BODY SUPPORT ARTICLES COMPRISING VISCOELASTIC FOAMS AND PYRETHROIDS AND/OR SUPPORT MEMBERS AND PYRETHROIDS

Abstract

A body support article, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face, the body support article comprising a viscoelastic foam layer; and a pyrethroid, wherein the pyrethroid is disposed in a first zone of the body support article, wherein the first zone consists of a volume of the body support article having an upper first zonal face. Methods of making body support articles comprising a pyrethroid.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

Generally, the present disclosure relates to body support articles, such as mattresses, and, more specifically, to body support devices comprising viscoelastic foams and pyrethroids.

Description of the Related Art

Insects that thrive on materials that come into contact with humans, such as beds and bedding, can cause a number of health problems. Bed bugs, bed-bugs, or bedbugs are parasitic insects of the cimicid family that feed exclusively on blood. Cimex lectularius, the common bedbug, is the best known, as it prefers to feed on human blood. The name “bedbug” derives from the preferred habitat of Cimex lectularius: warm houses, especially near or inside beds and bedding or other sleep areas. Bedbugs are mainly active at night, but are not exclusively nocturnal. They usually feed on their hosts without being noticed.

A number of adverse health effects may result from bedbug bites, including skin rashes, psychological effects, and allergic symptoms. They are not known to transmit any pathogens as disease vectors. Certain signs and symptoms suggest the presence of bedbugs; finding the insects confirms the diagnosis.

Bedbugs have been known as human parasites for thousands of years. At a point in the early 1940s, they were mostly eradicated in the developed world, but have increased in prevalence since 1995, likely due to pesticide resistance, governmental bans on effective pesticides, and greater ease of travel from underdeveloped countries. Because infestation of human habitats has been on the increase, bedbug bites and related conditions have been on the rise as well.

As suggested above, mattresses and other body support articles, e.g., mattress toppers, pillows, and cushions, may provide a habitat for Cimex species, particularly but not exclusively Cimex lenticularis.

Accordingly, it would be desirable to provide body support articles that resist, repel, control, or eliminate bedbugs.

SUMMARY OF THE INVENTION

The following presents a simplified summary of the disclosure in order to provide a basic understanding of some aspects of the disclosure. This summary is not an exhaustive overview of the disclosure. It is not intended to identify key or critical elements of the disclosure or to delineate the scope of the disclosure. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.

In one embodiment, the present disclosure is directed to a body support article, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face, the body support article comprising a viscoelastic foam layer; and a pyrethroid, wherein the pyrethroid is disposed in a first zone of the body support article, wherein the first zone consists of a volume of the body support article having an upper first zonal face.

In one embodiment, the present disclosure is directed to a method, comprising: combining at least one polyol and a pyrethroid, to yield a first zone precursor composition; foaming the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid, and forming a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.

In another embodiment, the present disclosure is directed to an article, such as a mattress or pillow, that includes viscoelastic foam that comprises a pyrethroid. The viscoelastic foam comprising the pyrethroid may form one or more zones of the article.

In one embodiment, the present disclosure is directed to a system, comprising a processing controller configured to control a body support article manufacturing system; and the body support article manufacturing system, wherein the body support article manufacturing system is configured to: combine at least one polyol and a pyrethroid, to yield a first zone precursor composition; foam the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid, and form a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.

The present disclosure may provide for body support articles that resist, repel, control, or eliminate bedbugs. Though not to be bound by theory, such anti-bedbug properties may be imparted by the pyrethroid contained within the body support article.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:

FIG. 1A depicts a stylized top view of a body support article, in accordance with embodiments herein.

FIG. 1B depicts a stylized left side view of a body support article, in accordance with embodiments herein.

FIG. 1C depicts a stylized head side view of a body support article, in accordance with embodiments herein.

FIG. 2A depicts a stylized left side view of a first body support article comprising a pyrethroid disposed in a first zone thereof, in accordance with embodiments herein.

FIG. 2B depicts a stylized left side view of a body support article comprising a pyrethroid disposed in an alternative first zone thereof, in accordance with embodiments herein.

FIG. 3 depicts a stylized left side view of a second body support article comprising a pyrethroid disposed in a first zone thereof, in accordance with embodiments herein.

FIG. 4 depicts a stylized left side view of a third body support article comprising a pyrethroid disposed in a first zone thereof, wherein the volume of the first zone is coincident with the volume of a mattress topper, in accordance with embodiments herein.

FIG. 5A depicts a stylized left side view of a fourth body support article comprising a pyrethroid in both a first zone and a second zone, in accordance with embodiments herein.

FIG. 5B depicts a stylized bottom view of the fourth body support article comprising a pyrethroid in both a first zone and a second zone, in accordance with embodiments herein.

FIG. 6 presents a flowchart of a method, in accordance with embodiments herein.

FIG. 7 is a schematic representation of a system, in accordance with embodiments herein.

FIG. 8 depicts a stylized left side view of a fifth body support article comprising a pyrethroid, in accordance with embodiments herein.

For the avoidance of doubt, and in accordance with practice before the United States Patent and Trademark Office, none of the present figures are to scale.

