U.S. patent application number 15/956079 was filed with the patent office on 2018-08-16 for impregnated odour control products and methods of making the same.
The applicant listed for this patent is Stewart Group Trading Inc.. Invention is credited to Philip P. Chow, Catherine Ciupa.
Application Number | 20180228164 15/956079 |
Document ID | / |
Family ID | 52691142 |
Filed Date | 2018-08-16 |
United States Patent
Application |
20180228164 |
Kind Code |
A1 |
Chow; Philip P. ; et
al. |
August 16, 2018 |
Impregnated Odour Control Products And Methods Of Making The
Same
Abstract
A product capable of controlling odours arising from organic
matter, and a method of making the product. The product comprises
an admixture of a moldable thermoplastic and a benign dormant
bacteria in a sporulated form, which admixture is formed by mixing
the benign dormant bacteria into the moldable thermoplastic when
the moldable thermoplastic is melted, and molding the admixture
into a molded product. The benign dormant bacteria are embedded
throughout the molded product, including being buried within a body
of the molded product and being presented on a surface of the
molded product. The benign dormant bacteria presented on the
surface of the molded product are activatable upon exposure of the
surface of the molded product to the organic matter, and the benign
activated bacteria digest the organic matter to control production
of offensive odours. Abrasive wear of the surface of the molded
product exposes fresh benign dormant bacteria buried in the body to
the surface for additional odour control.
Inventors: |
Chow; Philip P.; (Markham,
CA) ; Ciupa; Catherine; (Toronto, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Stewart Group Trading Inc. |
Markham |
|
CA |
|
|
Family ID: |
52691142 |
Appl. No.: |
15/956079 |
Filed: |
April 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14034109 |
Sep 23, 2013 |
9974311 |
|
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15956079 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 45/0001 20130101;
B29C 49/00 20130101; B29C 48/022 20190201; B29C 48/00 20190201;
A43B 1/0045 20130101; B29C 2049/001 20130101; A43B 13/04 20130101;
B29C 43/003 20130101; B29K 2105/0029 20130101; B29K 2023/083
20130101; B29K 2511/00 20130101; B29C 49/0005 20130101; A01N 63/00
20130101; B29K 2105/04 20130101; B29K 2105/0041 20130101; B29D 7/01
20130101; B29D 35/0009 20130101; B29B 7/34 20130101; B29D 35/122
20130101; B29K 2101/12 20130101; A01N 63/00 20130101; A01N 25/10
20130101; A01N 25/34 20130101; A01N 63/00 20130101 |
International
Class: |
A01N 63/00 20060101
A01N063/00; A01N 25/34 20060101 A01N025/34; A43B 1/00 20060101
A43B001/00; A43B 13/04 20060101 A43B013/04; B29B 7/34 20060101
B29B007/34; B29C 43/00 20060101 B29C043/00; B29C 45/00 20060101
B29C045/00; B29C 47/00 20060101 B29C047/00; B29D 35/00 20100101
B29D035/00; B29D 7/01 20060101 B29D007/01; A01N 25/10 20060101
A01N025/10; B29D 35/12 20100101 B29D035/12; B29C 49/00 20060101
B29C049/00 |
Claims
1. A footwear product adapted to control odors arising from organic
matter external to said footwear product, said footwear product
comprising: a self-supporting foam body sized and shaped to support
a person's foot, and defining a foot contacting surface; said
self-supporting foam body comprising a moldable thermoplastic and
sporulated benign dormant bacteria, said self-supporting foam body
being formed by melt-blending said moldable thermoplastic and said
sporulated benign dormant bacteria together, and molding said
melt-blend to form said self-supporting foam body; said sporulated
benign dormant bacteria being embedded throughout said
self-supporting foam body, including being buried within said
self-supporting foam body and being directly exposed on said foot
contacting surface; said sporulated benign dormant bacteria
directly exposed on said foot contacting surface being activatable
upon exposure of said foot contacting surface to said external
organic matter, wherein said activated benign bacteria digest said
external organic matter to control production of offensive odors,
without digesting said self-supporting foam body; and said
self-supporting foam body being adapted to allow abrasive wear of
said foot contacting surface by said person's foot during use of
said footwear product to expose fresh sporulated benign dormant
bacteria, buried within said self-supporting foam body, on said
foot contacting surface for additional odor control.
2. The footwear product according to claim 1, wherein said moldable
thermoplastic is a polyethylene, a polypropylene, a polyvinyl
chloride, a polyamide, an elastane, or a polystyrene.
3. The footwear product according to claim 1, wherein 10.sup.6 to
10.sup.16 of said sporulated benign dormant bacteria are present
per square inch of said foot contacting surface.
4. The footwear product according to claim 1, wherein said
self-supporting foam body is an open-cell foam, or a closed-cell
foam.
5. The footwear product according to claim 1, wherein said molding
comprises compression molding, injection molding, blow molding, or
extrusion molding.
6. The footwear product according to claim 1, wherein said
sporulated benign dormant bacteria comprises at least one strain of
the genus Bacillus.
7. The footwear product according to claim 6, wherein said
Bacillus, when activated, produces an enzyme to break down and
assist with said digesting of said external organic matter.
8. The footwear product according to claim 7, wherein said Bacillus
produces water and carbon dioxide as by-products of said break down
and digesting of said external organic matter.
9. The footwear product according to claim 7, wherein said Bacillus
returns back to a sporulated dormant state after said external
organic matter has been digested, and is re-activatable upon
exposure of said foot contacting surface to additional external
organic matter, wherein said re-activated benign bacteria digests
said additional external organic matter to control production of
offensive odors, without digesting said self-supporting foam
body.
10. The footwear product according to claim 7, wherein said
Bacillus comprises one or more of Bacillus megaterium, Bacillus
subtilis, Bacillus licheniformis, Bacillus cerus, Bacillus alvei,
Bacillus coagulans, Bacillus pumillus, Bacillus simplex, Bacillus
brevis, and Bacillus amyloliquefaciens.
11. The footwear product according to claim 1, wherein said
self-supporting foam body is an insole, or a footbed.
12. The footwear product according to claim 1, wherein said
external organic matter is a bodily fluid or organic waste, and
said bodily fluid or organic waste contains sufficient carbon,
nitrogen and moisture to activate said sporulated benign dormant
bacteria.
13. The footwear product according to claim 12, wherein said bodily
fluid is feces, urine, sweat, blood, saliva, or semen.
14. The footwear product according to claim 12, wherein said
organic waste is milk, wine, a soft drink, syrup, or an egg.
15. A textile product adapted to control offensive odors arising
from organic matter external to said textile product, said textile
product comprising: a fiber sized and shaped to be used in weaving,
knitting, or felting, and defining an external surface; said fiber
comprising a moldable thermoplastic and sporulated benign dormant
bacteria, said fiber being formed by melt-blending said moldable
thermoplastic and said sporulated benign dormant bacteria together,
and extruding said melt-blend into said fiber; said sporulated
benign dormant bacteria being embedded throughout said fiber,
including being buried within said fiber and being directly exposed
on said external surface; said sporulated benign dormant bacteria
exposed on said external surface being activatable upon exposure of
said external surface to said external organic matter, wherein said
activated benign bacteria digest said external organic matter to
control production of said offensive odors, without digesting said
fiber; and said fiber being adapted to allow abrasive wear of said
external surface during use of said textile product to expose fresh
sporulated benign dormant bacteria, buried within said fiber, on
said external surface for additional odor control.
16. The textile product according to claim 15, wherein said
moldable thermoplastic is a polyethylene, a polypropylene, a
polyvinyl chloride, a polyamide, an elastane, or a polystyrene.
17. The textile product according to claim 15, wherein said fiber
is a thread, or a yarn.
18. The textile product according to claim 17, which is bedding,
drapery, upholstery, a towel, an article of clothing, a floor
covering, a carpet, a carpet tile, a mat, or a rug.
