Substrate for volatile delivery systems

• US 20040151747A1
• Filed: 01/30/2003
• Published: 08/05/2004
• Est. Priority Date: 01/30/2003
• Status: Active Grant

• Current Assignee: SC Johnson & Son Incorporated
• Original Assignee: SC Johnson & Son Incorporated
• Inventors: Varanasi, Padma Prabodh, Davis, Brian T., Emmrich, Robert R., Fryan, Michael C., Strasser, Debra A., Welch, Kenneth J., Aulozzi, Michael J., Flashinski, Stanley J.
• Granted Patent: US 7,138,130 B2
• Time in Patent Office: Days
• US Class Current: 424/405
• CPC Class Codes: A01M 1/2077 using an electrical resistance as heat source A01M1/2083 takes precedence
• CPC Class Codes: A01M 1/2088 using a burner or a flame as heat source
• CPC Class Codes: A01N 2300/00 Combinations or mixtures of active ingredients covered by classes A01N27/00 - A01N65/48 with other active or formulation relevant ingredients, e.g. specific carrier materials or surfactants, covered by classes A01N25/00 - A01N65/48
• CPC Class Codes: A01N 25/18 Vapour or smoke emitting compositions with delayed or sustained release
• CPC Class Codes: A01N 25/34 Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group
• CPC Class Codes: A01N 53/00 Biocides, pest repellants or attractants, or plant growth regulators containing cyclopropane carboxylic acids or derivatives thereof
• CPC Class Codes: A61L 9/03 Apparatus therefor
• CPC Class Codes: A61L 9/037 comprising a wick
• CPC Class Codes: A61L 9/122 comprising a fan
• CPC Class Codes: A61L 9/127 comprising a wick
• CPC Class Codes: Y10S 424/10 Insect repellent
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]

Abstract

Volatile impregnated substrates, such as wicks and mats, that can be used in a dispensing device that uses a heat source or otherwise uses active means to promote the release of the volatile material from the substrate are disclosed. The preferred substrate has a structure including sand particles adhered together by a binder to form a network of pores and passages. The binder is selected from thermoset polymeric materials and mixtures thereof. A volatile material is disposed in the pores before the substrate is installed in the dispensing device. The impregnated substrate is positioned in the dispensing device on or near the heat source of the dispensing device. The heat source is activated thereby elevating the temperature of the substrate such that volatile material is released from the pores. In one embodiment, the sand particles comprise silica sand and the binder is a cured novolac resin.

Claims

12. A substrate for use in a volatile dispensing device that actively dispenses volatile material from the substrate, the volatile dispensing device having a slot through which the substrate can be inserted to load the substrate into the volatile dispensing device, the substrate comprising:

granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed; and

a volatile material disposed in the pores;

wherein the substrate is formed into a shape suitable for being inserted in the slot, and

wherein activation of the volatile dispensing device releases the volatile material from the pores, which volatile material is then dispensed.

13. The substrate of claim 12 wherein the volatile material comprises an insect control active ingredient initially deliverable by the dispenser at an insect controlling rate.

14. The substrate of claim 13 wherein no more than 10% residual volatile material remains in the pores when the dispenser has so depleted the volatile material as to no longer be able to deliver the volatile material at the insect controlling rate.

15. The substrate of claim 12 wherein the volatile material comprises an insect control active ingredient selected from the group consisting of natural pyrethrins, pyrethrum extract, synthetic pyrethroids, and mixtures thereof.

16. The substrate of claim 12 wherein the volatile material comprises an insect control active ingredient selected from the group consisting of transfluthrin, bioallethrin, prallethrin, pyrethrum extract, and mixtures thereof.

17. The substrate of claim 12 wherein the volatile material is essentially free of solvents when applied to the body.

18. The substrate of claim 17 wherein the volatile material comprises transfluthrin.

19. The substrate of claim 12 wherein the insect control active ingredient is released from the pores at a substantially linear rate when the volatile dispensing device releases the volatile material from the pores by heating the body.

20. The substrate of claim 12 wherein the body includes a keying structure that engages a portion of the dispensing device to secure the body in the dispensing device.

21. The substrate of claim 12 wherein the substrate includes a first volatile material disposed in the pores in a first region of the body and a second volatile material disposed in the pores in a second region of the body.

22. The substrate of claim 21 wherein the first volatile material vaporizes at a first temperature and the second volatile material vaporizes at a second temperature higher than the first temperature.

23. The substrate of claim 21 wherein the first volatile material and the second volatile material do not mix within the pores of the substrate.

24. The substrate of claim 12 wherein the dispenser supplies heat to a portion of the body less than the whole, and the body has heat transfer properties whereby heat applied to the portion of the body is transferred at a volatile-releasing rate to the remaining portions of the body.

25. The substrate of claim 12 wherein the substrate has different pore sizes and porosities at different regions of the body.

26. The substrate of claim 12 wherein the volatile material comprises a fragrance.

27. The substrate of claim 12 wherein:

the volatile material is released from the pores at an substantially linear rate until the action of the dispenser releases no more volatile material at an effective rate.

28. A method for delivering a volatile material from a dispensing device that uses a heat source to promote release of volatile materials from a wick designed to deliver a volatile liquid from a reservoir to a heated location within a heater wherein the volatile liquid can be heated and volatilized, the method comprising the steps of:

a. providing, as a replacement for the combination of a conventional wick and reservoir, a substrate comprising;

i. granular particles adhered together to form a body shaped to occupy the heated location within the heater, the body having no access to a liquid reservoir and having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed, the body being formed to occupy the heated location within the heater; and

ii. a volatile material disposed in the pores;

iii. wherein activation of the volatile dispensing device releases the volatile material from the pores, which volatile material is then dispensed; and

b. activating the heat source.

