents, preferably in combination with alkyl (50% C12, 30% C14, 17% C16, 3% C18) dimethyl benzyl ammonium chloride.
An antimicrobial solution of between about 0.2% and 0.6% silver nitrate mixed with between about 0.75% and 1.25% of alkyl (50% C12, 30% C14, 17% C16, 3% C18) Dimethyl Benzyl Ammonium Chloride is a very effective antimicrobial agent and may be used in concentrations of between about 1% and 10% when mixed with water. A particularly preferred concentration range is between about 3% and 5% when mixed with water.
Such silver nitrate antimicrobial agents are available commercially, including the commercial product known as SilverClear solution for the treatment of textiles which is marketed by TransTex Technologies of Montreal, Canada. It is supplied at a concentration of about 1% silver nitrate and Dimethyl Benzyl Ammonium Chloride. SilverClear does not contain any Substances of Very High Concerns (SVHC) as defined in Article 57 of the EU's REACH Regulation and as published by ECHA through Jun. 1, 2020.
Toy products treated with silver nitrate antimicrobial agents have demonstrated a significant anti-bacterial reduction with Staphylococcus aureus and Klebsiella pneumonia, typically above a 99% reduction in bacterial growth. More significantly, after 10 washes in a normal cycle and normal tumble dry cycle, the products retained a 95% reduction in bacterial growth with Staphylococcus aureus and 87.5% with Klebsiella pneumonia and passed all appropriate toy safety tests. See, for example, the test results in Example 1.
Another acceptable antimicrobial agent that may be used includes pyrithione zinc in concentrations between about 0.2% and about 10% and, preferably between about 1% and 3% when mixed with water. One particularly preferred pyrithione zinc antimicrobial agent is the commercial product known as Sanitized marketed by Sanitized AG of Burgdorf, Switzerland which is supplied at a concentration of about 30% pyrithione zinc.
Toy products treated with pyrithione zinc antimicrobial agents have demonstrated a 99% reduction in the growth of Staphylococcus aureus and Klebsiella pneumonia. More significantly, after 20 washes in a normal cycle and normal tumble dry cycle, the products retained a 99.9% reduction in bacterial with both Staphylococcus aureus and Klebsiella pneumonia and passed all appropriate toy safety tests. See, for example, the test results in Example 2.
Yet another acceptable antimicrobial agent that may be used is 3-(trimethoxysilyl) propyldimethyloctadecy ammonium chloride in concentrations between about 0.2% and about 10% and, preferably, in concentrations between about 2% and 3%. One particularly preferred 3-(trimethoxysilyl) propyldimethyloctadecy ammonium chloride antimicrobial agent is the commercial product known as Microban by Microban International Ltd. of Huntersville, N.C. Microban is supplied at a concentration of about 42% 3-(trimethoxysilyl) propyldimethyloctadecy ammonium chloride.
Toy products treated with 3-(trimethoxysilyl) propyldimethyloctadecy ammonium chloride antimicrobial agents have demonstrated a 99% reduction anti-bacterial with Staphylococcus aureus and a 97.7% reduction with Klebsiella pneumonia and it passed all appropriate toy safety tests. See, for example, the test results in Example 3.
Other possible antimicrobial agents that can be used include, for example, cupric ion, zinc oxide, dimethyl distearylammonium chloride, and polyhexamethylene guanidine hydrochloride and phosphate, preferably in concentrations between about 0.2% and about 10%. Products so tested under normal conditions reported a 99% reduction anti-bacterial with Staphylococcus aureus and Klebsiella pneumonia and passed all children's safety tests. See, for example, the actual test results in Examples 4 through 7.