19. The textile product as according to claim 15, comprising a
plurality of said fiber, wherein said plurality of said fiber are
woven, knitted, or felted together.
20. A method of making the footwear product according to claim 1,
comprising the steps of; a) melt-blending at a bacteria compatible
temperature range: i) said moldable thermoplastic; and ii) said
sporulated benign dormant bacteria; and b) molding the melt-blended
product of step (a) into said footwear product.
21. The method according to claim 20, wherein said sporulated
benign dormant bacteria comprises an aqueous carrier.
22. The method according to claim 20, wherein said sporulated
benign dormant bacteria comprises a dry powder carrier.
23. The method according to claim 22, wherein said dry powder
carrier comprises calcium carbonate, or sodium bicarbonate.
24. The method according to claim 20, wherein said molding step
comprises the steps of: kneading said melt-blend; rolling said
kneaded melt-blended product into a sheet; compressing said sheet;
heating said sheet; and compression molding said sheet.
25. The method according to claim 20, wherein said molding step
comprises injection molding, blow molding, or extrusion molding.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 14/034,109, filed Sep. 23, 2013, the entirety of which is
incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] Materials which are capable of controlling odour arising
from certain organic matter. More particularly, materials are
configured to control odours by using benign bacterial agents to
consume and digest the organic matter which can otherwise lead to
bad odours and to a method of manufacturing such odour control
materials. The effect of the odour control materials is long
lasting.
2. Description of the Prior Art
[0003] There are many instances where owing to deposits of organic
matter on surfaces, offensive odours can arise through the presence
of the organic matter and its decomposition. In fact, many
materials utilized in household applications are susceptible to
soiling by organic based material, which if allowed to remain, can
give rise to malodours.
[0004] Deposits of organic materials on surfaces may also give rise
to other concerns. Many of the organic materials, such as bodily
fluids like sweat, blood and saliva, organic waste such as feces
and urine, spilt food such as syrup and eggs, and beverages such as
milk, wine and soft drinks etc., are capable of supporting
bacterial growth. Some of the bacteria that may grow as a result of
a deposit of organic material may give rise to odour due to
decomposition and incomplete digestion of the organic material.
Some of the bacteria may also have the potential of causing disease
in persons exposed to them.
[0005] In order to control/reduce odours, there have been attempts
to reduce the number of bacteria present on surfaces by utilizing
various anti-microbial agents. See for example U.S. Pat. Nos.
4,110,504 and 5,024,840, which describe applying anti-microbial
agents to carpet in a manner similar to the way stain blockers are
applied to carpet. However, the use of antimicrobials raises
concerns such as the potential that some of the bacteria may become
resistant to effects of the antimicrobials, and the release of such
anti-microbials into the environment may have a detrimental effect
on the environment.
[0006] Many bacterial and fungal genera are known for use in odour
control due to their capability for producing enzymes that are
capable of breaking down organic material. Several such bacterial
genera such as Bacillus, Lactobacillus, Enterobacter,
Streptococcus, Nitrosomonas, Nitrobacter, Pseudomonas, Alcaligens
and Klebsiella amongst others are known for use in such
applications, with Bacillus and Lactobacillus sp. being the most
prevalent in use in various applications.
[0007] For example, European Patent Application No. 732,396
describes use of Bacillus sp. for odour control of feedstuffs used
in farming and JP Patent Application No. 7-031,668 describes its
use for odour control of toilets, shoe boxes and pet litter. Other
uses of Bacillus for odour control for baby diapers and wallpaper
are described in JP Patent Application Nos. 2-121,665 and 3-059,199
respectively. Preparations of sporulated Bacillus in a form
suitable for spraying or otherwise distributing on a deposit,
especially of pet urine and feces, on a carpet for controlling
odour are presently marketed by The Bramton Company of Dallas, Tex.
under the trademark OUTRIGHT. Once the deposit is deodorized, the
bacteria are depleted from the site or disposed of along with the
deodorized material. In the event of a new deposit of organic
material on the carpet, the treatment must be repeated.
[0008] U.S. Pat. Nos. 6,974,691 and 7,314,748 disclose methods for
controlling odour associated with spills of organic material which
involve applying to surfaces, including carpet, plastic and wood, a
preparation of dormant bacteria, which when activated are effective
to control odours. The dormant bacterial preparation is adhered to
the surface, such that when the treated surface is exposed to
organic material which can cause odours, the dormant bacteria are
capable of becoming active and digest the organic material.
[0009] Although, the methods described in the U.S. '691 and '748
patents are effective for surface treating fibrous materials,
including carpet, batting used for mattresses, pillows and pads, as
well as other relatively porous surfaces encountered in the
household or commercial environment, semiporous surfaces such as
wood and nonporous surfaces such as plastic, they are not effective
in treating non-fibrous materials that are subjected to surface
abrasion. Therefore, there remains a need to counteract the effects
of deposits of organic material, and especially for controlling
odour associated with the deposits, including in non-fibrous
materials such as thermoplastics, where the effects of the odour
control are preventative and long lasting, even in high wear
applications.
[0010] Other patent documents of general interest include: Canadian
Pat. Document Nos. 2,243,011 and 2,369,469; U.S. Pat. Nos.
3,636,927, 3,720,606, 3,720,606, 3,892,846, 3,941,090, 4,465,019,
4,607,594, 4,680,212, 4,704,989, 4,839,212, 4,844,010, 4,925,707,
4,946,672, 5,154,594, 5,683,575, 5,741,553, 5,863,882, 6,265,191,
6,325,934, 6,967,025, 7,507,402, 7,795,119; U.S. Pat. App. Pub.
Nos. 2003/0003138, 2003/0012810, 2003/0089381, 2003/0126688,
2008/0075794 and 2012/0114579; PCT Int'l Pat. App. Pub. Nos.
96/19611, 97/25865, 97/43385, 99/46350, 00/03752, 00/63338,
02/33035, 03/056096, 03/064755; European Pat. App. Pub. Nos.
0039522, 0076447, 0476915, 0878202, and 1096959; U.K. Pat. App.
Pub. No. 2362814; Japanese Pat. Document Nos. 5-153971, 7-222790,
and 9-28377; Czechoslovakian Pat. Document No. C5246119; and Soviet
Union Pat. Document No. SU1091889.
[0011] Other non-patent documents of general interest include:
[0012] Brochure for BI-CHEM.RTM. BIOCLEAN Carpet Cleaner; [0013]
Brochure for BI-CHEM.RTM. GC 600L; [0014] Brochure for BI-CHEM.RTM.
MSB 4X; [0015] Chemical Abstracts, vol. 108, No. 19, May 1998,
Abstract No. 169120y; XP002122802; [0016] CHEMICAL ABSTRACTS, vol.
108, no. 20, May 1998 (1998-05) Columbus, Ohio, US; abstract no.
169120y, XP002122802 & CS 246 119 A (DOSTAL JAROSLAV; VIEST
MIROSLAV) 16 Oct. 1986 (1986 Oct. 16); [0017] DATABASE WPI Section
Ch, Week 199715 Derwent Publications Ltd., London, GB; Class A97,
AN 1997-159089 XP002122803 & JP 09 028377 A (AZUMA K), 4 Feb.
1997 (1997 Feb. 4); [0018] Database WPI, Week 199329, Derwent
Publications Ltd., London, GB; An 1993-231489; XP002210738
Deodorise Supress Excretion Bad Smell Contain Bacillus Magaterium
Effect Range Malodorous Smell; [0019] Hans G. Schegel et al.,
General Microbiology, 7.sup.th ed., p. 83 (1993); [0020] Response
to Summons in Opposition by Novozymes Biologicals, Inc. in European
Patent No. 1 096 959 B1 with attached Declaration and Exhibits (139
pages) (August 2005); and [0021] XP002210738 Deodorise Supress
Excretion Bad Smell Contain Bacillus megaterium Effect Range
Malodorous Smell.
