Abstract:
Mattresses infested with bed bugs and/or dust mites may be cleaned and sanitized through a series of steps beginning with UV irradiation of the mattress. Next, the mattresses are subject to dry steam of a temperature of approximately 356° F. Odors are then removed from the mattress by immersing the mattress in ozone. The mattress is then vacuumed to remove debris and waste. Next the mattress is heated with infrared heaters which produce a temperature of up to 265° F. Finally, the mattress is again vacuumed to remove any remaining debris. The system is mounted on an enclosed trailer so that the system may be transported to a home, hospital, hotel or dormitory to clean and sanitize the mattresses. The system may also be contained within a building for a more permanent location.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The current application is a Continuation in Part of utility patent application Ser. No. 13/507,425 filed on Jun. 27, 2012 and which is incorporated herein by reference as if fully set forth. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    No part of the invention disclosed herein was the subject of federally sponsored research or development. 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    None 
       REFERENCE TO A SEQUENCE LISTING 
       [0004]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    The field of the invention disclosed herein is the cleaning and sanitizing of mattresses in both the commercial and residential setting. The invention disclosed herein is a le system incorporating ultraviolet light, dry steam, vacuum suction, ozone and infrared heat to kill and remove insects, bacteria and debris commonly found on residential and commercial bed mattresses. 
         [0007]    2. Description of the Prior Art 
         [0008]    Mattresses have been developed to enhance the comfort enjoyed by the individual while sleeping in bed. Mattresses are made from many different materials and may be of different sizes as well. With use, mattresses can become dirty and infested with parasites such as dust mites and bed bugs as well as bacteria such as  Staphylococcus . Dust mites are microscopic insects related to other mites, and ticks, in the class Arachnida, which also includes spiders, scorpions, harvestmen (daddy-longlegs) and similar eight-legged creatures. Classification of mites is ever evolving but are currently placed in the order Astigmata, family Pyroglyphidae, and genus  Dermatophagoides . The two most common species are 1)  Dermatophagoides farina , the North American house dust mite and 2)  Dermatophagoides pteronyssinus , the European house dust mite. Both species inhabit dwellings where humans live and where the humidity is optimal for the mite life cycle. Dust mites are infamous for causing allergies in people who sleep on mite infested mattresses. A protein in the mite fecal pellet causes asthma, or aggravates existing asthma symptoms. Dust mite material can also cause eczema whereby the skin becomes dry, itchy, red and scaly. One of the obstacles to removing mites from infested mattresses is that they are literally too small to be seen with the naked eye. Adult dust mites range in size from 250-300 microns and dust mite larvae and nymphs are even smaller making them invisible to the naked eye. Dust mites can be seen with a microscope, but such an instrument is not commonly found in the home or in a commercial setting such as a hotel, dormitory, nursing home and/or hospital. Further, microscopes require specific training on the part of the operator in order to be used properly. Dust mites can infest a used mattress in enormous numbers. Typically, the number of dust mites in an infested mattress range from 100,000 to ten million per mattress. Dust mites feed almost exclusively on dead skin cells which people shed daily by the thousands. Mattresses are the chief place where the majority of house dust mites reside. However, mites can also be found on pillows, overstuffed furniture, even rugs and carpeting. Mites can also be found where household pets sleep. 
         [0009]    In addition to dust mites inhabiting mattresses, bed bugs can also infest mattresses. Bed bugs feed on the blood of people. The bed bug will bite the victim and ingest the victim&#39;s blood. Bed bugs can live for more than a year without feeding. The bites themselves are painless, but may leave itchy, red scars which are apparent the next morning. Typical symptoms of bed bug bites are small red spots on the skin in rows of three or more. Some people who are bitten by bed bugs demonstrate no symptoms whatsoever, while others can have severe skin reactions. People become increasingly sensitive to bed bug bites with repeated exposure to bed bug bites over time. Bed bugs are much larger in size than dust mites ranging in size from 1.5-7 millimeters. At this size, the bed bugs are visible to the naked eye and visual inspection of an infested mattress may reveal the presence of bed bugs but not dust mites because of their small size. Bed bugs live on mattresses but are only active at night. During the day the bed bug may hide, often under the buttons on mattresses, or in the seams along the edge of the mattress. Bed bugs can also be found in the slots formed by the bed frame. Bed bugs have also been found behind headboards, pictures and posters on the wall and behind peeling wallpaper, among other locations. In contrast dust mites are small enough to slip easily between the threads in the fabric of a mattress pad or the mattress itself. 
         [0010]    In addition to bed bugs, dust mites and other insects, the mattress may be contaminated with bacteria such as those of the genus  Staphylococcus . These bacteria are classified as Gram positive bacteria and are resistant to drying. Staphylococci are small in size (1-3 microns) and are present on the skin of most people in enormous numbers. The bacteria are shed from the skin of an individual onto the mattress where the bacteria can survive for some time. Bacteria such as  Staphylococcus  can cause a broad spectrum of illness ranging from abscesses and pustules to blood infection and death. These organisms are also becoming alarmingly resistant to many antibiotics. 
