U.S. patent application number 15/373010 was filed with the patent office on 2017-03-30 for air freshening device.
This patent application is currently assigned to Philip Morris USA Inc.. The applicant listed for this patent is Philip Morris USA Inc.. Invention is credited to Walter A. Nichols, Christopher S. Tucker.
Application Number | 20170087267 15/373010 |
Document ID | / |
Family ID | 43428652 |
Filed Date | 2017-03-30 |
United States Patent
Application |
20170087267 |
Kind Code |
A1 |
Tucker; Christopher S. ; et
al. |
March 30, 2017 |
AIR FRESHENING DEVICE
Abstract
An air freshening device includes a liquid supply operable to
supply liquid fragrance material, a wick in contact with the liquid
supply, a conductive mesh material operable to retain the liquid
material in interstices thereof, and a power supply operable to
apply voltage across the mesh material so as to heat the mesh
material and the liquid fragrance material contained in interstices
of the mesh material to a temperature sufficient to vaporize the
liquid. The air freshening device is operable to substantially
prevent deposition of the vaporized liquid material.
Inventors: |
Tucker; Christopher S.;
(Midlothian, VA) ; Nichols; Walter A.;
(Chesterfield, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Philip Morris USA Inc. |
Richmond |
VA |
US |
|
|
Assignee: |
Philip Morris USA Inc.
Richmond
VA
|
Family ID: |
43428652 |
Appl. No.: |
15/373010 |
Filed: |
December 8, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12903419 |
Oct 13, 2010 |
9526808 |
|
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15373010 |
|
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61251189 |
Oct 13, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01M 1/2077 20130101;
B05B 1/24 20130101; A61L 2209/135 20130101; A61L 9/037 20130101;
A61L 9/02 20130101; A61L 9/14 20130101; A61L 2209/11 20130101 |
International
Class: |
A61L 9/03 20060101
A61L009/03; B05B 1/24 20060101 B05B001/24; A61L 9/02 20060101
A61L009/02 |
Claims
1. An air freshening device comprising: a liquid supply; a wick in
contact with liquid in the liquid supply; a flat layer of
conductive mesh material operable to retain the liquid in
interstices thereof; and a power supply operable to apply voltage
across a heater comprising the conductive mesh material so as to
heat the liquid contained in interstices of the mesh material to a
temperature sufficient to vaporize the liquid.
2. The air freshening device of claim 1, wherein the conductive
mesh material comprises at least one material selected from the
group consisting of stainless steel, copper, copper alloys, porous
ceramic materials coated with film resistive material,
nickel-chromium alloys, and combinations thereof.
3. The air freshening device of claim 1, wherein the conductive
mesh material is about 200 to about 600 mesh.
4. The air freshening device of claim 1, wherein the conductive
mesh material is about 400 mesh.
5. The air freshening device of claim 1, wherein the conductive
mesh material is formed with 0.001 inch diameter wire.
6. The air freshening device of claim 1, wherein the wick comprises
at least one polymer.
7. The air freshening device of claim 6, wherein the wick comprises
a porous plastic wick.
8. The air freshening device of claim 1, further comprising a
capillary tube underlying the conductive mesh and having an inlet
and an outlet, said capillary tube operable to draw liquid from the
wick via capillary action and supplying the liquid to the
conductive mesh.
9. The air freshening device of claim 8, wherein the capillary tube
has an internal diameter of about 0.05 to 0.4 mm and a length of
about 5 mm to about 100 mm or about 10 mm to 40 mm.
10. The air freshening device of claim 8, wherein the capillary
tube comprises a stainless steel tube or a non-metallic tube.
11. The air freshening device of claim 1, wherein the heater
comprises a section of the conductive mesh material located between
two spaced apart electrical leads.
12. The air freshening device of claim 1, wherein the power supply
includes a supercapacitor that supplies an energy pulse to the
heater.
13. The air freshening device of claim 1, further comprising
control circuitry operable to apply voltage from the power supply
to the mesh in timed heating cycles such that the liquid material
is at least partially vaporized after filling of a liquid retention
zone of the mesh.
14. The air freshening device of claim 1, wherein the liquid
comprises an aqueous liquid fragrance material.
15. A method for generation of vaporized material comprising:
drawing liquid into a wick from a liquid supply; using the wick to
deliver the liquid into interstices of a flat layer of mesh
material; and periodically applying voltage across the mesh
material to heat the liquid in the interstices of the mesh material
to a temperature sufficient to heat the mesh material and at least
partially vaporize the liquid such that the liquid is driven out of
the interstices of the mesh material and forms a vaporized
material.
16. The method of claim 15, wherein the vaporized material forms an
aerosol having a substantially uniform particle size, and wherein
the aerosol has particles ranging in size from about 0.5 micron to
about 4 microns or about 1 micron to about 4 microns.
17. The method of claim 15, wherein the liquid is vaporized in less
than about 1 second via heating.