While the subject matter disclosed herein is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

DETAILED DESCRIPTION

Various illustrative embodiments of the disclosure are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will, of course, be appreciated that, in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The present subject matter will now be described with reference to the attached figures. Various structures, systems and devices are conceptually depicted in the drawings for purposes of explanation only and to not obscure the present disclosure with details that are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.

The use of the words “a” or “an” when referring to an element of the present disclosure does not limit the disclosure to only one instance of that element being present. For example, if the disclosure refers to a body support article as comprising “a viscoelastic foam layer” or “a pyrethroid,” the body support article may include more than one viscoelastic foam layer, more than one pyrethroid, or both.

Embodiments herein may provide body support articles, such as mattresses containing a viscoelastic foam layer, that resist, repel, control, or eliminate certain insects, such as bedbugs.

Embodiments herein also may be directed to a method of combining at least one polyol and a pyrethroid, to yield a first zone precursor composition; foaming the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid, and forming a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.

Embodiments herein may also be directed to a directed to a system, comprising a processing controller configured to control a body support article manufacturing system; and the body support article manufacturing system, wherein the body support article manufacturing system is configured to: combine at least one polyol and a pyrethroid, to yield a first zone precursor composition; foam the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid, and form a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.

In one embodiment, the present disclosure relates to a body support article, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face, the body support article comprising a viscoelastic foam layer; and a pyrethroid, wherein the pyrethroid is disposed in a first zone of the body support article, wherein the first zone consists of a volume of the body support article having an upper first zonal face.

In some embodiments, the upper first zonal face may be coincident with the top face of the body support article.

Viscoelastic foams, and layers of body support articles formed therefrom, are known in the art. Typically, they comprise polyurethanes generated by polymerizing one or more polyols with one or more isocyanates, as is known to the person of ordinary skill in the art. Viscoelastic foams may be produced from a variety of starting materials under a variety of process conditions, to yield viscoelastic foams having a variety of properties. In one embodiment, the viscoelastic foam layer comprises an open-celled non-reticulated viscoelastic foam (sometimes referred to as “memory foam” or “low resilience foam”).

In one embodiment, the viscoelastic foam layer may have a density from about 10 kg/m³ to about 250 kg/m³, such as from about 50 kg/m³ to about 120 kg/m³. In an even more particular embodiment, the viscoelastic foam layer may have a density of about 80-85 kg/m³. Alternatively or in addition, the viscoelastic foam layer may have a hardness from about 5 N to about 20 N, such as a hardness of about 10 N.

In one embodiment, the viscoelastic foam layer may comprise from about 15 weight parts to about 75 weight parts toluene diisocyanate (TDI) residues per 100 weight parts polyol residues; the viscoelastic foam layer has an irregular cell structure; and/or the viscoelastic foam layer has a density less than or equal to 2 pounds/cubic foot (0.032 g/cm³), an air flow greater than or equal to 2.5 CFM, a recovery time greater than or equal to 4 seconds, an indentation force deflection (IFD) less than or equal to 10 pounds/square foot (478.8 Pa), and a height loss less than or equal to 10% after prolonged compression of 90% of an original height. Viscoelastic foams of these exemplary embodiments are described in more detail in a provisional application, U.S. 63/104,835, filed Oct. 23, 2020, entitled “Low-Density Viscoelastic Foams, Body Support Articles Comprising Same, And Methods for Making Same,” assigned to Sinomax USA, Inc and incorporated herein by reference.

In embodiments, in addition to a viscoelastic foam layer, a body support article may comprise one or more non-viscoelastic foam layers, such as non-viscoelastic polyurethanes, traditional mattress layers comprising mechanical support elements, e.g., springs encased in a fabric and/or surrounded by a foam, etc. Numerous variations in the number, type, and arrangement of layers to be included in a body support article may be effected as a routine matter by the person of ordinary skill in the art having the benefit of the present disclosure. The other layer(s) and the viscoelastic foam layer may be bonded together by any suitable adhesive. The other layer(s) and the viscoelastic foam layer may be assembled using any process and/or equipment known in the art.

In embodiments, the viscoelastic foam layer and/or one or more other layers of a body support article may comprise one or more channels permitting airflow through the layer, providing increased cooling to a user of the body support article. Alternatively or in addition, the viscoelastic foam layer and/or one or more other layers of a body support article may comprise one or more support elements, such as tubular foam springs, memory foam springs, mechanical springs, foam spheres, foam hemispheres, air bladders, water bladders, etc., providing increased support to the user of the body support article. In particular embodiments, the viscoelastic foam layer and/or one or more other layers of a body support article may comprise one or more channels, wherein at least one channel contains one or more support elements. Such embodiments include, but are not limited to, those disclosed in U.S. patent application Ser. Nos. 16/257,806; 16/746,481; 16/752,293; 16/693,091; and Ser. No. 16/693,133; all of which are hereby incorporated by reference.

A pyrethroid, as used herein, is a compound comprising a chrysanthemic acid moiety. The (+)-trans form of chrysanthemic acid is as follows:

An exemplary pyrethroid, permethrin ((±)-3-Phenoxybenzyl 3-(2,2-dichlorovinyl)-2,2-dimethylcyclopropanecarboxylate), has the formula:

In one embodiment, the pyrethroid is selected from the group consisting of allethrin; bifenthrin; cyfluthrin; cypermethrin; cyphenothrin; deltamethrin; esfenvalerate; etofenprox; fenpropathrin; fenvalerate; flucythrinate; flumethrin; imiprothrin; λ-cyhalothrin; metofluthrin; permethrin; prallethrin; resmethrin; silafluofen; sumithrin; T-fluvalinate; tefluthrin; tetramethrin; tralomethrin; and transfluthrin.