         [0011]    Efforts have been undertaken to remove the insects and bacteria from infested mattresses. Efforts to remove bacteria have met with limited success mainly because of the enormous numbers of bacteria present on the mattress. To remove bacteria from a mattress, the mattress is usually scrubbed with an antibacterial agent which is allowed to remain in contact with the mattress until the antibacterial agent has evaporated and the mattress is dry. This method of decontamination does not eliminate the bacteria but reduces the number of bacteria by about a factor of 10. 
         [0012]    Efforts to remove insects such as bed bugs and dust mites have centered around the use of special protective covers which are placed on the mattress to separate the insects from the sleeping individual. Clearly, this method acts only as a barrier to contact between the insects and the individual and does not kill or remove the insects from the mattress. Removal of dust mites is critical to preventing illness from dust mites because it is the digestive proteins found in the fecal pellet which causes illness and may be allergenic long after the dust mite has expired. What is needed in the art is a system and method which kills and removes insects and bacteria from a mattress. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0013]    The invention disclosed herein is a system and method which kills and removes insects and bacteria from a mattress. Specifically, the system and method which kills and removes insects and bacteria from a mattress is composed of several steps. The first step is to irradiate the mattress in UV light. The second step in the system and method disclosed herein is to clean the mattress with dry steam using distilled water of approximately 356° F. The third step is to remove any unwanted waste and debris left behind by the bed bugs and mites by a vacuum plenum. The fourth step is to heat the mattress with infrared heaters up to a temperature of 265° F. to dry any moisture created by the dry steam while killing any bed bugs and dust mites which may have survived the previous three steps. The sixth step is again a vacuum step to remove any remaining debris. The seventh step is to deodorize the mattress with an ozone immersion. The aforementioned UV lights, dry steam apparatus, vacuums, infrared heaters and ozone generator are mounted to an enclosed frame which is mounted to a box van or truck cab chassis or enclosed trailer which can be transported to a home, hospital, dormitory, hotel or other location where mattresses need to be cleaned and sanitized. Electric power is supplied to the components of the system and method by a gas or diesel powered generator. The mattress to be cleaned and sanitized is placed inside the trailer and the devices are activated and do their assigned functions automatically. In another embodiment the components of the mattress cleaning invention disclosed herein may also be housed in a building or other structure. Mattresses may be transported to the building for cleaning and sanitizing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING/FIGURES  
         [0014]    A better understanding of the system and method for cleaning and sanitizing mattresses may be had by examination of the following drawings/figures: 
           [0015]      FIG. 1  is a side oblique view of the system and method for cleaning and sanitizing mattresses; 
           [0016]      FIG. 2  is a side oblique view of the system and method for cleaning and sanitizing mattresses; 
           [0017]      FIG. 3  is an elevated end view of the system and method for cleaning and sanitizing mattresses with the conveyor system removed; 
           [0018]      FIG. 4  is a front side oblique view of the system and method for cleaning and sanitizing mattresses mounted on a vehicle; 
           [0019]      FIG. 5  is a rear side oblique view of the system and method for cleaning and sanitizing mattresses mounted on a vehicle; 
           [0020]      FIG. 6  is a side view of the system and method for cleaning and sanitizing mattresses mounted on a vehicle; 
           [0021]      FIG. 7  is a top view of the system and method for cleaning and sanitizing mattresses mounted on a vehicle; 
           [0022]      FIG. 8  is an end view of the system and method for cleaning and sanitizing mattresses mounted on a vehicle; 
           [0023]      FIG. 9  is a partial view of the system and method for cleaning and sanitizing mattresses showing the steam manifold and heat chamber convection fans. 
           [0024]      FIG. 10  is a view of the components of the mattress elevator system. 
           [0025]      FIG. 11  is a view of the components of the mattress conveyor system. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]    The invention disclosed herein is a system and method for cleaning and sanitizing mattresses which in one embodiment consists of ultraviolet lights, dry steam, vacuum, infrared heaters, an ozone generator and an electrical power source such as a gas or diesel powered generator. In a preferred embodiment, the ultraviolet lights, dry steam, vacuum, infrared heaters and ozone generator are situated in a contained movable enclosure such as an enclosed trailer capable of being towed by a car or pickup truck. The components of the system to clean and disinfect mattresses may also be contained within a closed truck or van for transport to the work site. The electrical generator is situated outside of the truck or trailer enclosure. An opening at the end or side of the truck or trailer enclosure permits the operator to insert the mattress inside the enclosure containing the components of the cleaning and sanitizing system. The operator starts the generator which provides power to the mattress cleaning and sanitizing system and inserts the mattress. A mattress conveyor system moves the mattress to each of the components of the mattress cleaning and sanitizing system. 
