COVER FOR REDUCING VOC EMISSIONS FROM A FOAM PAD

Abstract

A cover for reducing volatile organic compound emissions from a foam pad includes upper, lower and side panels, wherein the side panel has an integrated air filter and conductive snap attachment. The panels are installed on and removed from a foam pad via attachable seams between the upper panel and side panel, and the side panel and lower panel. The upper panel, lower panel, and attachable seams are air-tight, forcing air laden with chemical gases through the air filter providing cleaner air in the sleeping environment.

Description

FIELD OF THE INVENTION

The present invention generally relates to reducing volatile organic compound (VOC) emissions. More particularly, the present invention relates to reducing volatile organic compound emissions from foam mattresses and pillows in order to provide a healthier living environment.

BACKGROUND OF THE INVENTION

Chemical and polymer based foams were invented and first introduced into living environments in the 1960's. Chemical produced foam materials quickly became the padding of choice for mattress and furniture manufacturers as this type of padding is very comfortable for sitting and lying down. This foam material was compressible, but not to a very high degree.

In the early 1970's, NASA's Ames Research Center funded a development project designed to create a foam substance that could help relieve astronauts of the incredible forces experienced during lift-off. They believed that one of the key secrets to reducing the effects of these forces on the body was to use a foam material that could conform to a person's shape and hold this conformity. While a foam mold of each astronaut's body shape could accomplish this, any movement would take a person out of this position and create incorrect pressure points against the body. Instead, they created a new polyurethane foam material that was more viscous and able to conform to a person's shape and adapt for body movement and then return to its original shape once body pressure was relieved.

This innovation led one of Europe's largest foam manufacturers to begin experiments in the 1980's to perfect visco-elastic foam for mattresses and pillows. In 1991, a Swedish mattress company first introduced visco-elastic polyurethane foam mattresses and pillows in Sweden. In 1992, the new visco-elastic foam mattresses and pillows were introduced and marketed in North America. With wide consumer acceptance of the comfort associated with sleeping on the new foam mattresses and pillows, now commonly referred to as memory foam, nearly every mattress manufacturer in the world now markets memory foam beds and pillows. As of July 2012, memory foam beds and pillows make up approximately fifty percent of all beds and pillows sold in the United States and Canada. In addition, nearly all conventional spring-type mattresses now contain inner-core top layers of polyurethane foam, or other similar chemical produced foams. As such, nearly all mattress sold today contain some kind of chemical produced foam.

The rapid growth and wide consumer acceptance of foam mattresses and pillows is primarily due to the increased comfort they provide during sleep. However, over time, many who sleep on mattresses and pillows containing chemical foam report chemical sensitivities and in some cases adverse health conditions related to breathing the chemical outgases from the foam.

Theoretically, fully reacted chemical based foams are chemically inert. However, noticeable chemical emission odors do continuously outgas from all foam mattresses throughout their useful life. This suggests that all chemical reactions may not be fully complete. It also suggests that continuous mattress expulsion and intake of fresh, oxygenated air may slowly oxidize and break down the foam and thereby cause foam to continuously outgas and expel its degraded chemical load over the useable life of the foam mattress and pillows.

It is particularly problematic that chemical based foams emit volatile organic compounds (VOCs). VOCs are a major component of air pollution. The emission of VOCs are also a major concern for indoor air quality. VOCs include a variety of chemicals, some of which may have adverse health effects in both the long and short term. These health effects include: eye, nose, and throat irritation; headaches; loss of coordination; nausea; damage to liver; damage to kidneys; and damage to the central nervous system. In testing, certain VOCs have even been found to cause cancer in animals, and are suspected or known to cause cancer in humans. Symptoms associated with exposure to VOCs include: conjunctival irritation; nose and throat discomfort; headache; allergic skin reaction; dyspnea; declines in serum cholinesterase levels; nausea; emesis; epistaxis; fatigue; and dizziness. The severity of any symptom resulting from exposure to VOCs depends on the level of exposure and the length of the time exposed. Many who have been exposed to VOCs report immediate symptoms such as: eye and respiratory tract irritation; headaches; dizziness; visual disorders; and memory impairment. And VOC emissions from foam mattresses and pillows are even more problematic as the sudden compression of the mattress or pillow causes VOC laden air to be forced out of the mattress or pillow quickly, leaving a user surrounded by VOCs in the air. This expulsion of VOCs continues all night as a user moves around on a mattress or pillow through the night.