29. The method of claim 28 wherein the volatile material is an insect control active material that is dispensed at an insect controlling rate until no more than 10% residual volatile material remains in the pores.

30. A method for dispensing a volatile material from a heating device having an enclosed heating chamber designed to hold the a volatile-impregnated substrate therewithin, the heating chamber having chamber walls and being vented to the outside air;

a fuel burner; and

an air flow path to guide hot gases generated by the fuel burner past the substrate to heat the substrate and release the volatile material therefrom, the method comprising the steps of;

a. providing a substrate holdable by the enclosed heating chamber, the substrate having;

i. granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed; and

ii. the volatile material to be dispensed, disposed in the pores;

b. installing the substrate in the heating chamber; and

c. activating the fuel burner to release the volatile material from the pores, which volatile material is then dispensed.

31. The method of claim 30 wherein the volatile material is an insect control active material that is dispensed at an insect controlling rate until no more than 10% residual volatile material remains in the pores.

32. The method of claim 30 wherein the volatile material is transfluthrin.

33. A method for delivering a volatile-material from a dispensing device that uses a heat source to promote release of volatile materials from a substrate by application of heat from a heating surface, the method comprising the steps of:

a. providing a substrate of a size and shape selected to fit onto the heating surface, the substrate having;

i. granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed; and

ii. the volatile material to be dispensed, disposed in the pores;

b. installing the substrate on the heating surface; and

c. activating the dispensing device to cause the heating surface to heat to release the volatile material from the pores, which volatile material is then dispensed.

1. A substrate for use in a volatile dispensing device that actively dispenses volatile material from the substrate, the substrate comprising:

granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed; and

a volatile material disposed in the pores, the volatile material comprising an insect control active ingredient initially deliverable by the dispenser at an insect controlling rate;

wherein activation of the volatile dispensing device releases the volatile material from the pores, which volatile material is then dispensed, and

wherein no more than 10% residual volatile material remains in the pores when the dispenser has so depleted the volatile material as to no longer be able to deliver the volatile material at the insect controlling rate.

2. The substrate of claim 1 wherein the insect control active ingredient is selected from the group consisting of natural pyrethrins, pyrethrum extract, synthetic pyrethroids, and mixtures thereof.

3. The substrate of claim 1 wherein the insect control active ingredient is selected from the group consisting of transfluthrin, bioallethrin, prallethrin, pyrethrum extract, and mixtures thereof.

4. The substrate of claim 1 wherein the volatile material is essentially free of solvents when applied to the body.

5. The substrate of claim 1 wherein the insect control active ingredient is transfluthrin.

6. The substrate of claim 1 wherein the insect control active ingredient is released from the pores at a substantially linear rate when the volatile dispensing device releases the volatile material from the pores by heating the body.

7. The substrate of claim 1 wherein the body includes a keying structure that engages a portion of the dispensing device to secure the body in the dispensing device.

8. The substrate of claim 1 wherein the particles comprise sand.

9. The substrate of claim 1 wherein the binder is a phenolic resin.

10. The substrate of claim 1 wherein the dispenser supplies heat to a portion of the body less than the whole, and the body has heat transfer properties whereby heat applied to the portion of the body is transferred at a volatile-releasing rate to the remaining portions of the body.

11. The substrate of claim 1 formed into a flat slab suitable for use as a mat for dispensing volatiles from a volatile dispensing device that delivers heat to volatile-bearing mats.

34. The method of claim 33 wherein the volatile material is an insect control active material that is dispensed at an insect controlling rate until no more than 10% residual volatile material remains in the pores.

34-1. The method of claim 33 wherein the volatile material is transfluthrin.

35. A method for delivering a volatile material from a dispensing device that uses a heat source to promote release of volatile materials from a wick designed to deliver a volatile liquid from a reservoir to a heated location within a heater wherein the volatile liquid can be heated and volatilized, the method comprising the steps of:

a. providing, as a replacement for a conventional wick, a substrate comprising;

i. granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed, the body being formed to occupy the heated location within the heater; and

ii. a volatile material disposed in the pores;

iii. wherein activation of the volatile dispensing device releases the volatile material from the pores, which volatile material is then dispensed; and

b. activating the heat source.

36. A method for delivering a volatile material from a dispensing device that uses a heat source to promote release of volatile materials from a wick designed to deliver a volatile liquid from a reservoir to a heated location within a heater wherein the volatile liquid can be heated and volatilized, the method comprising the steps of:

a. providing as a volatile material in the liquid in the reservoir an insect control active ingredient selected from the group consisting of natural pyrethrins, pyrethrum extract, synthetic pyrethroids, and mixtures thereof;

b. providing as a wick a substrate comprising granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed, the body being formed to occupy the heated location within the heater, wherein activation of the volatile dispensing device releases the volatile material from the pores, which volatile material is then dispensed; and

c. activating the heat source.

37. The method of claim 36 wherein the insect control active ingredient is selected from the group consisting of natural pyrethrins, pyrethrum extract, and mixtures thereof.

38. A method for delivering a volatile material from a dispensing device that uses a moving air stream to promote release of volatile materials from a substrate held within the air stream, the method comprising the steps of:

a. providing a substrate of a size and shape selected to be held in the air stream, the substrate having;

i. granular particles adhered together to form a body having a network of pores and passages, the interior surfaces of which are non-reactive and non-absorptive with respect to the volatile material to be dispensed; and

ii. the volatile material to be dispensed, disposed in the pores;

b. installing the substrate in the air stream; and

c. activating the dispensing device to direct the air stream to the substrate to release the volatile material from the pores, which volatile material is then dispensed.

39. The method of claim 38 wherein the volatile material is an insect control active material that is dispensed at an insect controlling rate until no more than 10% residual volatile material remains in the pores.