18. A method for repeated pulsed generation of vaporized material
comprising: a) generating vaporized material according to the
method of claim 15; b) cooling the mesh material; and c) repeating
steps a) and b).
19. The method of claim 18, comprising cooling the mesh material in
less than 10 seconds.
20. The method of claim 18, comprising generating vaporized
material every 2 to 100 seconds.
21. The method of claim 18, comprising generating vaporized
material at least once an hour.
22. The method of claim 18, comprising periodically applying
voltage from a supercapacitor to the mesh material.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of U.S.
patent application Ser. No. 12/903,419, filed Oct. 13, 2010 which
claims priority under 35 U.S.C. .sctn.119(e) to U.S. Provisional
Patent Application No. 61/251,189, filed Oct. 13, 2009, the entire
content of both are incorporated herein by reference.
SUMMARY
[0002] Provided is an air freshening device for generating a
substantially deposition free vapor. The air freshening device
includes a liquid supply operable to supply liquid material, a wick
in fluid communication with the liquid supply, a conductive mesh
material operable to retain the liquid material in interstices
thereof; and a power supply operable to apply voltage across the
mesh material, which acts as a heater, so as to heat the liquid
material contained in interstices of the mesh material to a
temperature sufficient to at least partially vaporize the liquid.
In an embodiment, the vapor at least partially condenses to form an
aerosol. The air freshening device is operable to substantially
prevent deposition of the vaporized liquid material.
[0003] The conductive mesh material comprises at least one material
selected from the group consisting of stainless steel, copper,
copper alloys, porous ceramic materials coated with film resistive
material, nickel-chromium alloys, and combinations thereof.
Preferably, the conductive mesh material is about 200 to about 600
mesh. Most preferably, the conductive mesh material is about 400
mesh. The conductive mesh material is preferably formed with 0.001
diameter wire and can comprise one or more layers of woven
wire.
[0004] Preferably, the wick comprises at least one polymer. Also
preferably, the wick comprises a porous plastic wick.
[0005] In a preferred embodiment, the air freshening device can
also include a capillary tube underlying the conductive mesh
material. The capillary tube includes an inlet end in fluid
communication with the wick, and an outlet end operable to deliver
liquid to the mesh material by capillary action or direct the
liquid material onto the mesh as a result of heating of the
capillary tube. Preferably, the capillary passage has an internal
diameter of about 0.05 mm to about 0.4 mm and a length of about 5
mm to about 100 mm, more preferably about 10 mm to about 40 mm. In
an embodiment, the capillary passage comprises the interior of a
stainless steel tube or the interior of a non-metallic tube.
[0006] In an embodiment, the power supply includes a supercapacitor
that supplies an energy pulse to the heater. The air freshening
device can also include control circuitry operable to deliver power
from the power supply to the mesh in timed heating cycles such that
the liquid material is at least partially vaporized after filling
interstices of the mesh.
[0007] Also provided is a method for generation of vaporized
material. The method includes drawing liquid material into a mesh
material, and periodically applying voltage across the mesh
material to rapidly heat the liquid material in interstices of the
mesh material to a temperature sufficient to at least partially
vaporize the liquid material such that the liquid material forms a
vaporized material. The method can also include drawing the liquid
material into a wick from a liquid supply, and drawing the liquid
material into the interstices of the mesh material from the
wick.
[0008] The method can also include a) generating vaporized
material, b) cooling the mesh material, and c) repeating steps a)
and b). Preferably, the mesh material is cooled in less than 10
seconds. Also preferably, vaporized material is generated about
every 2 to 100 seconds. In the preferred embodiment, vaporized
material is generated at least once an hour. The method can also
include periodically applying voltage to the heater from a
supercapacitor.
[0009] In an other embodiment, the method includes drawing liquid
material into a capillary tube, applying voltage to the capillary
tube to at least partially volatilize and expel the liquid
material, catching remaining liquid material in the mesh material,
and applying voltage to the mesh material to at least partially
vaporize the liquid material contained in interstices of the mesh
material by heating the liquid.
[0010] When formed, the vaporized liquid is discharged into ambient
air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an illustration of a first embodiment of an air
freshening device including a mesh material and a capillary
tube.
[0012] FIG. 2 is an enlarged view of the air freshening device of
FIG. 1 showing the capillary tube and mesh material.
[0013] FIG. 3 is an illustration of a first embodiment of a mesh
material.
[0014] FIG. 4 is an illustration of a second embodiment of a mesh
material.
[0015] FIG. 5 is an illustration of a third embodiment of a mesh
material.
[0016] FIG. 6 is an illustration of a second embodiment of an air
freshening device including a mesh material.
[0017] FIG. 7 is an illustration of a third embodiment of an air
freshening device including a mesh material.