In accordance with the present disclosure, the pyrethroid is not merely deposited on the body support article, such as by spraying, dipping, or applying an aerosol of a solution comprising the pyrethroid in a particular solvent. Rather, the pyrethroid is incorporated into at least a first zone of the body support article during manufacturing thereof, as will be described in more detail below.

The pyrethroid may be incorporated into the body support article alone, with the aid of a emulsifying agent, as part of an extended release-formulation (e.g., by inclusion of the pyrethroid in a slowly-degradable particle, such as a polylactic acid (PLA) particle, a polyglycolic acid (PGA) particle, or a particle comprising a mixture of PLA and PGA, among other possibilities), or in other forms, all of which will be apparent to the person of ordinary skill in the art having the benefit of the present disclosure

The incorporation of a pyrethroid into the body support article during manufacturing, instead of by a user of the body support article, reduces the need for users to purchase and use compositions comprising the pyrethroid, reduces the risk of pyrethroid misuse or accident harming domestic cats or fish, reduces the risk of pyrethroid release into the environment and harm to wildlife, and allows economies of scale, thereby potentially lowering costs to consumers.

In embodiments, a body support article may further comprise a secondary insecticide, such as a secondary insecticide selected from the group consisting of dimethyl sulfoxide (DMSO), chlorfenapyr, imidacloprid, fipronil, indoxacarb, abamectin, hydroprene, benzyl benzoate, ivermectin, antibiotic miticides, carbamate miticides, formamidine miticides, organochlorine, organophosphate miticides, diatomaceous earth, and dicofol. Although the term “insecticide” is literally functional, in practice, the person of ordinary skill in the art will understand that the term refers to compounds having particular, though varied, structures that repel, control, or eliminate insects.

The secondary insecticide may be desirable to provide an additional insecticidal function. The secondary insecticide may be disposed in the same zone(s) of the body support article as the pyrethroid or in different zone(s).

Body support articles refer to articles intended to bear at least a portion of the weight of at least a portion of a human or animal body, thereby providing comfort to the human or animal. In one embodiment, the body support article is a mattress, a mattress topper, a pillow, or a cushion. Exemplary body support articles will be described with reference to FIG. 1A through FIG. 5B.

Turning to FIG. 1A, a stylized top view of a mattress 100, in accordance with embodiments herein, is illustrated. The mattress 100 is substantially a rectangular prism, i.e., it has a generally rectangular profile in top view, with top face 110t facing the viewer; left side face 110l and right side face 110r being opposed; and head side face 110h and foot side face 110f being opposed. Bottom face 110b opposed to the top face 110t is not shown in FIG. 1A but is a mirror image of top face 110t.

FIG. 1B shows a stylized left side view of the mattress 100. Left side face 110l faces the viewer; top face 110l and bottom face 110b are opposed; and head side face 110h and foot side face 110f are opposed. Right side face 110r opposed to the left side face 110l is not shown in FIG. 1B but is a mirror image of left side face 110l.

FIG. 1C shows a stylized head side view of the mattress 100. Head side face 110h faces the viewer; top face 110l and bottom face 110b are opposed; and right side face 110r and left side face 110l are opposed. Foot side face 110f opposed to the head side face 110h is not shown in FIG. 1C but is a mirror image of head side face 110h.

In some embodiments, the mattress 100 may be conformable such that either of the two largest faces may be the top face 110t; either of two opposed sides may be the left side face 110l; and either of the other two opposed sides may be the head side face 110h. In other embodiments, the mattress 100 may be configured such that one of the two largest faces is intended to be the top face 110t. Alternatively or in addition, the mattress 100 may be configured such that one of the opposed sides that could be the head or foot side face is intended to be the head side face 110h; one of opposed sides that could be the left or right side face is intended to be the left side face 110l; or both.

FIG. 2A illustrates a stylized side view of a first mattress 200 in accordance with embodiments herein. The side view shows left side face 110l. In the depicted embodiment, the first mattress 200 comprises a single viscoelastic foam layer. In other words, the first mattress 200 may be considered to consist of a viscoelastic foam layer having an upper foam face and a lower foam face, wherein the upper foam face is coincident with the top face 110t of the first mattress 200, and the lower foam face is coincident with the bottom face 110b of the first mattress 200.

In the first mattress 200, the pyrethroid is disposed in a first zone 221 of the first mattress 200. The first zone 221 consists of a volume of the body support article having an upper first zonal face 221t. In one embodiment, such as that shown in FIG. 2A, the upper first zonal face 221t is coincident with the top face 110t of the body support article 100.

Herein, we will use phrases along the lines of “first face coincident with second face” to mean that each point of the first face is also a point of the second face, and vice versa. Referring to this aspect of the first mattress 200, each point of the upper first zonal face 221t is a point of the top face 110t and vice versa. This phrasing is consistent with the specialized meaning of “coincident” in geometry and allied disciplines.