SUMMARY OF THE INVENTION
[0022] An object is to provide an improved product capable of
controlling odours arising from organic matter, and methods of
making the product.
[0023] This object and others are provided by a molded (i.e.
compression molded, injection molded, blow molded, extrusion
molded, etc.) Ethylene Vinyl Acetate (EVA) thermoplastic, having
benign dormant bacteria embedded generally throughout, buried
within, and presented on the surface thereof. The benign dormant
bacteria presented on the surface of the molded product are
activatable, upon exposure to organic matter, to generate enzymes
and digest the organic matter while controlling the production of
offensive odours. Abrasive wear of the surface of the molded
product exposes fresh benign dormant bacteria buried within the
molded product to the surface of the product to provide renewed and
additional odour control.
[0024] Examples of molded products include automotive products such
as car seats, child safety seats, carpet underlay, and headliners;
marine products such as life jackets; electronics accessory
products such as work station mats and mouse pads; sport and
leisure products such as sports mats, gym mats exercise mats, yoga
mats, garden mats, personal protective equipment, sport protective
pads, toys and games, camping bedrolls, backpacks, hand shopping
baskets, luggage, travel bags and visors; footwear such as shoes,
clogs, flip flops, slippers, insoles and boots; and toys such as
play mats and blocks, etc.
[0025] According to an embodiment the molded product is formed into
fibers, pellets, sheets, blocks or tiles.
[0026] According to another embodiment the sheet, block, or tile
form of the molded product is formed into a secondary structure by
cutting, abrading, shaping, forming or additional molding.
[0027] According to another embodiment the fiber form of the molded
product is formed into a secondary structure by braiding, twisting,
weaving, knitting, crocheting, knotting, spinning, crimping or
felting.
[0028] According to yet another embodiment of the present invention
the secondary structure is formed into threads, yarns or
textiles.
[0029] Examples of textiles include floor coverings, bedding,
drapery, upholstery, a towel, at least a portion of an article of
clothing, and at least a portion of a footwear.
[0030] Examples of floor coverings include carpets, carpet tiles,
mats and rugs.
[0031] Examples of articles of clothing include dresses, coats,
socks, pants, shirts, jackets and headwear.
[0032] Therefore, in accordance with one embodiment there is
provided a product capable of controlling odours arising from
organic matter, said product comprising:
[0033] an admixture of a moldable thermoplastic and benign dormant
bacteria in a sporulated form, formed by admixing said benign
dormant bacteria into said moldable thermoplastic when said
moldable thermoplastic is melted, said admixture being molded into
a molded product;
[0034] said benign dormant bacteria being embedded throughout said
molded product, including being buried within a body of said molded
product, including being presented on a surface of said molded
product, said benign dormant bacteria presented on said surface
being activatable upon exposure of said surface to said organic
matter;
[0035] wherein said benign activated bacteria digest said organic
matter to control production of offensive odours, and abrasive wear
of said surface of said molded product exposes fresh benign dormant
bacteria buried within said body to said surface for additional
odour control.
[0036] In accordance with another aspect there is provided a
secondary structure formed by cutting, abrading, shaping, forming,
or additional molding, a sheet, block or tile form of the above
product.
[0037] In accordance with another aspect there is provided a
secondary structure formed by braiding, twisting, weaving,
knitting, crocheting, knotting, spinning, crimping or felting a
fiber form of the above product.
[0038] In accordance with yet another aspect of the present
invention, there is provided a method of making a product capable
of controlling odours arising from organic matter, comprising the
steps of: [0039] a) melt-blending at a bacteria compatible
temperature range: [0040] i) a moldable thermoplastic; and [0041]
ii) benign dormant bacteria in a sporulated form; and [0042] b)
forming the melt-blended product of step (a) into a molded product,
with said benign dormant bacteria being embedded throughout said
molded product, including being buried within a body of said molded
product and being presented on a surface of said molded product,
said benign dormant bacteria presented on said surface being
activatable upon exposure of said surface to said organic
matter;
[0043] wherein said benign activated bacteria digest said organic
matter to control production of offensive odours and abrasive wear
of said surface of said molded product exposes fresh benign dormant
bacteria buried within said body to said surface for additional
odour control.
[0044] In accordance with yet another aspect there is provided a
product capable of controlling odours arising from organic matter,
said product being formed by the above method.
[0045] In accordance with yet another aspect there is provided a
use of benign dormant bacteria in a sporulated form in the
preparation of a product capable of controlling odours arising from
organic matter, said product comprising an admixture of a moldable
thermoplastic and benign dormant bacteria in a sporulated form,
formed by admixing said bacteria and said moldable thermoplastic
when said moldable thermoplastic is melted, said admixture being
molded into a molded product, said benign dormant bacteria being
embedded throughout said molded product, including being buried
within a body of said molded product and being presented on a
surface of said molded product, said benign dormant bacteria
presented on said surface being activatable upon exposure of said
surface to said organic matter, wherein said benign activated
bacteria digest said organic matter to control production of
offensive odours and abrasive wear of said surface exposes fresh
benign dormant bacteria buried within said body to said surface for
additional odour control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIG. 1 is a product according to one embodiment;
[0047] FIG. 2 are results of tests of bacterial growth in test
specimens of the product of FIG. 1;
[0048] FIG. 3 is a footbed for a sandal according to another
embodiment of the present invention;
[0049] FIG. 4 is a sandal assembled using the footbed of FIG.
3;
[0050] FIG. 5 is a footbed for a sandal according to another
embodiment of the present invention;
[0051] FIG. 6 is a sandal assembled using the footbed of FIG. 5;
and
[0052] FIG. 7 is an insole for a shoe according to another
embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0053] The present invention is described in more detail with
reference to exemplary embodiments thereof as shown in the appended
drawings. While the present invention is described below including
preferred embodiments, it should be understood that the present
invention is not limited thereto. Those of ordinary skill in the
art having access to the teachings herein will recognize additional
implementations, modifications, and embodiments which are within
the scope of the present invention as disclosed and claimed
herein.
[0054] A product capable of controlling odours arising from organic
matter is shown generally with reference numeral 10 in FIG. 1.
Product 10 is an admixed combination of a moldable thermoplastic
containing benign dormant bacteria 12 in a sporulated form, which
combination was melt-blended and molded into a molded product, in
this case a sheet, from which the square piece of product 10, shown
in FIG. 1, was cut. Preferably, the moldable thermoplastic is an
ethylene vinyl acetate (EVA), however, as discussed in more detail
below, different suitable moldable thermoplastics may be utilized
as desired. The benign dormant bacteria 12 are embedded generally
throughout the product 10, including being buried within the body
of the product 10 as well as being presented on the surface 14 of
the product 10. The benign dormant bacteria 12 presented on the
surface 14 of the product 10 are activatable upon exposure of the
surface 14 of the product 10 to organic matter. When activated,
bacteria 12 digest the organic matter to control production of
offensive odours.
[0055] Preferably, the product 10 contains a surface population of
the benign dormant bacteria 12 large enough to digest the organic
matter at a rate sufficient to control by reducing or eliminating
odours associated with the organic matter. In this regard, good
results have been obtained with between 10.sup.6 and 10.sup.8 of
the benign dormant bacteria 12, estimated by calculating colony
forming units (cfu), being present on the surface of the product
10, per square inch. Preferably, the surface population of the
benign dormant bacteria 12 will be at least 10.sup.7 cfu per square
inch.
[0056] Beneficially, abrasive wear of the surface 14 of the product
10 exposes fresh benign dormant bacteria buried in the body to the
surface 14 for additional odour control. Accordingly, the product
10 contains a buried population of the benign dormant bacteria 12
large enough to continue to digest the organic matter at a rate
sufficient to control odours associated with the organic matter as
the surface wears. In this regard, good results have been obtained
with between 10.sup.12 and 10.sup.16 of the benign dormant bacteria
12 being present per cubic inch of the product 10.