In light of the rapid increase of use of foam mattresses and pillows (and associated levels of reports of adverse health experiences), and given that there has been little scientific research done to verify exposure to chronic low level VOC emissions during sleep is completely safe, it is likely that indoor exposure to chronic low level VOCs, like those released from foam mattresses and pillows during sleep, may have unknown or unrecognized adverse effects. This is especially true for those who are chemically sensitive or who have compromised immune systems or other existing chronic health disorders.

Accordingly, there is a need for a system to reduce and prevent exposure to VOCs and related foam chemical outgas emissions from foam mattresses and pillows during sleep. The present invention fulfills these needs and provides other related advantages.

SUMMARY OF THE INVENTION

The present invention is a cover for reducing volatile organic compound (VOC) emissions from a foam pad. The cover comprises a non-breathable upper and lower panel, as well as a side panel. The side panel has a first edge and a second edge with the first edge being attached to the upper panel, and the second edge being attached to the lower panel. There is also an air filter within the side panel between the first and second edges.

The upper and lower panels are detachable from the first and second edges of the side panel, respectively. The present invention may also include a series of inter-locking teeth for attaching the upper panel to the first edge of the side panel, and another series of inter-locking teeth for attaching the lower panel to the second edge of the side panel. The series of inter-locking teeth create an air-tight seal.

The upper and lower panels may comprise a fabric adjacent to an air-impermeable material. The fabric of the upper and lower panels may be made of a material that wicks heat and moisture away from a user by dissipating heat and moisture across the entire surface of the upper or lower panel.

The air filter within the side panel may comprise a non-woven material containing conductive, activated carbon fibers for filtering chemical-laden air. The conductive, activated carbon fibers may be capable of filtering particles smaller than 20 angstrom. The filter may also include a conductor for electrically grounding the conductive, activated carbon fibers of the air filter.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the invention. In such drawings:

FIG. 1 is a partially cutaway, front perspective view of the filtered mattress cover of the present invention covering a foam mattress;

FIG. 2 is an enlarged view of the different sections of the filtered mattress cover taken from square 2 of FIG. 1;

FIG. 2a is a cross-section taken from line 2a-2a of FIG. 2, illustrating the conductive, activated carbon fibers of the air filter;

FIG. 3 is a side cutaway view of a foam mattress with the filtered mattress cover, illustrating the directed expulsion of VOCs from the foam mattress through the filter of the mattress cover;

FIG. 4 is a rear perspective view of the filtered mattress cover of the present invention covering a foam mattress, illustrating the air-tight seam and zipper; and

FIG. 5 is an enlarged view, taken from square 5 of FIG. 4, of the air-tight seam and zipper allowing for easy installation and removal of the mattress cover.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The filtered cover for reducing volatile organic compound (VOC) emissions from a foam pad of the present invention is generally referred to by the number 10. Although the preferred embodiment in the illustrations is a filtered cover for a foam mattress, the present invention may also be sized to act as a filtered cover for a foam pillow, a foam mattress pad, or any other type of foam pad. In FIG. 1, a foam mattress 20 is shown fitted inside a filtered cover for reducing VOC emissions 10. The filtered cover for reducing VOC emissions 10 is made of an upper panel 12, a lower panel 14, a side panel 16, and an air filter 28.

The upper panel 12 and the lower panel 14 are air-tight. In the preferred embodiment, the upper panel 12 and the lower panel 14 are made of fabric that is coated with a thin layer of polyurethane or similar material to prevent air flow through the panels. The coating may be polyurethane or another similar material that prevents air from passing through the fabric. The fabric of the upper panel 12 and the lower panel 14 may consist of any natural or synthetic woven or knit fabric. The fabric of the upper panel 12 will also help wick heat away from the user in order to prevent the user from becoming too hot. Likewise, the fabric of the upper panel 12 may also wick moisture away from the user as he sleeps, thus enhancing the sleep experience.