The person of ordinary skill in the art will understand that use of geometric terms such as “point,” “face,” “coincident,” etc. represents an idealization, and that no real-world process can generate instances of the first mattress 200 or any portion thereof, or any other mattress depicted herein (e.g., 100, 300, 400, or 500), that perfectly embody a geometric ideal. For example, we use the term “face” when the term “substantially facial” may be technically more precise, but is unnecessarily wordy and does no better at facilitating understanding of the present disclosure. For example, a quilted or tufted top face of a mattress or mattress topper is not strictly, in the geometric definition, a “face,” but is substantially facial (e.g., approximately planar), and will be referred to as a “face” herein.

In the first mattress 200, the first zone 221 further comprises a lower first zonal face 221b. The lower first zonal face 221b may not be visibly defined, i.e., in a true side view of a real-world instance of the first mattress 200, or a cross-section taken by physical slicing the first mattress 200 along a plane parallel to the left side face 110l, the naked eye may not be able to discern the first zone 221 from other portions of the first mattress 200.

In one embodiment, the lower first zonal face 221b may be more than 0.25 inches (0.64 cm) and less than 6 inches (15 cm) from the upper first zonal face 221t.

In a particular further embodiment, the lower first zonal face 221b may be 0.3 inches (0.76 cm) or more from the upper first zonal face 221t. In another particular further embodiment, the lower first zonal face 221b may be 0.4 inches (1.02 cm) or more from the upper first zonal face 221t. In yet another particular further embodiment, the lower first zonal face 221b may be 0.5 inches (1.27 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 0.6 inches (1.52 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 0.7 inches (1.78 cm) or more from the upper first zonal face 221t. In yet another particular further embodiment, the lower first zonal face 221b may be 0.8 inches (2.03 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 0.9 inches (2.29 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 1.0 inches (2.54 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 1.25 inches (3.18 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 1.5 inches (3.81 cm) or more from the upper first zonal face 221t. In an additional particular further embodiment, the lower first zonal face 221b may be 1.75 inches (4.45 cm) or more from the upper first zonal face 221t. In still an additional particular further embodiment, the lower first zonal face 221b may be 2 inches (5.08 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 2.5 inches (6.35 cm) or more from the upper first zonal face 221t. In yet another particular further embodiment, the lower first zonal face 221b may be 3.0 inches (7.62 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 4.0 inches (10.16 cm) or more from the upper first zonal face 221t. In still another particular further embodiment, the lower first zonal face 221b may be 5.0 inches (12.7 cm) or more from the upper first zonal face 221t.

The above description of the lower zonal face 221b being a particular distance or more from the upper zonal face 221t is compatible with the first zone 221 having the shape of a rectangular prism. However, the first zone 221 need not be a rectangular prism. In such embodiments, any stated distance between the lower zonal face 221b and the upper zonal face 221t is a minimum distance therebetween.

In one embodiment, wherein the pyrethroid is permethrin, the permethrin may be present in the first zone 221 in a concentration from 1 weight part per trillion weight parts of the first zone 221 to 1 weight part per thousand weight parts of the first zone 221. The concentration may vary from point to point within the first zone 221, either through intra-run variation when forming a particular instance of the first mattress 200; through limits in the manufacturing technology used to incorporate permethrin into the first zone 221; through intentional generation of a permethrin concentration gradient within the first zone 221, e.g. to yield a greater permethrin concentration in proximity to the top face 110t and hence to a user of the first mattress 200; through inclusion of a highly concentrated permethrin in a slowly-degradable particle, wherein the degradation of the particle releases permethrin to yield a steady, lower concentration thereof in the first zone 221; through differential environmental degradation of permethrin during use, e.g., permethrin is susceptible to degradation by oxygen or solar radiation, and as a result, permethrin in proximity to a face 110 of the first mattress 200 may degrade more rapidly than permethrin deeper in the interior of the first mattress 200, thereby lowering the permethrin concentration in proximity to a face 110 relative to the interior; and/or for other reasons known to the person of ordinary skill in the art having the benefit of the present disclosure.

The person of ordinary skill in the art having the benefit of the present disclosure may determine optimal subranges for permethrin, and ranges, optimal subranges, and concentration variations for other pyrethroids, as a routine matter.

FIG. 2B shows an alternative embodiment of a mattress 201. The mattress 201 and many of its elements generally resemble the first mattress 200 and many of its elements described with reference to FIG. 2A. Elements with like reference numerals between FIG. 2A and FIG. 2B, or between any two figures herein, will substantially be identical, except for specific features or properties described with reference to a particular figure.

In embodiments such as that shown in FIG. 2B, the first zone 221 may be positioned such that the upper first zonal face 221t is not coincident with the top face 110t of the mattress, e.g., mattress 201. In other words, the first zone 221 may be positioned in the mattress 201 such that the first zone 221 substantially does not come into contact with a person or a pet reclining on the mattress 201, but still has substantial proximity to the surface to decrease the amount of insects or bedbugs residing in the mattress 201 and/or traversing the first zone 221 to access a person's body for feeding. Preventing contact of the pyrethroid with a person or pet is especially desirable when the owner of the mattress owns a housecat, because pyrethroids are generally highly toxic to cats.