[0057] The present invention comprehends adding an effective amount
of benign dormant bacteria to reduce and thus control odours. While
certain ranges are identified it will be understood that different
applications may have different insult levels typically, which can
vary. For example, a shoe insole may have a heavy daily load of
sweat, whereas another application may not receive such continual
insults. In all cases it is preferable to provide the beneficial
bacteria are present on a surface initially when insults occur, and
to remain present during and after wear due to being incorporated
into the material. As such the specific amounts of bacteria present
are intended to be shown as examples and not as limitations per
se.
[0058] The product 10 is preferably made by first melt-blending at
a bacteria compatible temperature range a mixture comprising a
moldable thermoplastic, then continuing to blend the moldable
thermoplastic mixture in a double-roller blending or kneading
machine, and adding a mixture of benign dormant bacteria in a
sporulated form. Preferably, one or more of a foaming agent (i.e. 3
to 10% w/w), a cross-linking agent (i.e. 1 to 5% w/w), a lubricant
(i.e. 0.5% to 2% w/w), and a filler, can be included in the
moldable thermoplastic mixture depending on the application, as
will be appreciated by persons skilled in the art. The ingredients
may be melt-blended together all at once, or in separate stages. In
generally, it has been found that up to 1% w/w of an aqueous
mixture of benign dormant bacteria can be added to a moldable
thermoplastic mixture comprising EVA. However, it is contemplated
that lower or higher % w/w of aqueous mixture of benign dormant
bacteria may be used, depending on the moldable thermoplastic being
used, for example in the range of 0.01% to 5%
[0059] The bacteria compatible temperature range is governed mostly
by the melting temperature of the moldable thermoplastic being
used, and temperatures of up to 175.degree. C. have yielded
acceptable results. It is helpful that the bacteria compatible
temperature range be sufficient to melt the moldable thermoplastic
so that the mixture of benign dormant bacteria and other
ingredients will homogeneously blend or knead, and an effective
amount of the benign dormant bacteria will be present to control
odours. It will be understood that the bacteria compatible
temperature range does not exceed a temperature at which the
sporulated bacteria are destroyed. While certain bacteria
compatible temperature ranges are identified it will be understood
that different applications will require different temperatures. As
such the temperatures described herein are intended to be shown as
examples only and not as limitations.
[0060] The melt-blended product is then transferred from the
blending/kneading machine and formed by molding into the molded
product, with the benign dormant bacteria 12 being embedded
generally throughout the product 10, including being buried within
the body of the product 10 and being presented on a surface 14 of
the product 10. The benign dormant bacteria 12 presented on the
surface 14 of the product 10 are activatable upon exposure of the
surface 14 of the product 10 to the organic matter, and upon
activation, the benign activated bacteria digest the organic matter
to control production of offensive odours. As mentioned above,
abrasive wear of the surface 14 of the product 10 preferably
exposes fresh benign dormant bacteria 12 buried in the body to the
surface 14 for additional odour control.
[0061] The moldable thermoplastic may be an open-cell foam, or a
close-cell foam, which can be compression molded, injection molded,
blow molded, or extrusion molded, according to techniques well
known in the art. Although preferred thermoplastics are EVA, those
persons skilled in the art will appreciate that other moldable
thermoplastic materials may be used in place of EVA, such as for
example a polyethylene, a polypropylene, a polyvinyl chloride, a
polyamide, an elastane or a polystyrene. All such moldable
thermoplastics may be used herein.
[0062] It is important that the moldable thermoplastic mixture,
when combined with the mixture of benign dormant bacteria, can be
molded into the specific shape desired for the product 10, and a
sufficient amount of the benign dormant bacteria 14 survive the
processing and molding steps to form the product 10. The product 10
may be formed into numerous shapes and sizes for countless
applications.
[0063] For example, the product 10 may be formed into a fiber by
extruding the moldable thermoplastic mixture impregnated with the
mixture of benign dormant bacteria into fibers or filaments. The
present invention also contemplates forming a secondary structure
by braiding, twisting, weaving, knitting, crocheting, knotting,
spinning, crimping, or felting, the fiber form of product 10, using
techniques which are well known in the art.
[0064] Alternately, the product 10 may be formed into a sheet, a
block, or a tile, by compression molding, injection molding, blow
molding, or extrusion molding, using techniques well known in the
art.
[0065] For example, compression molding can be used to make insoles
for shoes, as follows. After forming the melt-blended product
containing the moldable thermoplastic mixture and the mixture of
benign dormant bacteria, it is kneaded at room temperature (i.e.
about 20 to 25.degree. C.) for about 10 minutes, and then rolled
into sheets. The sheets are cut, compressed into large sheets at
170.degree. C. to 175.degree. C., and a pressure of about 150
kg/cm.sup.2 for about 10 to 20 minutes during which process
cross-linking takes place and the product is foamed. It is then
pressed into an insole mold at approximately 160.degree. C. for 15
minutes.
[0066] As another example, injection molding can be used to make
one piece shoes, as follows. After forming the melt-blended product
containing the moldable thermoplastic mixture and the mixture of
benign dormant bacteria, it is brought to a temperature of
70.degree. C. and injected into a mold. The mold is then hot
pressed in an oven at 160.degree. C. for 7 minutes.
[0067] Forming a secondary structure by cutting, abrading, shaping,
forming, or additional molding, the sheet, block, or tile, using
well known techniques, is also contemplated.
[0068] As can now be appreciated, the moldable thermoplastic
mixture impregnated with the benign dormant bacteria, can be made
in large batches, and formed into bricks that are then cut into
sheets, or it can be extruded into sheets, in either case, the
sheets can then be put into molds and cold or hot formed into
shapes, such as, for example, insoles or sandal beds. Alternately,
the moldable thermoplastic mixture impregnated with the benign
dormant bacteria can be extruded, placed onto molds, or injected
into molds, for shaping.
[0069] The following is a non-exhaustive list of the numerous
applications contemplated for the product 10 according to various
embodiments of the present invention: [0070] threads; [0071] yarns;
[0072] textiles; [0073] floor coverings (i.e. carpets; carpet
underlays; carpet tiles; mats including sports mats, gym mats,
exercise mats, yoga mats, children's play mats, and garden mats;
and rugs); [0074] bedding; [0075] drapery; [0076] upholstery;
[0077] towels; [0078] articles of clothing or portions thereof
(i.e. dresses, coats, socks, pants, shirts, headwear, and jackets);
[0079] footwear or portions thereof (i.e. sandals, shoes, boots,
slippers, flip flops, clogs, insoles, footbeds, and outsoles);
[0080] body protective gear [0081] toys and games (i.e. play mats,
blocks); [0082] automotive products (i.e. car seats, child safety
seats, carpet underlay, and headliners); [0083] marine products
(i.e. life jackets); [0084] electronics accessory products (i.e.
work station mats, mouse pads); [0085] sport and leisure products
(i.e. sports mats, gym mats, exercise mats, yoga mats, garden mats,
personal protective equipment, sport protective pads, camping
bedrolls, backpacks, hand shopping baskets, luggage and travel
bags, and visors).
[0086] Many bacterial genera are known to produce enzymes that are
capable of breaking down organic matter. Such bacteria are
particularly useful where the organic matter, if allowed to remain,
will give rise to malodours. Several such bacterial genera such as
Bacillus, Lactobacillus, Enterobacter, Streptococcus, Nitrosomonas,
Nitrobacter, Pseudomonas, Alcaligens, and Klebsiella amongst others
are known for use in such applications, with Bacillus and
Lactobacillus sp. being the most prevalent in use in various
applications. Strains of bacteria from the genera Bacillus are
useful in practicing the present invention. The preferred benign
dormant bacteria 12 are those which when activated by the presence
of organic matter, produce an enzyme to break down and assist with
digesting the organic matter, creating only water and carbon
dioxide as by-products. Once the organic matter has been digested
the preferred benign dormant bacteria 12 return to a dormant state
until organic matter is presented again and the cycle repeats.