The upper panel 12 and lower panel 14 are joined to a side panel 16. The side panel 16 follows the perimeter of the mattress 20. The upper panel 12 and lower panel 14 are joined to the side panel 16 via seams 24. The seams 24 are air-tight, and can be stitched, glued, or fused by some other method that creates an air-tight seal. In the preferred embodiment, the seam 24 is created by interlocking teeth, such as an air-tight zipper. The side panel 16 is made of a non-woven material that contains conductive, activated carbon fibers creating an air filter 28. Thus, the air filter 28 is integral with the side panel 16 all along the perimeter of the mattress 20. The conductive, activated carbon fibers of the air filter 28 are capable of filtering sub-20A (angstrom) particles. This makes the conductive, activated carbon fibers of the air filter 28 ideal for filtering VOCs. The air filter 28 is also capable of filtering phthalates and other related chemical gases. The size of the side panel 16 and integrated air filter 28 will depend on the size of the foam pad being covered. For example, a standard queen size mattress (10 inches deep, 60 inches wide, 80 inches long) with two people sleeping on it would require approximately 600 square inches of filter area to effectively capture and reduce VOCs, phthalates, and related chemical outgasses. This equates to a 2 inch wide by 300 inch long side panel 16 with integrated air filter 28 that would run around the entire circumference of the mattress.

In use, the filter cover 10 is installed on a foam mattress 20 by first positioning the foam mattress 20 on top of the lower panel 14. The sides of the lower panel 14 are brought up to encompass the sides of the foam mattress 20. The side panel 16 with integral air filter 28 is then attached along one edge to the sides of the lower panel 14 via an air-tight zipper, adhesive, or another similar means. The upper panel 12 is then spread across the top of the foam mattress 20. The sides of the upper panel 12 are draped over the edges of the foam mattress and attached to the free edge of the side panel 16 with integral filter. In this way, the foam mattress 20 is entirely contained within the filtered cover 10.

FIG. 1 also illustrates a conductor 18 positioned in the side panel 16. When a person lies on the foam mattress 20, the air carrying chemicals and particles and related gases is rapidly displaced and forced through the foam core creating friction which causes the chemical-laden air to develop a high positive tribo-electric charge. Air is the most positive of the tribo-electric series and polymer foams are highly negative. The conductor 18 connects to an electrical earth ground and is provided to prevent the buildup of electrical charges. As the air passes through the side panel 16 with integral carbon air filter 28 that has been grounded by the conductor 18, the activated carbon absorbs particles and molecules. The grounded surface of the conductive carbon fibers in the air filter 28 electrically attract and hold the smaller electrostatically charged gaseous molecules that are less likely to be readily absorbed by the activated carbon filter alone. This allows for more absorption time. This process captures air born particles, reduces chemically charged outgasses, and prevents those chemically charged outgasses from leaving the mattress core. This leads to a reduction in contaminated bedroom air and creates healthier breathing air space around a person during sleep. In the preferred embodiment, the conductor 18, is a conductive snap attachment.

In FIG. 2, the upper panel 12, lower panel 14, and side panel 16 are shown more closely. Here it can be seen that these panels are joined together by seams 24. As stated above, the seams 24 are air-tight. In another embodiment, the upper panel 12, lower panel 14, and side panel 16 may be joined by interlocking teeth closures, or zippers (not shown). If the panels are joined by zippers, it should be noted that the seal created by the zipper should still be air-tight. This ensures that the chemical gases expelled from the foam mattress are filtered through the air filter 28 integrated into the side panel 16.

FIG. 2a is taken from line 2a-2a of FIG. 2. FIG. 2a illustrates a cross-section of the air filter 28 (as shown in FIG. 2) and the conductive, activated carbon fibers 30 contained therein. The air filter 28 is air-permeable and is made of non-woven activated carbon fibers 30. These carbon fibers 30 trap VOCs and other chemical gases while allowing clean air to pass through. The activated carbon fibers 30 may build up an electrical charge, so the conductor 18 (shown in FIG. 1) must be placed somewhere along the length of the air filter 28, as described above.

FIG. 3 illustrates the process by which chemical gases are filtered through the air filter 28 of the filtered cover for reducing VOC emissions 10. As shown, when the foam mattress 20 is compressed, VOCs 22 and other chemical gases are expelled from the foam mattress 20. Because the foam mattress 20 is encased in the filtered cover for reducing VOC emissions 10, the VOCs cannot escape through the cover 10. Rather, the VOCs 22 and other chemical gases are directed through the air filter 28. The air filter 28 captures the VOCs 22 and other chemical gases, so only that purified air exits the filtered cover 10. It should be noted that while VOCs 22 and other chemical gases are expelled quickly when the foam mattress 20 is compressed, these chemicals continue to outgas from the foam mattress 20 even when there is no compression. When there is no compression, these chemicals will continue to be filtered through the air filter 28 because they will have nowhere else to go.