[0018] FIGS. 8A, 8B and 8C are photographs showing the deposition
created by an air freshening device including only a capillary
tube, an air freshening device including a capillary tube and a
mesh as described herein, and an air freshening device including
only a mesh as described herein.
[0019] FIG. 9 is schematic of a first exemplary control circuit for
use with the air freshening device.
[0020] FIG. 10 is a schematic of a second exemplary control circuit
for use with the air freshening device.
DETAILED DESCRIPTION
[0021] Provided is a vapor and/or aerosol generator. Preferably,
the vapor and/or aerosol generator is an air freshening device for
generation of vaporized and/or aerosolized fragrance material. The
air freshening device is operable to substantially prevent
deposition of the vaporized liquid and provide a vapor and/or
aerosol having a substantially uniform particle size.
[0022] As shown in FIG. 1, in a first embodiment, the air
freshening device 100 includes a supply of liquid 10, a wick 20 in
contact with the supply of liquid 10, a capillary tube 40 in fluid
communication with the wick 20, a conductive mesh material 30 in
communication with the capillary tube 40, and a power supply 60
operable to apply voltage across the mesh material 30. The liquid
supply 10 is operable to supply liquid fragrance material to the
wick 20, which is in fluid communication with a capillary tube 40.
The capillary tube 40 underlies the mesh material 30 and transfers
at least some of the liquid from the wick 20 to the mesh material
30 after voltage is applied to the capillary tube 40 in an amount
sufficient to at least partially volatilize the liquid material
contained in the capillary tube 40, which acts as a first heater.
In a preferred embodiment, the capillary tube 40 contacts the mesh
material 30. Once the liquid 10 has been delivered to the mesh
material 30, the mesh material 30 retains the liquid material in
interstices 35 thereof. The power supply 60 is then operable to
rapidly heat the mesh material 30, which acts as a second heater.
The liquid is rapidly heated to above its boiling point and is then
released as a vapor. In an embodiment, the vapor at least partially
condenses to form an aerosol. Preferably, the liquid is heated in
less than about 1 second. Thus, the liquid material contained in
the interstices 35 of the mesh material 30 is heated to a
temperature sufficient to vaporize the liquid 10 once the mesh
material 30 is heated.
[0023] In the preferred embodiment, the mesh material 30 and the
capillary tube 40 are formed of conductive materials, and thus each
acts as a heater. Preferably, the capillary tube 40 is heated
before the mesh material 30 is heated. By heating the capillary
tube 40, at least part of the liquid is volatilized and the
remaining liquid is caught by the mesh material 30, which is then
heated to vaporize the remaining liquid material.
[0024] In the preferred embodiment, the mesh material 30 is formed
of a thermally and/or electrically conductive material. Suitable
materials for forming the mesh material 30 are selected from the
group consisting of stainless steel, copper, copper alloys, porous
ceramic materials coated with film resistive material, Inconel.RTM.
available from Special Metals Corporation, which is a
nickel-chromium alloy, Nichrome.RTM., which is also a
nickel-chromium alloy, and combinations thereof.
[0025] In use, once the capillary tube 40 is heated, the liquid
material contained within a heated portion of the capillary tube 40
is volatilized and ejected out of the outlet 42. Any remaining
liquid is propelled into the mesh material 30, where it is held in
the interstices 35 of the mesh material 30. To prevent breakthrough
of the liquid through the mesh material 30, a film 55 can be added
to a top portion 45 of the mesh material 30. Voltage can then be
applied to the mesh material 30 to rapidly heat the liquid 10 and
vaporize any liquid in the interstices 35 of the mesh material 30.
The vaporized material is released via an outlet 200 in the film
55, when present and on top of the mesh material 30, once pressure
from the expanding liquid 10 forces the vaporized material out of
the outlet 200. The outlet 200 can be positioned at an opening of
the film 55. Alternatively, the outlet 200 can be located at the
bottom of the mesh material 30. An enlarged view showing the
relationship of the capillary tube 40 to the mesh material 30 is
shown in FIG. 2.
[0026] In a preferred embodiment, a top portion 45 of the mesh
material 30 can be at least partially covered with a film 55, such
as a polyimide film. Suitable polyimide films include Kapton.RTM.,
which is available from DuPont. Preferably, the film 55 is a
non-porous film that prevents liquid material from breaking through
the film 55.
[0027] In an embodiment, the vaporized material formed as described
herein can at least partially condense to form an aerosol including
particles. Preferably, the particles contained in the vapor and/or
aerosol range in size from about 0.5 micron to about 4 microns,
preferably about 1 micron to about 4 microns. In the preferred
embodiment, the vapor and/or aerosol has particles of about 3.3
microns or less. Also preferably, the particles are substantially
uniform throughout the vapor and/or aerosol.