[0087] Preferably, the mixture of benign dormant bacteria for use
in the present invention includes one or more strains of Bacillus
megaterium, Bacillus subtilus, Bacillus Licheniformis, Bacillus
Cerus, Bacillus, Alvei, Bacillus Coagulans, Bacillus Pumillus,
Bacillus Simplex, Bacillus Brevis, and Bacillus Amyloliquefaciens,
which are available for example from Envera, LLC, whose address is
220 Garfield Ave., West Chester, Pa., 19380, U.S.A. More
preferably, the strains of bacteria for use in the present
invention are selected from Bacillus megaterium, Bacillus subtilus,
and Bacillus Licheniformis species. Each of these species a)
effectively express enzymes that break down particular types of
organic matter, without producing odorous metabolites, b) are
ubiquitous in nature, c) are non-hazardous to humans, and d) are
included in the Domestic Substances List (DSL) in Canada, and are
therefore eligible to be imported and used within Canada.
[0088] The selection of the strains of bacteria for use in the
present invention may depend upon many factors. One such factor is
the nature of the organic matter most commonly expected for the
particular application. However, the most common forms of organic
matter include bodily fluids, or organic waste. In most cases, to
activate the benign dormant bacteria, the organic matter will need
to contain carbon, nitrogen, and sufficient moisture content.
Typically the bodily fluids include sweat, blood, saliva, and
semen. Typical organic wastes include feces, urine, soil,
beverages, such as, coffee, tea, milk, wine, and soft drinks, other
food, such as, syrup, and eggs, and the like.
[0089] In an indoor environment, the nature of the deposits of
organic matter may differ from those of an outdoor environment.
Therefore, due consideration may need to be given to the
environment where the product 10 will most likely be used.
Depending upon the nature of the deposited organic matter, the
mixture of benign dormant bacteria 12 may be selected to contain
strains having enhanced activity against such materials. Another
factor that may affect the nature of the deposit is the
geographical location of the surface of the product. This factor
would especially relate to the nature of deposits of out-doors soil
and to the nature of food deposits. Different regions are known to
have different soil types and different regions may also have
differences in the foods commonly consumed due to cultural and
environmental factors. In addition, the temperature of the product
will influence the activity of the bacteria. Depending on the
strain selected the bacteria will tend to exhibit enhanced activity
at higher temperatures. At lower ambient temperatures, more active
strains may be desired.
[0090] The mixture of benign dormant bacteria will typically
comprise of one or more strains selected from the species described
above, and a carrier. When utilizing a mixture of more than one
strain, each of the individual strains may comprise between 3% and
97% of the total of the benign dormant bacteria present in the
mixture. These percentages are based on the total cell number. When
mixtures of more than two strains are employed, each of the strains
is most preferably present in an amount of from 10% to 60% of the
total bacteria in the preparation. Particularly preferred mixtures
of benign dormant bacteria for general use in almost all
applications are as follows:
TABLE-US-00001 % of Total Bacteria Preferred Most Species Range
Range Preferred Bacillus megaterium 3-97 5-15 10 Bacillus subtilus
3-97 10-50 30 Bacillus licheniformis 3-97 40-80 60 *Total benign
dormant bacteria in mixture equals 100%
[0091] In a preferred embodiment of the present invention an
effective amount of a bacterial composition comprising one or more
strains selected from the group consisting of Bacillus megaterium,
Bacillus subtilus, Bacillus Licheniformis, Bacillus Cerus,
Bacillus, Alvei, Bacillus Coagulans, Bacillus Pumillus, Bacillus
Simplex, Bacillus Brevis, and Bacillus Amyloliquefaciens are
provided in a state in which the composition may be combined with a
moldable thermoplastic material. The effective amount is a
sufficient number of benign dormant bacteria 12 to provide a
relatively uniform coverage on the surface 14 of the product 10
such that when any portion of the surface 14 is exposed to a
deposit of an odour causing organic matter, the activated benign
bacteria will undergo rapid growth and consume the odour causing
organic matter. The factors that can affect the number of benign
dormant bacteria 12 to be used relate in most part to the nature of
the product 10. As mentioned above, however, for most products
between about 10.sup.6 and 10.sup.8 benign dormant bacteria per
square inch of the surface 14 of the product is most effective with
about 10.sup.7 cfu per square inch being most preferred.
[0092] The bacteria may be provided in an aqueous carrier or a dry
powder carrier. The purpose of the carrier is to transport the
benign dormant bacteria 12 to, and facilitate with dispersing the
benign dormant bacteria 12 throughout, the melt-blended mixture of
moldable thermoplastic during the kneading step. In this regard,
the aqueous carrier is preferred over the dry powder carrier,
because the dry powder carrier has been found to be susceptible to
dispersing into the air when being applied to the kneading moldable
thermoplastic mixture. This phenomenon is problematic because when
portions of the benign dormant bacteria mixture are dispersed into
the air, concentrations of some components of the melt-blended
product will vary, which may adversely affect characteristics of
the resulting product 10.
[0093] Distilled water can be used as the aqueous carrier if the
benign dormant bacteria mixture will be combined with the moldable
thermoplastic mixture immediately. According to this embodiment,
the benign dormant bacteria 12 are in a spray dried, dry powder
form, and simply rehydrated in the water to form the benign dormant
bacteria mixture on site, just before the benign dormant bacteria
mixture is combined with the moldable thermoplastic mixture, as
discussed above. Preferably, the aqueous benign dormant bacteria
mixture contains between 0.0001% and 2% w/w of the benign dormant
bacteria, with the remainder being distilled water. What is desired
is for the aqueous benign dormant bacteria mixture to contain a
sufficient amount of benign dormant bacteria to result in at least
10.sup.6 benign dormant bacteria being present at the surface of
the product 10 per square inch, as mentioned above, without
introducing too much water to the moldable thermoplastic mixture so
as not to significantly alter the characteristics or quality of the
resulting product.
[0094] However, if the benign dormant bacteria mixture will not be
used immediately, the aqueous form of the benign dormant bacteria
mixture will preferably also include: [0095] 0.1% to 10% w/w of a
surfactant, such as sodium lauryl sulphate, glucopon, or sterol, to
break up the benign dormant bacteria clumps and disperse them in
the solution; [0096] 0.03% to 2% of a buffer, such as a phosphate
based buffer system comprising a blend of potassium phosphate
monobasic and potassium phosphate dibasic, to maintain a pH of 6.5
to 7.5; and [0097] 0.001% to 1% preservative, such as a biocide, to
a) prevent the benign dormant bacteria from germinating, and b)
prevent contamination of the benign dormant bacteria mixture with
outside bacteria.
[0098] It is contemplated that the benign dormant bacteria mixture
may be provided in either a concentrated form, which will need to
be diluted prior to being used, or in a ready to use form, which
may be directly applied to the moldable thermoplastic mixture at
the appropriate stage in the manufacturing process.
[0099] The preferred dry powder carrier is calcium carbonate or
sodium bicarbonate in a fine powder form. It has been found that
the dry powder form of the benign dormant bacteria mixture does not
require a preservative, since the lack of moisture both inhibits
germination of the benign dormant bacteria, and inhibits growth of
outside bacteria. Thus, the preferred dry powder form of the benign
dormant bacteria mixture includes: [0100] 0.0001% to 2% w/w of the
benign dormant bacteria in a spray dried, powder form; and [0101]
the remainder being calcium carbonate, or sodium bicarbonate in a
fine powder form.