The process of the present invention is best described in the flow chart of
A plush toy product was treated with the silver nitrate antimicrobial agent described herein was tested for both efficacy and safety. The efficacy test results were as follows: Sample Description:
Two (2) Group of Submitted Samples Said to be:
(A) Anti-Microbial Fabric in Black (After Washed)
(B) Anti-Microbial Fabric in Black
Standard: --
Buyer's Name: --
Color: --
Vendor: --
Manufacturer: --
Supplier: --
Style No./Name: --
P.O. No.: --
Ref.: Anti-microbial Fabric
Country of Origin: China
Goods Exported To: --
Date Rec′d/Test Started: Jul. 29, 2020
Date Final Information: Confirmed
Pre-treatment conditions: AATCC 135-2012, Test No. (1) (Ill) (Ai), Machine Wash At 105° F. With 1.8 kg Total Loading (Type I Bleach Cotton Ballast+Specimen) And 66±1 g of 1993 AATCC Standard Reference Detergent (Without Optical Brightener). Normal Cycle, Tumble Dry Normal, 10 washes.
Staphylococcus Aureus (ATCC 6538)
Klebsiella Pneumoneiae (ATCC 4352)
Sample Received condition: Sample in Closed Plastic Bag Reference Rating:
Anti-Microbial Activity of Immobilized Antimicrobial Agents Under Dynamic Contact Conditions with Reference to Standard Test Method ASTM E2149-13a
Escherichia coli (ATCC 25922)
The safety test results were as follows:
Sample Description:
Comment: The testing scope of the standard was not applicable to the submitted samples. However, the test results of the samples met the related requirements as stated in this report.
A plush toy product was treated with pyrithione zinc in amounts between about 0.2% and about 10% with the following results. The efficacy test results were as follows: Sample Description:
Tests Conducted (as requested by Applicant)
Staphylococcus Aurea (ATCC 6838)
Kiebsiella Pneumoniae (ATCC 4352)
The safety test results were as follows:
A plush toy product was treated with the 3-(trimethoxysilyl) propyldimethyloctadecy ammonium chloride antimicrobial agents described herein was tested for both efficacy and safety. The efficacy test results were as follows:
Staphylococcus aureus (ATCC 6538)
Klebsiella pneumoniae (ATCC 4352)
The safety test results were as follows:
A plush toy product was treated with a cupric ion antimicrobial agents described herein was tested for both efficacy and safety. The efficacy test results were as follows:
Staphylococcus aureus (ATCC 6538)
Klebsiella pneumoniae (ATCC 4362)
Comment:
The safety test results were as follows:
A plush toy product was treated with a zinc oxide antimicrobial agents described herein was tested for both efficacy and safety. The efficacy results were as follows:
Sterilization method: Autoclave before test
Result:
Staphylococcus aureus (ATCC 6538)
Klebsiella pneumoniae (ATCC 4362)
The safety test results were as follows:
A plush toy product was treated with Dimethyl Distearylammonium Chloride antimicrobial agents described herein was tested for both efficacy and safety. The efficacy tests and test results were as follows:
Sterilization method: Autoclave before test.
Staphylococcus aureus (ATCC 6538)
Klebsiella pneumoniae (ATCC 4362)
The safety test results were as follows:
A plush toy product was treated with Polyhexamethylene Guanidine Hydrochloride and Phosphate antimicrobial agents described herein was tested for both efficacy and safety. The efficacy test and test results were as follows:
Staphylococcus aureus (ATCC 6538)
Klebsiella pneumoniae (ATCC 4362)
The safety test and test results were as follows:
While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.
Particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed embodiments but also all equivalent ways of practicing or implementing the invention.
The above-detailed description of the embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
All of the above patents and applications and other references, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the invention.
Changes can be made to the invention in light of the above “Detailed Description.” While the above description details certain embodiments of the invention and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Therefore, implementation details may vary considerably while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated.
While certain aspects of the invention are presented below in certain claim forms, the inventor contemplates the various aspects of the invention in any number of claim forms. Accordingly, the inventors reserve the right to add additional claims after applying to pursue such additional claim forms for other aspects of the invention.
This application claims the benefit of U.S. Provisional Patent Application 63/054,615, filed on Jul. 21, 2020, and incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 63054615 | Jul 2020 | US |
| Child | 17128637 | US |