[0028] The particle size can be analyzed using a Spraytec.RTM.
detector having the following settings and conditions: a 300 mm
lens, a particulate refractive index of 1.40+0.00i, a dispersant
refractive index of 1.00, a path length of 25.4000 mm, a particle
density of 0.90 gm/cc, a mesh factor of 0%, a wavelength of 632.8
mm, a beam diameter of 10.00 mm and a transmission of
98.719543457%. When tested, the volume median diameter particle
values are as follows: dv(10) of about 0.198 micron (dv(10) is the
particle size below which 10% of the volume of particles exist),
dv(50) of about 0.598 micron (dv(50) is the particle size below
which 50% of the volume of particles exist) and dv(90) of about
3.300 microns (dv(90) is the particle size below which 90% of the
volume of particles exist).
[0029] In the preferred embodiment, the mesh material 30 can range
in size from about 200 mesh to about 600 mesh. In the preferred
embodiment, the mesh material 30 is about 400 mesh and includes
small voids/interstices 35 between the wires that form the mesh
material 30. Preferably, the mesh material 30 is formed with 0.001
inch diameter wire, such as wire available from Smallparts, Inc.
Preferably, the wire is solid and not hollow and/or tube-like. Also
preferably, the mesh material 30 has a criss-cross, checkerboard
type pattern with interstices 35 therein. In the preferred
embodiment, the mesh material 30 is a single, flat layer of mesh
material.
[0030] In the preferred embodiment, the mesh material 30 is formed
as a rectangle (shown in FIG. 3) having dimensions ranging from
about 2.0 mm to about 10 mm in width and about 15 mm to about 40 mm
in length. In the preferred embodiment, the mesh material 30 has
dimensions of about 2.75 mm in width and about 23 mm in length.
Preferably, the mesh material 30 achieves an electrical resistance
ranging from about 0.1 Ohm to about 50 Ohms, more preferably about
0.8 Ohm to about 2.5 Ohms. In the preferred embodiment, the mesh
material 30 has an electrical resistance of about 2.0 Ohms.
Preferably, the size of the mesh material 30, and thus the
interstices 35, will determine the amount of vaporized material
released therefrom.
[0031] The mesh material 30 can be formed having other geometries
as shown in FIGS. 4 and 5. As shown in FIG. 4, the mesh material 30
can be formed in a barbell type shape having ends 33 and a narrow
central region 31. As shown in FIG. 5, the mesh material 30 can be
formed in a trapezoid shape.
[0032] Not wishing to be bound by theory, it is believed that by
changing the geometry of the mesh material 30, the temperature
profile of the heater (mesh material) can be altered. Altering the
temperature profile of the heater can result in the use of less
energy for forming the vapor. For example, the rectangular shaped
mesh material 30 shown in FIG. 3 is substantially uniform in
temperature across the length and width of the heater. In contrast,
a barbell shaped mesh material 30, as shown in FIG. 4, is
configured such that the heating can be preferentially focused in
the central region 31, leaving the ends 33 of the mesh material 30
cooler. Thus, the barbell shaped mesh material 30 provides an
efficient heating system where heat is generated when the mesh
material 30 contacts the wick at a liquid retention zone 300 (shown
in FIG. 7), and thus where the liquid is contained in the
interstices 35 of the mesh material 30. The trapezoid shape of FIG.
5, can be used to provide a means for increasing the temperature
from right to left thereby allowing for release of a vapor over
time. By pairing different wick geometries with different heater
geometries, an efficient rapid heater design can be achieved.
[0033] Preferably, at least two electrical leads 50 are bonded to
the mesh material 30. In the preferred embodiment, the at least two
electrical leads 50 are brazed to the mesh material 30. Preferably,
one electrical lead 50 is brazed to a first end 101 of the mesh
material 30 and a second electrical lead 50 is brazed to a second
end 102 of the mesh material 30, as shown in FIGS. 6 and 7.
[0034] In a preferred embodiment, the wick 20 is submerged in the
supply of liquid 10. While the wick 20 can be made of a variety of
materials, porous plastic wicks are preferred. An example of a
porous plastic wick is a wick 20 composed of ultra high molecular
weight, high density polyethylene (HDPE). Such wicks 20 are
generally made of blends of HDPE in particle form, and the blends
are developed to meet the target pore characteristics of the wick
20. Preferably, the solubility parameter of the polymer is
significantly different from that of the liquid material, which
prevents the wick 20 from swelling or other changes that can lead
to a change in the pore size and porosity of the wick 20.
[0035] Preferably, the wick 20 is positioned so as to be remote
from the heat source so as to avoid damage to the wick 20. However,
in a preferred embodiment, the wick 20 contacts the mesh material
30. Also preferably, the wick 20 is cylindrical and has a diameter
of about 4 mm to about 5 mm. In the preferred embodiment, the
diameter of the wick is about 4.8 mm.