PREPARATION EXAMPLE
[0102] A test specimen of product 10 was prepared according to an
embodiment of the present invention, as follows. [0103] 1. Add
4,086 g (25.58% w/w) of ethylene-vinyl acetate (EVA) resin, 4,540 g
(28.42% w/w) of CaCO.sub.3, 908 g (5.68% w/w) of natural rubber,
100 g (0.63% w/w) of zinc oxide (ZnO), 35 g (0.22% w/w) of zinc
salt of stearic acid (ZnSt), 1,135 g (7.10% w/w) of polyethylene
(PE), and 2,951 g (18.47% w/w) of polyolefin elasotomer (POE) to a
mixing machine set to a temperature of between 115.degree. C. and
120.degree. C. Mix the mixture for 5 minutes. [0104] 2. Add 120 g
(0.75% w/w) of dicumyl peroxide (DCP) crosslinking agent, 450 g
(2.82% w/w) of AC foaming/blowing agent, and 1,500 g (9.39% w/w)
black color dye to the mixture. Continue mixing for another 5
minutes. [0105] 3. Transfer the mixture to a double-roller
blending/kneading machine with 21 inch diameter rollers set to a
temperature of 110.degree. C. Knead the mixture for about 2
minutes. [0106] 4. Add 150 g (0.94% w/w) of an aqueous dormant
bacteria mixture comprising about 2.12.times.10.sup.9 cfu/ml of
Bacillus megaterium, Bacillus subtilus, and Licheniformis in a
ratio of about 1:3:6 obtained from Envera LLC, West Chester, Pa.,
U.S.A, by slowly pouring onto the mixture as it is being
blended/kneaded on the roller of the double-roller
blending/kneading machine. [0107] 5. Knead the mixture for 3 to 6
minutes. [0108] 6. Transfer the mixture to a cutting machine to cut
the mixture into thin sheets of 1.2 mm thickness. [0109] 7. Put
stacks of thin sheets about 16 mm high into a mold measuring 150
cm.times.75 cm.times.1.6 cm. Insert the mold into a blowing machine
set at 171.degree. C. and apply a pressure of 183 kg/cm.sup.2 for
22 minutes. [0110] 8. Release the pressure and remove the blown EVA
slabs, which become about 32 mm thick, from the blowing machine.
[0111] 9. Set the blown EVA slabs aside for a minimum of 2 hours to
allow them to cool and shrink to a stable size, resulting in smooth
EVA sheets with no fine details. The actual time the EVA slabs are
to be set aside for will depend on the size and thickness of the
EVA slabs, and the ambient temperature and humidity. [0112] 10. Cut
the EVA sheets into smaller sizes. [0113] 11. Trim off the smooth
surface of the EVA sheets and cut the EVA sheets to the desired
thickness.
[0114] The presence of activatable benign dormant bacteria on the
surface of the test specimens of the product 10 was tested as
follows: [0115] 1. Prepare petri dishes containing agar by dispense
sterilized tryptic soy broth agar (cooled to 47.degree.
C..+-.2.degree. C.) by pouring 15.+-.2 ml into each standard
(15.times.100 mm) flat bottomed petri dish. Allow the agar to gel
firmly. [0116] 2. Cut test specimens (non-sterile) of the product
10 by hand using sterile scissors, or with a sterile die, into
approximately 1 inch.times.1 inch squares, [0117] 3. For each test
specimen press the test specimen into a petri dish to ensure
intimate contact of the test specimens with the agar surface.
[0118] 4. Incubate the petri dishes containing the test specimens
for 24 hours at 35.degree. C. [0119] 5. Remove the petri dishes
containing the test specimens from the incubator. [0120] 6.
Visually inspect each petri dish to determine the presence or
absence of bacterial growth from each test specimen.
[0121] FIG. 2 shows representative test results for two test
specimens. The test results show good growth the bacteria in the
petri dishes radiating outwardly from the test specimens,
confirming that the benign dormant bacteria were present on the
surface of the test specimens and activatable upon exposure to
organic matter.
[0122] the surface population of the benign dormant bacteria in the
test specimens of the product 10 was estimated as follows: [0123]
1. Prepare 500 ml of tryptic soy broth (TSB) per label directions.
[0124] 2. Add the 500 ml of TSB to a clean 1-liter baffle flask.
[0125] 3. Add a stopper and foil covering to the 1-liter baffle
flask, [0126] 4. Repeat steps 1 to 3 to prepare a second 1-litre
baffle flask. [0127] 5. Autoclave the 1-liter baffle flasks
containing the 500 ml of TSB for 15 minutes at 121.degree. C. and
15 psi. [0128] 6. Autoclave a 12''.times.18'' paper wrapped
stainless steel plate. [0129] 7. Allow the stainless steel plate to
cool completely. [0130] 8. Cool the 1-litre baffle flasks
containing TSB to 80.degree. C. in an 80.degree. C. water bath.
[0131] 9. Unwrap the stainless steel plate, and place the plate
into a biosafety hood. [0132] 10. Place a test specimen on top of
the stainless steel plate, so that it is laid out flat on the
surface of the stainless steel plate. [0133] 11. Using a new,
disposable scalpel blade attached to a reusable scalpel handle, cut
two one-inch squares from the center of the test specimen. [0134]
12. Place each one-inch square into one of the sterile 1-liter
baffle flasks containing the 500 ml of TSB. [0135] 13. Keep the
1-liter baffle flasks in the water bath for 10 minutes. [0136] 14.
Remove the 1-liter baffle flasks from the water bath and cool to
30.degree. C. in a temperature controlled shaker set at 150 RPM.
[0137] 15. When the 1-liter baffle flasks have cooled to 30.degree.
C., begin timing a 24 hour growth period. [0138] 16. At the end of
the 24-hour growth period, aseptically transfer 10 ml of the TSB
broth from each 1-liter baffle flask to a 90 ml buffer dilution
blank. [0139] 17. Continue making serial dilutions by adding 10 ml
to 90 ml blanks through to a 10.sup.-6 dilution. [0140] 18. Plate
the 10.sup.-4 through the 10.sup.-6 dilutions onto tryptic soy agar
plates. [0141] 19. Incubate the tryptic soy agar plates for 24
hours at 35.degree. C. [0142] 20. Count the bacterial colonies on
each plate. [0143] 21. Determine Bacillus colony forming units
(cfu) per ml from the serial plate count calculations. [0144] 22.
Divide the serial plate count calculation by 2, to obtain the
cfu/ml which is the potential for growth from each one-square inch
of the test material.
[0145] The results ranged between 1.11.times.10.sup.9 and
1.55.times.10.sup.9 potential colony forming units of growth per
one square inch of test specimen. This test confirmed that the
desired number of benign dormant bacteria was exposed on the
surfaces of the test specimens of the product 10.
[0146] When the surfaces of the test specimens were roughed up by
scraping with a piece of plastic, the results ranged between
0.92.times.10.sup.9 and 1.33.times.10.sup.9 potential colony
forming units of growth per one square inch of test specimens. This
test confirmed that abrasive wear of the surface of the product 10
exposed sufficient fresh benign dormant bacteria buried in the body
to the surface for additional odour control.
[0147] The present invention is further described by means of the
examples, presented below. The use of such examples is illustrative
only and in no way limits the scope and meaning of the invention or
of any exemplified term, nor to any particular preferred
embodiments described herein. Indeed, many modifications and
variations of the invention will be apparent to those skilled in
the art upon reading this specification. The invention is therefore
to be limited only by the terms of the appended claims.
EXAMPLE 1
Pressed EVA Footbed for Sandal with Benign Dormant Bacteria
Embedded Generally Throughout
[0148] The following example describes a method for making a
pressed EVA footbed for a sandal, as shown in FIG. 3. In this
example, a sample of an aqueous dormant bacteria mixture was added
to EVA and melt-blended as follows.