In alternative embodiments, the first zone 221 may continue to the sides 110h, 110f and/or to the bottom 110b portions of the mattress 201 in a similar fashion as shown in FIG. 2A or FIG. 2B.

FIG. 3 depicts a stylized side view of a second mattress 300, in accordance with embodiments herein. Generally, many elements and properties of the second mattress 300 will be as described above regarding comparable elements and properties of the first mattress 200. For the sake of brevity, such comparable elements and properties need not be described again.

In the embodiment depicted in FIG. 3, the second mattress 300 may comprise a single viscoelastic foam layer but need not. The precise arrangement of viscoelastic foam layer(s), other foam layer(s), if any, and non-foam layer(s), if any can be effected in the practice of routine skill for the ordinary artisan having the benefit of the present disclosure.

Regardless how many viscoelastic foam layers, other foam layers, and/or non-foam layers may be present in the second mattress 300, the upper zonal face 221t of the first zone 221 of the second mattress 300 is below the top face 110t of the second mattress 300. The second mattress 300 accordingly comprises a pyrethroid-free zone 120 between the top face 110t of the second mattress 300 and the upper first zonal face 221t of the first zone 221.

For the avoidance of doubt, any layers (e.g., the viscoelastic foam layer(s), any non-viscoelastic foam layer(s), and any non-foam layer(s)) of any mattress 200, 201, 300, 400, or 500, and any zones of the mattress may be coincident, but need not be. In other words, the first zone 221 should not be construed as being coincident with one particular layer of the mattress. Also, unless a face of the first zone 221 is expressly identified as being coincident with a face of the mattress, the face in question of the first zone 221 should not be construed as being coincident with a boundary between two adjacent layers of the mattress.

FIG. 4 depicts a stylized side view of a third mattress 400, in accordance with embodiments herein. Generally, many elements and properties of the third mattress 400 will be as described above regarding comparable elements and properties of the first mattress 200 and/or the second mattress 300. For the sake of brevity, such comparable elements and properties need not be described again.

In the third mattress 400, the mattress comprises multiple layers, e.g., a viscoelastic foam layer 430 and a second layer 440. In other words, the viscoelastic foam layer 430 has an upper foam face 431t and a lower foam face 431b, wherein the upper foam face 431t is coincident with the top face 110t of the third mattress 400 and the lower foam face 431b is more than 2 inches (5.08 cm) and less than 8 inches (20.32 cm) from the upper foam face. In this embodiment, the viscoelastic foam layer 430 may be configured as a mattress topper.

The second layer 440 may comprise a different viscoelastic foam and/or have different firmness, support, comfort, etc. properties than the viscoelastic foam layer 430. Alternatively, the second layer 440 may comprise a non-viscoelastic foam or a non-foam. The second layer 440 may be replaced with a plurality of second layers (not shown) as a routine practice for the person of ordinary skill in the art having the benefit of the present disclosure.

In the third mattress 400, the volume of the first zone 221 is a subset of the volume of the viscoelastic foam layer 430, with the upper first zonal face 221t being below the top face 110t, 431t of the viscoelastic foam layer 430t and the third mattress 400. In other words, the third mattress 400 may contain a viscoelastic foam mattress topper with anti-bedbug properties. This embodiment may be implemented by manufacturers who wish to differentiate mattresses containing the same lower layer(s) 440 by providing mattress toppers with different properties.

Turning to FIG. 5A and FIG. 5B, a fourth mattress 500 is depicted in side view (e.g., left side view) in FIG. 5A and in bottom view in FIG. 5B. Generally, many elements and properties of the fourth mattress 500 will be as described above regarding comparable elements and properties of the first mattress 200, the second mattress 300, and/or the third mattress 400. For the sake of brevity, such comparable elements and properties need not be described again.

The fourth mattress 500 has in common with the mattress 201 of FIG. 2B that the first zone 221 contains a partial volume of the mattress in proximity to the top face 110t. The fourth mattress 500 differs in further comprising a second zone 522 in which the pyrethroid is further disposed. The second zone 522 comprises a second zonal face. In one embodiment, every point on the second zonal face may be coincident with a point on one of the bottom face, the left side face, the right side face, the head side face, and the foot side face. In other words, the second zone 522 may, but need not, be exposed on a face of the fourth mattress 500 other than the top face 110t.

In the depicted embodiment, best seen in FIG. 5B, the second zone 522 comprises four second zonal faces, with one face coincident with a portion of the left side face 110l, another face coincident with a portion of the right side face 110r, an additional face coincident with a portion of the head side face 110h, and a further face coincident with a portion of the foot side face 110f. In this embodiment, the presence of the pyrethroid interdicts bedbug passage in and out of most of the area of all faces of the fourth mattress 500 proximate to a reclining user or to the top face 110t. The passage of bedbugs in and out of the central region of the bottom face 110b need not be interdicted, because bedbugs would either have to traverse the exposed faces of the second zone 522 and the first zone 221 to reach a user reclining on the top face 110t of the fourth mattress 500, or burrow through the first zone 221 to do so.

In other embodiments, not shown, a face of the second zone 522 may be coincident with the bottom face 110b of the fourth mattress 500. In this embodiment, the pyrethroid interdicts passage of bedbugs in and out of the bottom face 110b in addition to most of the side faces 1101, 110r, 110h, and 110f.