[0036] In the preferred embodiment, the supply of liquid 10
includes liquid fragrance material, which may be any suitable
liquid fragrance material that can be delivered to the mesh
material 30 and/or capillary tube 40 for generation of vapor and/or
aerosol. For example, the liquid material may be any commercially
available liquid material suitable for use in commercial vaporized
and/or aerosolized fragrance generators. The liquid material is
preferably aqueous based, alcohol based, such as, for example,
methanol, or propylene glycol based. In an alternative embodiment,
the air freshening device 100 can be used as a vapor and/or aerosol
generator for use with liquid supplies including, without
limitation, insecticides, disinfectants, deodorizers, lubricants,
fumigants, pest and weed control agents and combinations
thereof.
[0037] In an embodiment, as shown in FIG. 1, an inlet end 41 of a
capillary tube 40 contacts the wick 20 and transports the liquid
from the wick 20 through the capillary tube 40 by capillary action.
The capillary tube 40 preferably has an internal diameter of 0.01
to 10 mm, preferably 0.05 to 1 mm, and more preferably 0.05 to 0.4
mm. For example, the capillary tube can have an internal diameter
of about 0.05 mm. Capillary tubes having a smaller diameter are
more preferred due to the heat transfer to the fluid because the
shorter the distance to the center of the fluid the less the amount
of energy and time to vaporize. Alternatively, the capillary tube
has an internal cross sectional area of 8.times.10.sup.-5 to 80
mm.sup.2, preferably 0.002 to 0.8 mm.sup.2, more preferably 0.002
to 0.05 mm.sup.2. For example, the capillary tube can have an
internal cross sectional area of about 0.002 mm.sup.2.
[0038] The capillary tube 40 may have a length of about 5 mm to
about 100 mm, more preferably about 10 mm to about 40 mm, e.g.,
about 25 mm or about 50 mm. The capillary tube 40 preferably is a
stainless steel capillary tube 40, which serves as a second heater
via electrical leads 50 attached thereto for passage of direct or
alternating current along a length of the tube 40. Thus, the
stainless steel tube 40 is heated by resistance heating. The
stainless steel tube 40 is preferably circular in cross section.
The tube 40 may be of tubing suitable for use as a hypodermic
needle of various gauges. For example, a 32 gauge needle has an
internal diameter of 0.11 mm and a 26 gauge needle has an internal
diameter of 0.26 mm.
[0039] However, the capillary tube 40 may be any electrically
conductive material capable of being resistively heated, while
retaining the necessary structural integrity at the operating
temperatures experienced by the capillary tube 40, and which is
sufficiently non-reactive with the liquid material. Such materials
include, but are not limited to stainless steel, INCONEL, metal
composites, or other metals and alloys.
[0040] In an additional embodiment, the capillary tube 40 may be a
non-metallic tube such as, for example, a glass tube. In such an
embodiment, the heater is formed of a conductive material capable
of being resistively heated, such as, for example, stainless steel,
NICHROME or platinum wire, arranged along the glass tube. When the
heater arranged along the glass tube is heated, liquid material in
the capillary tube 40 is heated to a temperature sufficient to at
least partially volatilize liquid material in the capillary tube
40.
[0041] The power supply 60 for applying a voltage may include a
voltage source and at least two electrical leads 50 as described in
commonly assigned U.S. Patent Application Publication No.
2009/0194607, filed Aug. 28, 2008, the entire content of which is
incorporated herein by reference. At least two electrical leads 50
are connected to the mesh material 30 and at least two electrical
leads 50 are connected to the capillary tube 40. Preferably, the
capillary tube 40 includes a first voltage source and the mesh
material 30 includes a second voltage source. In one embodiment,
the voltage source can be a direct current battery. The battery can
be a rechargeable battery. In another embodiment, the voltage
source provides an alternating current. The air freshening device
100 can be connected to the voltage source in a tethered and/or
untethered manner. In the preferred embodiment, the electrical
leads 50 are attached to spaced apart locations along the mesh 30
and/or capillary tube 40 to supply power that resistively heats the
mesh material 30 and/or capillary tube 40. The capillary tube 40
and the mesh material 30 can be powered by the same or different
voltage source.
[0042] The power supply 60 preferably delivers a pulse of power to
the mesh material 30 and/or capillary tube 40 via the electrical
leads 50. The voltage chosen determines the amount of energy that
will be used to heat the mesh material 30 and/or capillary tube 40
in each pulse. The energy transferred to the mesh material 30
and/or capillary tube 40 from the voltage source is governed by
Ohm's Law.
V(voltage)=I(current)R(resistance) (1)
Power=VI=V.sup.2/R (2)
[0043] Preferably, the liquid supply 10 is vented. The liquid
supply 10 may include a wick 20 that delivers liquid material from
the liquid supply to the inlet of the capillary tube 40 via
capillary action. Preferably, the wick material contains numerous
pores, and these pores act as capillary passages, which cause the
liquid material to be drawn into them and then into an inlet of the
capillary tube 40.