FIGS. 4 and 5 illustrate an embodiment of the present invention where the side panel does not run all the way around the perimeter of the filtered cover for reducing VOC emissions 10. Depending on the size of the foam pad to be covered, it may not be necessary to include a side panel 16 and integral air filter 28 that run all the way around the perimeter of the foam pad. In that case, a portion of the filtered cover 10 may exist where the upper panel 12 is joined directly to the lower panel 14. As shown, the upper panel 12 and lower panel 14 are joined by a series of interlocking teeth, commonly referred to as a zipper 26. The zipper 26 creates an air-tight seal that does not allow for air to escape the cover 10. As shown in FIG. 5, the upper panel 12 and lower panel 14 joined by the zipper 26 create a close fit with the foam mattress 20 contained therein.

Although several embodiments have been described in detail for purposes of illustration, various modifications may be made to each without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.

Claims

1. A cover for reducing volatile organic compound emissions from a foam pad, comprising:

a non-breathable upper panel;

a side panel with a first edge and a second edge, wherein the non-breathable upper panel is attached to the first edge;

a non-breathable lower panel attached to the second edge of the side panel; and

an air filter within the side panel between the first and second edges.

2. The cover of claim 1, wherein the upper panel is detachable from the first edge of the side panel, and the lower panel is detachable from the second edge of the side panel.

3. The cover of claim 2, including a series of inter-locking teeth for attaching the upper panel to the first edge of the side panel and creating an air-tight seal.

4. The cover of claim 2, including a series of inter-locking teeth for attaching the lower panel to the second edge of the side panel and creating an air-tight seal.

5. The cover of claim 1, wherein the upper and lower panels comprise a fabric adjacent to an air-impermeable material.

6. The cover of claim 1, wherein the upper panel further comprises a material that wicks heat and moisture away from a user by dissipating heat and moisture across the entire surface of the upper panel.

7. The cover of claim 1, wherein the air filter comprises a non-woven material containing conductive, activated carbon fibers.

8. The cover of claim 7, wherein the conductive, activated carbon fibers are capable of filtering sub-20 angstrom sized particles.

9. The cover of claim 7, wherein the air filter further comprises a conductor for electrically grounding the conductive, activated carbon fibers of the air filter.

10. A cover for reducing volatile organic compound emissions from a foam pad, comprising:

a non-breathable upper panel;

a side panel with a first edge and a second edge, wherein the non-breathable upper panel is attached to the first edge;

a non-breathable lower panel attached to the second edge of the side panel; and

an air filter within the side panel between the first and second edges, wherein the air filter comprises a non-woven material containing conductive, activated carbon fibers and a conductor for electrically grounding the conductive, activated carbon fibers of the air filter, the conductor comprising a conductive snap attachment.

11. The cover of claim 11, wherein the air filter is capable of filtering sub-20 angstrom sized particles.

12. The cover of claim 11, wherein the upper panel is detachable from the first edge of the side panel, and the lower panel is detachable from the second edge of the side panel.

13. The cover of claim 11, including a series of inter-locking teeth for attaching the upper panel to the first edge of the side panel, and for attaching the lower panel to the second edge of the side panel, thereby creating an air-tight seal between the upper panel and the first edge of the side panel and between the lower panel and the second edge of the side panel.

14. The cover of claim 11, wherein the upper and lower panels comprise a fabric adjacent to an air-impermeable material.

15. The cover of claim 11, wherein the upper panel further comprises a material that is heat conductive, and the fabric comprises a material that wicks heat and moisture away from the user by dissipating heat and moisture across the entire surface of the upper panel.

16. A cover for reducing volatile organic compound emissions from a foam pad comprising:

a non-breathable air-tight upper panel, comprising a fabric adjacent to an air-impermeable material, wherein the fabric comprises a material that wicks heat and moisture away from the user by dissipating heat and moisture across the entire surface of the upper panel;

a side panel with a first edge and a second edge, wherein the non-breathable upper panel is attached to the first edge;

a non-breathable air-tight lower panel, comprising a fabric adjacent to an air-impermeable material, attached to the second edge of the side panel, the cover created by the upper, lower and side panels sized to fit a standard mattress or pillow;

an air filter contained within the side panel between the first and second edges comprising a non-woven material containing conductive, activated carbon fibers capable of filtering sub-20 angstrom sized particles, and a conductor for electrically grounding the conductive, activated carbon fibers of the air filter; and

a series of inter-locking teeth between the upper panel and the first edge of the side panel, and between the lower panel and the second edge of the side panel that close to create an air-tight seal between the upper panel and the first edge of the side panel, and between the lower panel and the second edge of the side panel.