FIG. 8 depicts a fifth mattress 800 in side view (e.g., left side view). Generally, many elements and properties of the fifth mattress 800 will be as described above regarding comparable elements and properties of the first mattress 200, the second mattress 300, the third mattress 400, the fourth mattress 500, and/or mattress 201. For the sake of brevity, such comparable elements and properties need not be described again.

The fifth mattress 800 comprises a plurality of support members 860. In one embodiment, the support members 860 may be steel springs, foam springs, plastic springs, gel bodies, or two or more thereof, among other possibilities. Each of the support members 860 is encased by a encasing member 821. The encasing member 821 may be a viscoelastic foam element, a non-viscoelastic foam element, a woven element, a non-woven element, a plastic element, a gel element, or two or more thereof, among other possibilities.

In the fifth mattress 800, each of the encasing members 821 may comprise the pyrethroid. In other words, any of the encasing members 821 is a first zone, as the term “first zone” is used herein. Any of the other encasing members 821 is a second zone, as the term “first zone” is used herein.

The embodiments shown in FIG. 2-FIG. 5 and FIG. 8 are merely exemplary of a body support article that may comprise a viscoelastic foam layer and a pyrethroid in accordance with embodiments herein. The person of ordinary skill in the art having the benefit of the present disclosure will readily be able to combine aspects of two or more of the various embodiments, unless such aspects are mutually exclusive. The person of ordinary skill in the art having the benefit of the present disclosure could readily prepare a mattress topper, a pillow, a cushion, or the like instead of a mattress without moving beyond the spirit and scope of the invention as defined by the appended claims. For example, the teachings above regarding a body support article having four side faces apply to a cylindrical cushion, i.e., a cushion that has a top face, an opposed bottom face, and a single side face, such as is commonly used with papasan chairs. The person of ordinary skill in the art will understand that any quadrant of the circumference of the single side face is equivalent to one of the left side face 110l, right side face 110r, head face 110h, and foot face 110f.

In alternative embodiments, the concepts disclosed herein regarding incorporating the insecticide, e.g., pyrethroid, into the body support article 100 may be applicable to a variety of types of articles, such as mattresses that contain support members, such as coils, pocket coils, non-woven pocket coils, foam support members, etc. In some embodiments, the support members may be separately treated with an insecticide, e.g., pyrethroid, prior to being implemented into an article 100, such as a mattress 201.

FIG. 6 presents a flowchart of a method 600, in accordance with embodiments herein. The method 600 comprises combining (at 610) at least one polyol and a pyrethroid, to yield a first zone precursor composition.

A polyol is an organic compound containing more than one hydroxyl groups. Any polyol may be used. If multiple polyols are used, any relative proportions thereof may be used. Polyols range from very small molecules, such as methylene oxide, ethylene oxide, and propylene oxide, to long-chain and or polymeric compounds having molecular weights in the thousands or tens of thousands of daltons (Da).

Other compounds, e.g., emulsifiers or the like, may be combined with the polyol(s) and the pyrethroid when combining (at 610). Techniques for combining polyol(s) and the pyrethroid, and other compounds that may be desirable and techniques for including those, will be apparent to the person of ordinary skill in the art having the benefit of the present disclosure.

The method 600 also comprises foaming (at 620) the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid.

As is well known, viscoelastic foams may be formed by preparing a first mixture, typically comprising one or more polyols, followed by foaming the first mixture with an isocyanate, to yield the viscoelastic foam.

An isocyanate is an organic compound containing a functional group with the formula R—N═C═O. A diisocyanate is an organic compound comprising two isocyanate functional groups. Exemplary isocyanates that may be used herein include toluene diisocyanate (TDI), specifically, any of the various TDI isomers in various relative proportions, e.g., commonly commercially available formulations of 80/20 TDI (80 wt % 2,4-TDI and 20 wt % 2,6-TDI) and 65/35 TDI (65 wt % 2,4-TDI and 35 wt % 2,6-TDI).

Other compounds, e.g., foaming aids or the like, may be combined with the first zone precursor composition and the isocyanate(s) when foaming (at 620). Techniques for foaming polyol(s) compositions with isocyanate(s), and other compounds that may be desirable to include and techniques for including those, will be apparent to the person of ordinary skill in the art having the benefit of the present disclosure.

Specifically, in addition to the polyol(s), the pyrethroid, and the isocyanate(s), the combining (at 610) and/or the foaming (at 620) may further include combining one or more other materials.

In one embodiment, the combining (at 610) and/or the foaming (at 620) may include a cell-opening silicone additive.

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include a surfactant, such as a silicone surfactant formulated for use in a flexible slabstock foam. According to one embodiment, the surfactant may be Tegostab® B8220 (Evonik Industries, Essen, Germany).

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include a gel-catalyzing amine.

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include a blow-catalyzing amine.

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include stannous octoate.

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include a chain modifier.

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include acetone.

Alternatively or in addition, the combining (at 610) and/or the foaming (at 620) may include water.

The method 600 further comprises forming (at 630) a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.