[0044] Not wishing to be bound by theory, it is believed that
manipulation of parameters of the air freshening device, such as,
for example, the internal diameter of the capillary tube 40,
geometry of the wick 20 and/or mesh material 30 and/or heat
transfer characteristics of the material defining the capillary
tube 40 and/or mesh material 30, can be selected to control heater
temperature and mass median particle diameter. Furthermore, choice
of the liquid material can affect heater temperature and mass
median particle diameter of the vaporized material.
[0045] The air freshening device 100 may be a small portable device
including a power supply 60 in the form of a battery. In a second
embodiment, the power supply 60 may be an alternating current (AC)
source, such as an AC outlet and the air freshening device can
include a converter if desired to convert the AC to direct current
supplied to the heater. The air freshening device 100 may be
operated by control circuitry 70 (shown in FIGS. 6 and 7) operable
to deliver power from the power supply 60 to the heater (mesh
material 30 and/or capillary tube 40) in timed heating cycles.
Thus, the control circuitry 70 controls the application and/or
frequency of voltage across the mesh material 30 and/or capillary
tube 40 in order to vaporize the liquid material.
[0046] The control circuitry 70 may automatically control the
frequency of repeated pulsed vaporization of liquid material.
Alternatively, the frequency of repeated pulsed generation of
vaporized material may be preset or manually set, with the control
circuitry 70 controlling generation of vaporized material according
to the preset or manually selected frequency. If desired, the
control circuitry 70/power supply 60 may include primary and/or
secondary cells, preferably primary cells, capacitors including
supercapacitors, charge pumps, and combinations thereof. Use of a
supercapacitor may extend battery life and/or allow for use of
fewer or smaller batteries.
[0047] It is desirable for an air freshening device 100 to produce
a particle size as small as possible. Stokes' Law predicts the
settling velocity of small spheres in fluid such as air or water.
The equation for Stokes' Law is: w=2(.rho..sub.p-.rho..sub.f)g
r.sup.2/9.mu. where w is the settling velocity, .rho. is density
(the subscripts p and f indicate particle and fluid respectively),
g is the acceleration due to gravity, r is the radius of the
particle and p is the dynamic viscosity of the fluid. Table 1 shows
the settling velocity in air for a series of particle sizes from
1-50 micron.
TABLE-US-00001 TABLE 1 Particle Size Diameter Settling Velocity
Micron cm/sec 1 0.003 5 0.07 10 0.3 50 7.4
[0048] During the power cycle, any tendency for liquid to be drawn
into the heated zone 90, including the capillary tube 40 and/or the
mesh material 30, is interrupted by the heating of liquid already
within the heated zone 90, and preferably sufficient energy is
applied along the heated portion of the capillary tube 40 and/or
mesh material 30 to fully evacuate the liquid along the heated zone
90 by conclusion of the power cycle. The requisite energy is
readily resolved by knowing the volume and therefore the mass of
liquid contained along the heated zone 90 of the capillary tube 40
and/or mesh material 30, the latent heat of that mass plus the
specific heat of the volume/mass, with the addition of
approximately 25% margin to accommodate variations and losses. Such
operation assures that the liquid is fully evacuated and does not
remain at any location along the heated zone 90 of the capillary
tube 40 and/or mesh material 30, so that feeding of liquid to the
heated zone 90 can resume after completion of the power cycle and
is not blocked. The time between power cycles is preferably greater
than the time required for capillary action to draw liquid from the
liquid supply 10 and refill the heated zone 90.
[0049] FIG. 9 is schematic of a basic 555 timer circuit for use
with the air freshening device 100. Two resistive potentiometers
(POT) are used to set the timing of the square wave pulse signal.
The signal is sent to a field-effect transistor (FET) that connects
the power supply to the heater. Alternatively, programmable
circuits, such as those described above can be used.
[0050] FIG. 10 is a schematic of exemplary control circuitry,
including a heater for the capillary tube and/or mesh material
("capillary" in FIG. 10) and electrical leads ("Caplry+" and
"Caplry-"). These leads can be attached at spaced apart locations
along a stainless steel capillary tube and/or mesh material in
which liquid material is heated by pulsing power through the leads.
While the control circuitry may be powered by one or more
batteries, such as AA cells, the control circuitry is powered by
one battery B. The control circuitry preferably comprises a master
power switch SW1, as well as a microcontroller U1, such as a
PIC12F675, manufactured by Microchip. The microcontroller U1 has
unutilized outputs 2, 3, 5, 7, which may be employed depending on
the complexity of the control circuitry. The timing of energizing
the heater of the air freshener is preferably set by an internal
clock of the microcontroller. For adjustable timing, a pushbutton
switch can be pressed one or more times to set the time interval
between vapor delivery. An indicator LED displaying information
such as the set time interval may also be controlled by the
microcontroller. The field effect transistor Q1, such as, for
example, Si4876, is used to switch power to the capillary heater
under control of the microcontroller. While energy can be directly
delivered to the heater by the battery, the control circuitry has a
power supply that includes a supercapacitor C1, which supplies
energy as an energy pulse to the capillary heater, i.e., the
supercapacitor discharges a pulse of energy to the heater
sufficient to volatilize liquid fragrance material in the capillary
tube and/or vaporize the liquid fragrance material mesh material.