TABLE-US-00002 WEIGHT INGREDIENTS Grams % w/w SUPPLIER aqueous
dormant bacteria 150 0.94 Envera LLC, West Chester, mixture
(containing about Pennsylvania 2.12 .times. 10.sup.9 cfu/ml of
Bacillus megaterium, Bacillus subtilus, and Licheniformis in a
ratio of about 1:3:6) EVA resin 4,086 25.58 The Polyolefin Company
(Singapore) Pte. Ltd, Singapore; Formosa Plastics Corporation,
Taiwan; Braskem, Brazil; Asia Polymer Corporation, Taiwan
CaCO.sub.3 (filler) 4,540 28.42 Shangdong Bo-Liao, China dicumyl
peroxide (DCP) 120 0.75 Akzo Nobel Cross-linking cross-linking
agent Peroxides (Ningbo) CO., Ltd., China; Sinopec, China AC
foaming/blowing agent 450 2.82 zinc oxide (ZnO) blowing 100 0.63
Shijiazhuang Zinc Industry Co., agent promoter Ltd., China;
Taiyang, China; Shijiazhuang Zinc Industry Co., Ltd., China zinc
salt of stearic acid (ZnSt) 35 0.22 Pt. Sumi Asih Oleochemicals
blowing agent promoter Industry, Indonesia Polyethylene (PE) 1,135
7.10 National Petrochemical Company, Thailand; PTT Polyethylene
Company Limited, Thailand; Kunlun, China Polyolefin Elastomer (POE)
2,951 18.47 LG Chem, Korea natural rubber 908 5.68 color dye -
black 1,500 9.39 Total 15,975 g 100%
Preparing/Mixing EVA Mixture
[0149] 1. Add the EVA resin, the CaCO.sub.3, the natural rubber,
the ZnO, the ZnSt, the PE, and the POE to a mixing machine set to a
temperature of between 115.degree. C. and 120.degree. C. Mix the
mixture for 5 minutes. [0150] 2. Add the dicumyl peroxide (DCP)
cross-linking agent, the AC foaming/blowing agent, and the color
dye to the mixing machine. Continue mixing the mixture for another
5 minutes. [0151] 3. Transfer the mixture to a double-roller
blending/kneading machine with 21 inch diameter rollers set to a
temperature of 110.degree. C. Knead the mixture for about 2
minutes. [0152] 4. Add the aqueous dormant bacteria mixture by
slowly pouring it onto the mixture kneading on the roller. [0153]
5. Knead the mixture for 3 to 6 minutes. [0154] 6. Transfer the
mixture to a cutting machine to cut the mixture into thin sheets
which are 1.2 mm thick.
Foaming/Blowing
[0154] [0155] 7. Put stacks of the thin sheets about 16 mm high
into a mold of 150 cm.times.75 cm.times.1.6 cm. Insert the mold
into a blowing machine at 171.degree. C. and apply a pressure of
183 kg/cm.sup.2 for 22 minutes. [0156] 8. Release the pressure and
remove the blown EVA slabs, which become about 32 mm thick, from
the blowing machine. [0157] 9. Set the blown EVA slabs aside for a
minimum of 2 hours to allow them to cool and shrink to a stable
size, resulting in smooth EVA sheets with no fine details. The
actual time the EVA slabs are to be set aside for will depend on
the size and thickness of the EVA slabs, and the ambient
temperature and humidity.
Cutting
[0157] [0158] 10. Cut the EVA sheets to smaller sizes. [0159] 11.
Trim off the smooth surface of the EVA sheets and cut the EVA
sheets to the desired thickness. [0160] 12. Cut the EVA sheets
through a roller with emboss for a design, resulting in a final,
detailed sandal footbed, which is then ready for assembly into a
sandal, as shown in FIG. 4.
EXAMPLE 2
EVA Footbed for Sandal with Benign Dormant Bacteria Embedded
Generally Throughout
[0161] The following example describes a method for making an EVA
footbed for a sandal, as shown in FIG. 5. The EVA footbeds
according to this embodiment provide two layers: a top layer EVA,
which the wearer's foot touches, contains dormant bacteria, and a
bottom layer that has no dormant bacteria. In this example, a
sample of an aqueous dormant bacteria mixture was added to EVA and
melt-blended as follows.
TABLE-US-00003 WEIGHT INGREDIENTS grams % w/w SUPPLIER aqueous
dormant bacteria 90 0.99 Envera LLC, West Chester, mixture
(containing about Pennsylvania 2.12 .times. 10.sup.9 cfu/ml of
Bacillus megaterium, Bacillus subtilus, and Licheniformis in a
ratio of about 1:3:6) EVA resin 6,300 69.31 The Polyolefin Company
(Singapore) Pte. Ltd, Singapore; Formosa Plastics Corporation,
Taiwan; Braskem, Brazil; Asia Polymer Corporation, Taiwan
CaCO.sub.3 (filler) 1,440 15.84 Shangdong Bo-Liao, China dicumyl
peroxide (DCP) 45 0.50 Akzo Nobel Cross-linking cross-linking agent
Peroxides (Ningbo) CO., Ltd., China; Sinopec, China AC
foaming/blowing agent 135 1.49 Zinc Oxide (ZnO) blowing 90 0.99
Shijiazhuang Zinc Industry Co., agent promoter Ltd., China;
Taiyang, China; Shijiazhuang Zinc Industry Co., Ltd., China Zinc
Salt of Stearic Acid 45 0.50 Pt. Sumi Asih Oleochemicals (ZnSt)
blowing agent Industry, Indonesia promoter flow promoting agent 450
4.95 color dye - black 495 5.45 Total 9,090 g 100%
Preparing/Mixing EVA Mixture
[0162] 1. Add the aqueous dormant bacteria mixture to the
CaCO.sub.3 filler. [0163] 2. Add the EVA resin, the CaCO.sub.3 and
dormant bacteria mixture, the ZnO, the ZnSt, and the color dye to a
blending/kneading machine set to an initial temperature of
90.degree. C. and gradually rising at a rate of about 1.5.degree.
C./min. Knead for about 6 minutes. [0164] 3. Add the dicumyl
peroxide (DCP) cross-linking agent, the AC-foaming agent, and the
flow promoting agent to the blending/kneading machine and continue
kneading for another 6 minutes, with the temperature of the
blending/kneading machine continuing to gradually rise at a rate of
1.5.degree. C./min to 108.degree. C. [0165] 4. Transfer the mixture
to a pellet-making machine set to a temperature of 90.degree. C.,
in which the material is cut to round EVA flat pellets measuring 4
mm in diameter and 1-3 mm thick.
Initial Foaming/Molding to Rough EVA Footbed
[0165] [0166] 5. Put the pellets into molds for foaming at
165.degree. C., pressed at 150 kg/cm.sup.2 for 15 minutes for Men's
and 13 minutes for Women's, according to the following weights:
[0167] a. for men's size 10, total 140 g:
TABLE-US-00004 [0167] top layer - 87 g EVA pellets with benign
dormant bacteria bottom layer - 53 g EVA pellets without benign
dormant Bacteria
[0168] b. for women's size 8, total 99 g:
TABLE-US-00005 [0168] top layer - 68 g EVA pellets with benign
dormant bacteria bottom layer - 31 g EVA pellets without benign
dormant bacteria
[0169] 6. Remove the rough EVA footbeds from the molds and allow
them to cool. The rough EVA footbeds are smooth, slightly larger,
general shaped footbeds, with no fine details. [0170] 7. Buff the
surfaces of the rough EVA footbeds.
Final Shaping
[0170] [0171] 8. Mold the rough EVA footbeds at a hot pressing
temperature of 165.degree. C. and a pressing pressure of 80
kg/cm.sup.2 for 390 seconds for men's and 360 seconds for women's.
[0172] 9. Cold shape the footbeds at 40.degree. C. for 460 seconds.
[0173] 10. Trim the final, detailed footbeds, which are then ready
for assembly into sandals, an example of which is shown in FIG.