Forming (at 620) may comprise one or more actions, depending on operator preference and selectable as a routine matter by the person of ordinary skill in the art having the benefit of the present disclosure. The person of ordinary skill in the art having the benefit of the present disclosure is well aware how to make single layer and multi-layer body support articles, wherein one or more layers comprise viscoelastic foam, zero or more layers comprise a non-viscoelastic foam, and zero or more layers comprise a non-foam material.

The body support article resulting from forming (at 620) may be a mattress, a mattress topper, a pillow, or a cushion. In one embodiment, forming (at 620) may yield a mattress 200, 201, 300, 400, or 500.

In embodiments, the method 600 may further comprising forming (at 640) a second zone comprising a second viscoelastic foam and the pyrethroid, wherein the second zone comprises a second zonal face; wherein forming (at 630) the body support article further comprises including the second zone in the body support article. In one embodiment, every point on the second zonal face may be coincident with a point on one of the bottom face, the left side face, the right side face, the head side face, and the foot side face. Forming (at 640) the second zone may be substantially similar to combining (at 610) and foaming (at 620).

Alternatively or in addition, the method 600 may further comprise including (at 650) a secondary insecticide in the body support article. Particular secondary insecticides to include, techniques for doing so, locations within the body support article to do so, and other parameters may be routinely selected by the person of ordinary skill in the art having the benefit of the present disclosure.

The method 600 may also comprise additional steps, not shown, to form one or more other layers of the body support article and to bond such other layers with the first zone.

For the avoidance of doubt, the first zone may be coincident in volume with a discrete viscoelastic foam layer, but need not be. For example, if multiple polyol-containing streams are foamed under conditions such that the foamed streams will form an integrated mass of viscoelastic foam, then one, some, or all of the streams may consist of the first zone precursor composition, yielding a unitary viscoelastic foam layer comprising pyrethroid only in a first zone.

Turning now to FIG. 7, a stylized depiction of a system 700 for forming a body support article comprising a viscoelastic foam layer and a pyrethroid, in accordance with embodiments herein, is illustrated. The system 700 of FIG. 7 may comprise a body support article manufacturing system 710. The body support article manufacturing system 710 may comprise various processing stations, such as a mixing station 720, a foaming station 730, a body support article forming station 740, etc. Data may be gathered from any of the foregoing stations or any other component of the body support article manufacturing system 710 and may be used to modify one or more process parameters used by the various stations or any other component for performing process steps.

The system 700 may also comprise a processing controller 750. One or more of the processing steps performed by the body support article manufacturing system 710 may be controlled by the processing controller 750. The processing controller 750 may be a workstation computer, a desktop computer, a laptop computer, a tablet computer, or any other type of computing device comprising one or more software products that are capable of controlling processes, receiving process feedback, receiving test results data, performing learning cycle adjustments, performing process adjustments, etc.

In the particular embodiment depicted schematically in FIG. 7, the body support article manufacturing system 710 may receive one or more polyols 721 and a pyrethroid 722 at a mixing station 720. For example, the polyol(s) 721 and the pyrethroid 722 may be provided as liquids or in solutions via a first piping/pumping system 702 or comparable apparatus. The received polyol(s) 721 and the pyrethroid 722 may be mixed or combined at mixing station 720, to yield a first zone precursor composition, as described above. The mixing station 720 may comprise any appropriated apparatus known to the person of ordinary skill in the art.

The body support article manufacturing system 710 may foam the first zone precursor composition with one or more isocyanates to form a first zone comprising a viscoelastic foam and the pyrethroid, at foaming station 730. The foaming station 730 may receive the isocyanate(s) 731 as liquid(s) or in solution(s) via a second piping/pumping system 703 or comparable apparatus. The foaming station 730 may comprise any appropriate apparatus known to the person of ordinary skill in the art.

The body support article manufacturing system 710 may form, at a body support article forming station 730, a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face. The body support article forming station 730 may comprise any appropriate apparatus known to the person of ordinary skill in the art.

The body support article forming station 730 may deliver body support articles, e.g., mattress 200, 201, 300, 400, or 500, such as by conveyor belt 704 or comparable conveyance apparatus, to subsequent processing steps, including, but not necessarily limited to, curing the viscoelastic foam, other foams, or other non-foam materials; packaging the body support article, and entering the body support article into the chain of commerce. Such subsequent steps will be apparent to the person of ordinary skill in the art having the benefit of the present disclosure and need not be described further.

The body support article manufacturing system 710 may further include stations comprising apparatus configured to form a second zone comprising a second viscoelastic foam and the pyrethroid, wherein the second zone comprises a second zonal face; wherein forming the body support article further comprises including the second zone in the body support article; include a secondary insecticide in the body support article; and/or perform other processing actions known to the person of ordinary skill in the art.

The particular embodiments disclosed above are illustrative only, as the disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the process steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the disclosure.

Accordingly, the protection sought herein is as set forth in the claims below.

Claims

1. A body support article, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face, the body support article comprising:

a viscoelastic foam layer; and

a pyrethroid, wherein the pyrethroid is disposed in a first zone of the body support article, wherein the first zone consists of a volume of the body support article having an upper first zonal face.