The microcontroller U1 is preprogrammed or manually set for a
timing cycle whose duration is shorter than time required for the
supercapacitor C1 to recharge. Additional elements of the control
circuitry include a capacitor C2 and resistors R1, R2, R3, R4.
[0051] FIG. 6 shows a second embodiment of an air freshening device
100 including a mesh material 30 which forms both the wick 20 and a
heater. The mesh material 30 can form an L-shaped piece, with one
portion at least partially submerged in a liquid supply 10 and a
second portion perpendicular to the submerged portion and not in
contact with the liquid supply 10. Preferably, the mesh material is
flat, has a criss-cross pattern, and is about 400 mesh to about 600
mesh. The portion not in contact with the liquid supply 10 forms a
heated portion 204 operable to vaporize liquid material contained
in the interstices 35 of the mesh material 30. The submerged
portion forms an unheated portion 202 that acts as a wick to
transfer liquid 10 from the liquid supply to the heated portion
204. Liquid is contained in the interstices of the wick 20 and then
pushed into interstices of portions of the unheated portion 202 in
contact with the interstices of the unheated portion 202 containing
liquid. Liquid is then heated to a temperature sufficient to
vaporize the liquid contained in interstices 35 of the mesh
material 30. Electrical leads 50 are attached to the heated portion
204 of the mesh material 30 at a first end 101 and a second end 102
of the heated portion 204.
[0052] FIG. 7 shows a third embodiment of an air freshening device
100 including a mesh material 30 in contact with a wick 20, which
is submerged in a supply of liquid 10. Preferably, the mesh
material 30 is a single, thin layer of wire mesh that lays on top
of and contacts the tip of the wick 20. The mesh material 30 is
removable from the wick 20, and thus is not permanently connected
to or otherwise affixed to the wick 20. In other embodiments, the
mesh material 30 can be wrapped around the end of the wick 20
and/or the mesh material 30 can contact the top and sides of the
wick 20. Preferably, the wick 20 is a porous, polymeric wick as
described above. The mesh material 30 contacts the wick such that
the liquid is transferred to interstices 35 of the mesh material 30
where the mesh material 30 contacts the wick 20. Preferably,
capillary action is not used to draw liquid into the interstices 35
of the mesh material 30. Instead, the liquid is transferred to the
interstices by contact therewith. Electrical leads 50 are attached
to a first end 101 and a second end 102 of the mesh material 30. A
heated zone 90 is formed between the electrical leads 50 when
voltage is applied. The air freshening device 100 may be operated
by control circuitry 70 operable to deliver power from the power
supply to the heater. The power supply is operable to apply voltage
across the mesh so as to heat the liquid material contained in
interstices of the mesh material to a temperature sufficient to
vaporize the liquid. The vaporized material is then released
through an outlet on the top of the mesh.
[0053] In the preferred embodiment, the liquid contained in
interstices of the mesh material is vaporized in less than about 1
second, more preferably in less than about 0.5 second, and most
preferably in less than about 0.2 second.
[0054] The following examples are exemplary and are not meant to
limit any aspect of the embodiments disclosed herein.
Example 1
[0055] An air freshening device was formed including a mesh
material made of stainless steel wires having a diameter of about
0.001 inch. The mesh material has dimensions of about 2.75 mm by
about 23 mm so as to provide a heater that does not draw excessive
current and covers a majority of the top of a polymeric wick. The
mesh material has a theoretical resistance of about 0.793 Ohm and a
measured resistance of about 0.84 Ohm. On each end of the mesh
material, an electrical lead was brazed across the width of the
mesh material. The heater assembly was attached to a pulse width
modulation 555 timer circuit driven with 5 volts. The 555 timer
circuit was set to cycle on for 0.14 seconds, every 7 seconds. The
555 timer circuit output triggered a field effect transistor to
apply 5 volts across the heater. The heater was mounted on top of
the polymeric wick that extended into a reservoir of liquid
fragrance material. When the mesh heater contacted the top of the
wick, liquid drawn by capillary action to the of the top of the
wick filled the interstices of the mesh material that was in
contact with the wick. No capillary action moved liquid along the
length of the heater. The circuit was turned on and fragrance
output was measured at the end of an hour. The liquid fragrance
output was about 114 mg/hr.
[0056] The air freshening device output of Example 1 correlates
with the theoretical calculation of interstitial area of the heater
over the wick and a liquid film thickness within the interstices of
about 0.0015 inch. This correlation further supports that capillary
action is not occurring along the length of the mesh material. In
addition, no signs of degradation or melting of the wick was
observed.