6.
EXAMPLE 3
EVA Footbed for Sandal with Benign Dormant Bacteria Embedded
Generally Throughout
[0174] The following example describes an alternate method for
making an EVA footbed for a sandal, as shown in FIG. 5. In this
example, a sample of an aqueous dormant bacteria mixture was added
to EVA and melt-blended as follows.
TABLE-US-00006 WEIGHT INGREDIENTS grams % w/w SUPPLIER aqueous
dormant bacteria 33 1.01 Envera LLC, West Chester, mixture
(containing about Pennsylvania 2.12 .times. 10.sup.9 cfu/ml of
Bacillus megaterium, Bacillus subtilus, and Licheniformis in a
ratio of about 1:3:6) EVA resin 2,280 69.47 The Polyolefin Company
(Singapore) Pte. Ltd, Singapore; Formosa Plastics Corporation,
Taiwan; Braskem, Brazil; Asia Polymer Corporation, Taiwan
CaCO.sub.3 (filler) 600 18.28 Shangdong Bo-Liao, China dicumyl
peroxide (DCP) 15 0.46 Akzo Nobel Cross-linking cross-linking agent
Peroxides (Ningbo) CO., Ltd., China; Sinopec, China AC
foaming/blowing agent 84 2.56 Zinc Oxide (ZnO) blowing 30 0.91
Shijiazhuang Zinc Industry Co., agent promoter Ltd., China;
Taiyang, China; Shijiazhuang Zinc Industry Co., Ltd., China Zinc
Salt of Stearic Acid 15 0.46 Pt. Sumi Asih Oleochemicals (ZnSt)
blowing agent promoter Industry, Indonesia flow promoting agent 18
0.55 color dye - black 180 5.48 plasticizer 27 0.82 Total 3,249 g
100%
Preparing/Mixing EVA Mixture
[0175] 1. Add the EVA resin, the CaCO.sub.3, the ZnO, and the ZnSt
into a mixer set to a temperature of between 105.degree. C. and
110.degree. C. [0176] 2. Mix the mixture for about 12 minutes.
[0177] 3. Remove the mixture from the mixer and roll it into 40
cm.times.60 cm.times.2 mm slabs. [0178] 4. Transfer 2,925 g of the
slabs to a double-roller blending/kneading machine with 40 cm
diameter rollers set to a temperature of 90.degree. C. Knead for
about 2 minutes. [0179] 5. Add the aqueous dormant bacteria mixture
to the blending/kneading machine. Knead for 2 minutes. [0180] 6.
Add the flow promoting agent, the color dye-black, and the
plasticizer (preferably at the same time by pouring out of a
pre-mixed bag). Knead for 2 minutes. [0181] 7. Add the dicumyl
peroxide (DCP) cross-linking agent, and the AC foaming/blowing
agent (preferably at the same time by pouring out of a pre-mixed
bag). Knead for 6 minutes. [0182] 8. Remove the mixture from the
blending/kneading machine and roll it out into one big flat sheet
about 3 mm thick. Set aside the sheet and allow it to cool down.
[0183] 9. Cut the sheet into small pellets measuring 3 mm.times.6
mm.times.9 mm.
Initial Foaming/Molding to Rough EVA Footbed
[0183] [0184] 10. Put the pellets into molds for foaming at
160.degree. C., pressed at 180-200 kg/cm.sup.2 for 680 seconds,
according to the following weights: [0185] a. for men's size 10:
98.5 g [0186] b. for women's size 8: 80 g. [0187] 11. Remove the
rough EVA footbeds from the molds and allow them to cool. The rough
EVA footbeds are smooth, slightly larger, general shaped footbeds,
with no fine details. [0188] 12. Buff the surfaces of the rough EVA
footbeds.
Final Shaping
[0188] [0189] 13. Mold the rough EVA footbeds at a hot pressing
temperature of 150.degree. C. and a pressing pressure of 55
kg/cm.sup.2 for 460 seconds. [0190] 14. Cold shape the foot beds at
40.degree. C. for 460 seconds. [0191] 15. Trim the final, detailed
footbeds, which are then ready for assembly into a sandal, an
example of which is shown in FIG. 6.
EXAMPLE 4
EVA Insole with Benign Dormant Bacteria Embedded Generally
Throughout
[0192] The following example describes a method for making an EVA
insole for a shoe, as shown in FIG. 7. In this example, an aqueous
dormant bacteria mixture was added to EVA and melt-blended as
follows.
TABLE-US-00007 WEIGHT % INGREDIENTS grams w/w aqueous dormant
bacteria mixture (containing 28 0.99 about 2.12 .times. 10.sup.9
cfu/ml of Bacillus megaterium, Bacillus subtilus, and Licheniformis
in a ratio of about 1:3:6) obtained from Envera LLC, West Chester,
Pennsylvania EVA resin 1,000 35.38 dicumyl peroxide (DCP)
cross-linking agent 51.18 1.81 AC foaming/blowing agent 110.27 3.90
zinc oxide (ZnO) blowing agent promoter 50 1.77 zinc salt of
stearic acid (ZnSt) blowing agent 25 0.88 promoter polyethylene
(PE) or polyolefin elastomer (POE) 1,500 53.08 color dye - black
41.61 1.47 powder (Tyressen Co., Ltd., 426-19 Yeocheon 20.06 0.71
Dong, Nam-gu, Ulsan, South Korea) Total 2,826.12 g 100%
Preparing/Mixing EVA Mixture
[0193] 1. Mix the ZnO and ZnSt powders in a container and add the
aqueous dormant bacteria mixture. [0194] 2. Add the EVA resin, and
the PE or POE into a mixer set to a temperature of 80.degree. C.,
and a mixing speed of 500 to 580 rpm. [0195] 3. Mix the mixture for
about 1 minute. [0196] 4. Add the mixture of ZnO, ZnSt, and dormant
bacteria mixture from step 1 above to the mixer. Mix the mixture at
90.degree. C. and a mixing speed of 580 to 740 rpm, for 10
minutes.
Kneading
[0196] [0197] 5. Transfer the mixture from step 4 to a
double-roller blending/kneading machine with 21 inch diameter
rollers set to a temperature of 100.degree. C. Knead for about 5
minutes. [0198] 6. Add the AC foaming agent and the color dye to
the mixture. Continue mixing the mixture for another 3.5 minutes.
[0199] 7. Add the dicumyl peroxide (DCP) cross-linking agent, and
the powder to the mixture. Continue mixing the mixture for another
5 minutes.
Blowing/Foaming
[0199] [0200] 8. Transfer a portion of the mixture from step 7 into
a mold measuring 17.5 cm.times.12 cm.times.2.3 cm. [0201] 9. Insert
the mold into a blowing machine at 160.degree. C. and apply a
pressure of 155 kg/cm.sup.2 for 35 minutes. [0202] 10. Release the
pressure and take the blown EVA slab from the mold. [0203] 11. Set
the blown EVA slab aside to cool and shrink to its stable size.
Results in a smooth EVA sheet, with no fine details. [0204] 12.
Repeat steps 8-11 above until the entire mixture is foamed.
Cutting
[0204] [0205] 13. Cut the EVA sheets into smaller sizes, [0206] 14.
Trim off the smooth surface of the EVA sheets and cut the EVA
sheets to the desired thickness. [0207] 15. Cut insoles out from
the EVA sheets.
[0208] While reference has been made to various preferred
embodiments of the invention other variations, implementations,
modifications, alterations and embodiments are comprehended by the
broad scope of the appended claims. Some of these have been
discussed in detail in this specification and others will be
apparent to those skilled in the art. Those of ordinary skill in
the art having access to the teachings herein will recognize these
additional variations, implementations, modifications, alterations
and embodiments, all of which are within the scope of the present
invention, which invention is limited only by the appended
claims.
* * * * *