2. The body support article of claim 1, wherein the pyrethroid is selected from the group consisting of allethrin; bifenthrin; cyfluthrin; cypermethrin; cyphenothrin; deltamethrin; esfenvalerate; etofenprox; fenpropathrin; fenvalerate; flucythrinate; flumethrin; imiprothrin; λ-cyhalothrin; metofluthrin; permethrin; prallethrin; resmethrin; silafluofen; sumithrin; τ-fluvalinate; tefluthrin; tetramethrin; tralomethrin; and transfluthrin.

3. The body support article of claim 1, wherein the pyrethroid is permethrin.

4. The body support article of claim 3, wherein the permethrin is present in the first zone in a concentration from 1 weight part per trillion weight parts of the first zone to 1 weight part per thousand weight parts of the first zone.

5. The body support article of claim 1, further comprising a support member, and wherein the first zone is coincident with a member encasing the support member.

6. The body support article of claim 1, wherein the first zone further comprises a lower first zonal face, wherein the lower first zonal face is more than 0.25 inches (0.64 cm) and less than 6 inches (15 cm) from the upper first zonal face.

7. The body support article of claim 1, wherein the viscoelastic foam layer has an upper foam face, wherein the upper foam face is coincident with the top face of the body support article.

8. The body support article of claim 7, wherein the viscoelastic foam layer has a lower foam face, wherein the lower foam face is more than 0.25 inches (0.64 cm) and less than 6 inches (15 cm) from the upper foam face.

9. The body support article of claim 7, wherein the viscoelastic foam layer has a lower foam face, wherein the lower foam face is coincident with the bottom face of the body support article.

10. The body support article of claim 1, wherein the pyrethroid is further disposed in a second zone of the body support article, wherein the second zone comprises a second zonal face.

11. The body support article of claim 10, wherein every point on the second zonal face is coincident with a point on one of the bottom face, the left side face, the right side face, the head side face, and the foot side face.

12. The body support article of claim 1, further comprising a secondary insecticide.

13. The body support article of claim 12, wherein the secondary insecticide is selected from the group consisting of dimethyl sulfoxide (DMSO), chlorfenapyr, imidacloprid, fipronil, indoxacarb, abamectin, hydroprene, benzyl benzoate, ivermectin, antibiotic miticides, carbamate miticides, formamidine miticides, organochlorine, organophosphate miticides, diatomaceous earth, and dicofol.

14. The body support article of claim 1, wherein the body support article is a mattress, a mattress topper, a pillow, or a cushion.

15. A method, comprising:

combining at least one polyol and a pyrethroid, to yield a first zone precursor composition;

foaming the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid, and

forming a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.

16. The method of claim 15, wherein the pyrethroid is selected from the group consisting of allethrin; bifenthrin; cyfluthrin; cypermethrin; cyphenothrin; deltamethrin; esfenvalerate; etofenprox; fenpropathrin; fenvalerate; flucythrinate; flumethrin; imiprothrin; λ-cyhalothrin; metofluthrin; permethrin; prallethrin; resmethrin; silafluofen; sumithrin; τ-fluvalinate; tefluthrin; tetramethrin; tralomethrin; and transfluthrin.

17. The method of claim 15, wherein the pyrethroid is permethrin.

18. The method of claim 17, wherein the permethrin is present in the first zone in a concentration from 1 weight part per trillion weight parts of the first zone to 1 weight part per thousand weight parts of the first zone.

19. The method of claim 15, wherein the first zone comprises an upper first zonal face.

20. The method of claim 15, further comprising:

incorporating a support member into the body support article, and

encasing the support member with an encasing member comprising the first zone.

21. The method of claim 15, wherein the first zone further comprises a lower first zonal face, wherein the lower first zonal face is more than 0.25 inches (0.64 cm) and less than 6 inches (15 cm) from the upper first zonal face.

22. The method of claim 15, further comprising:

forming a second zone comprising a second viscoelastic foam and the pyrethroid, wherein the second zone comprises a second zonal face;

wherein forming the body support article further comprises including the second zone in the body support article.

23. The method of claim 22, wherein the second zone is formed such that every point on the second zonal face is coincident with a point on one of the bottom face, the left side face, the right side face, the head side face, and the foot side face.

24. The method of claim 15, further comprising including a secondary insecticide in the body support article.

25. The method of claim 24, wherein the secondary insecticide is selected from the group consisting of dimethyl sulfoxide (DMSO), chlorfenapyr, imidacloprid, fipronil, indoxacarb, abamectin, hydroprene, benzyl benzoate, ivermectin, antibiotic miticides, carbamate miticides, formamidine miticides, organochlorine, organophosphate miticides, diatomaceous earth, and dicofol.

26. The method of claim 15, wherein the body support article is a mattress, a mattress topper, a pillow, or a cushion.

27. A system, comprising:

a processing controller configured to control a body support article manufacturing system; and

the body support article manufacturing system, wherein the body support article manufacturing system is configured to:

combine at least one polyol and a pyrethroid, to yield a first zone precursor composition;

foam the first zone precursor composition with at least one isocyanate, to form a first zone comprising a viscoelastic foam and the pyrethroid, and

form a body support article comprising the first zone, wherein the body support article comprises a top face, a bottom face opposed to the top face, a left side face, a right side face opposed to the left side face, a head side face, and a foot side face opposed to the head side face.