[0057] Additionally provided is a method for generation of
vaporized material, which includes drawing liquid material into an
inlet 41 of a capillary tube 40 only via capillary action. Liquid
enters interstices 35 of the mesh material 30 by contacting the
mesh material 30 and the wick 20. The method also includes
periodically applying voltage across the mesh material 30 and
capillary tube 40 in a first embodiment, or to the mesh material 30
alone in a second embodiment, to heat liquid material in the mesh
material 30 and/or capillary tube 40 to a temperature sufficient to
at least partially vaporize the liquid material.
[0058] In the preferred embodiment, when both a capillary tube 40
and a mesh material 30 are used, liquid is drawn into the capillary
tube 40 by capillary action. Then, voltage is applied to the
capillary tube 40 to at least partially volatilize the liquid
material contained therein and expel the fragrance material from
the outlet 42 of the capillary tube and thus the device 100. Any
remaining liquid expelled along with the fragrance material is
caught by the mesh material 30 where the liquid is contained in
interstices 35 thereof. Then, voltage is applied to the mesh
material 30 to rapidly heat the mesh material 30 and cause the
liquid material caught by the mesh material 30 and contained in the
interstices 35 thereof to form a vapor. Thus, both the capillary
tube 40 and the mesh material 30 are heaters which have individual
circuits including two electrical leads and a power supply.
[0059] After the voltage is applied across a mesh and/or capillary
tube, the liquid material is vaporized and the mesh and/or
capillary tube cools and are refilled. The mesh and/or capillary
tube refill time is a function of the length of the mesh material
and/or length and diameter of the capillary tube as well as the
properties of the wick and liquid material. For example, for a 25
mm long, 0.15 mm internal diameter capillary tube, refill can occur
in less than 10 seconds. Once the capillary tube and/or mesh
material cools, more liquid material is drawn into the capillary
tube and interstices of the mesh material are filled with liquid
material where the mesh material contacts the wick. The control
circuitry can activate periodically to apply voltage across the
mesh and/or capillary tube to heat liquid material in the
interstices of the mesh and/or contained in the capillary tube.
Accordingly, a method for repeated pulsed generation of vaporized
material includes vaporizing liquid material, cooling the mesh
and/or capillary tube, and repeating the filling and vaporization
steps.
[0060] The frequency of repeated pulsed generation of vaporized
material is limited by the mesh and/or capillary tube refill time.
Thus, depending on the length of the mesh material and the length
and diameter of the capillary tube and the liquid material,
vaporized fragrance material may be generated as frequently as
every 2 to 100 seconds, perhaps at least once a minute, or less
frequently, such as, for example, at least once an hour or at least
once a day. In order for the mesh and/or capillary tube to be
effectively refilled, substantially all of the liquid material
contained in the mesh and/or capillary tube is driven out of the
mesh and/or capillary tube by heating, thus providing a
substantially dry mesh and/or capillary tube.
[0061] To determine the deposition of vaporized liquid material
product by the air freshening device of FIG. 1 and FIG. 2 as
compared to air freshening devices including only a capillary tube
and no mesh material, air freshening devices were prepared and
filled with the same liquid material. Then, each air freshening
device was heated every 15 seconds for about one hour. A piece of
thermal paper was placed under and at the outlet end of each air
freshening device. When exposed to liquid droplets, the thermal
paper shows a contrast in color where liquid has contacted the
thermal paper. The results are shown in FIG. 8A, FIG. 8B and FIG.
8C.
[0062] FIG. 8A shows substantial deposition of liquid material by
air freshening device including only a heated capillary tube and no
mesh material. FIG. 8B shows substantially less deposition by an
air freshening device including a heated capillary tube and heated
mesh material as compared to an air freshening device including
only a capillary tube. FIG. 8C shows the least deposition occurs as
a result of using an air freshening device including only a heated
mesh material without a heated capillary tube.
[0063] In this specification, the word "about" is often used in
connection with a numerical value to indicate that mathematical
precision of such value is not intended. Accordingly, it is
intended that where "about" is used with a numerical value, a
tolerance of 10% is contemplated for that numerical value.
[0064] Moreover, when the words "generally" and "substantially" are
used in connection with geometric shapes, it is intended that
precision of the geometric shape is not required but that latitude
for the shape is within the scope of the disclosure. When used with
geometric terms, the words "generally" and "substantially" are
intended to encompass not only features which meet the strict
definitions but also features which fairly approximate the strict
definitions.
[0065] While the foregoing describes in detail an apparatus and
method for forming a vaporized fragrance material, it will be
apparent to one skilled in the art that various changes and
modifications may be made to the disclosed apparatus and methods
and further that equivalents may be employed, which do not
materially depart from the spirit and scope of the invention.
Accordingly, all such changes, modifications, and equivalents that
fall within the spirit and scope of the invention as defined by the
appended claims are intended to be encompassed thereby.
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