         [0027]    As shown in  FIG. 1  the mattress cleaning and sanitizing system  10  disclosed herein is comprised of a frame  16  to which is attached or which contains the components of the cleaning and sanitizing system  10 . As shown, the cleaning and sanitizing system  10  may be a stationary device which is housed in a building. In this embodiment mattresses to be cleaned and sanitized are transported to the building for treatment by the mattress cleaning and sanitizing machine  10 . The mattress to be cleaned and sanitized is placed into the mattress cleaning and sanitizing machine  10  on a mattress conveyor system  8  which moves the mattress through the cleaning and sanitizing process. The components of the mattress conveyor system  8  include: a platform  30  to which is attached a plurality of rollers  28  arranged in two rows which run longitudinally through the mattress cleaning and sanitizing machine  10 , a conveyor track (not shown), a screw drive (not shown), mattress holder (not shown) and mattress movement connectors (not shown). The mattress initially is exposed to the ultraviolet light from a plurality of upper ultraviolet light assemblies  2   b  which receive power from a UV light assembly power supply  1 . The upper ultraviolet light assemblies  2   b  are mounted to be located approximately 2-6 inches from the mattress. In the embodiment of the system and method disclosed herein and shown in  FIG. 1 , 26 upper ultraviolet light assemblies  2   b  are mounted and configured so as to irradiate the entire mattress for approximately six minutes with ultraviolet light of approximately 254 nanometers wavelength. Bed bugs, dust mites and dust mite eggs are susceptible to UV light in approximately the 254 nanometer wavelength. The mattress is also UV irradiated by side ultraviolet lights  13 . The mattress to be cleaned and sanitized is continuously moved by the mattress conveyor system  8  so that when the UV light irradiation is initiated, the mattress will start moving to the steam manifold (not shown) which will cleanse the mattress by dry steam obtained from the steam generator  7 . The mattress elevator system  9  adjusts the height of the mattress conveyor system  8  so that the mattress is approximately 3 inches from the steam manifold  23 . The mattress elevator system  8  is composed of a plurality of actuators  24 , connected to the conveyor platform  30  by a corresponding plurality of actuator rods  29 . Activation of the actuator  24  raises the conveyor platform  30  (and mattress) to the correct height. Since bed bugs are destroyed by a temperature of 113° F., the mattress to be sanitized and cleaned is dry steamed by the steam from the dry steam spray manifold (not shown) for approximately 6 minutes. The steam is created by a steam generator  7  and is transported to the dry steam spray manifold (not shown) by a steam supply line  15 . Offensive odors are removed from the mattress by ozone obtained from an ozone generator  14 . The ozone generator  14  produces ozone and ozone is dispersed onto the mattress to saturate the interior of the mattress cleaning and sanitizing system  10 . As shown in this embodiment, two separate vacuum fans  5  each developing 1.5 horsepower are used to provide vacuum. These vacuum fans  5  create a volumetric air flow of 1280 cubic feet per minute each. The mattress is vacuumed by the vacuum plenums  22  for removal of waste and debris from the surface of the mattress which is then trapped and contained in a filter assembly located in a vacuum exhaust plenum  4 . Upon leaving the vacuum plenum  22 , the mattress is moved by the mattress conveyor system  8  to a position underneath the upper infrared heaters  6   b  and above the lower infrared heaters  6   a . The infrared heaters  6   a ,  6   b  generate a heat of up to 265° F. to evaporate any moisture remaining from the dry steam cycle and kill any remaining insects. The mattress is exposed to the heat of the infrared heaters  6   a ,  6   b  for approximately 6 minutes. The mattress elevator system  9  position the mattress conveyor system  8  so that the mattress is approximately 18 inches from the upper infrared heaters  6   b  lower infrared heaters  6   a . The heat from the upper infrared heaters  6   b  and lower infrared heaters  6   a  is dispersed over the mattress by a plurality of heat chamber convection fans  12 . A plurality of thermal limiters  31  positioned on the sides and end of the frame  16  open the circuit energizing the heater relay coils until the wall temperature falls below 150° F. at which time the limits resent and reenergize the infrared heater circuit. At the conclusion of the infrared heating cycle, the conveyor system  8  moves the mattress from the infrared heaters  6   a ,  6   b  to the vacuum plenum  22  for removal of any remaining debris. After passing under the vacuum plenums  22 , the mattress is moved to the starting position underneath the upper UV light assemblies  2   b  and above the lower UV light assemblies  2   a . The mattress elevator system  9  lowers the mattress for removal from the mattress cleaning and sanitizing system  10 . The power is turned off and the mattress is removed from the mattress cleaning and sanitizing system  10  enclosure. The entire cleaning and disinfecting cycle takes about 15 minutes. At the conclusion of the cleaning and sanitizing procedure, the mattress is cleaner and free of observable bed bugs or dust mites. 
         [0028]    Another perspective the of the mattress cleaning and sanitizing system  10  is shown by viewing the end opposite from the end of the mattress cleaning and sanitizing system  10  in which the mattress is inserted into the mattress cleaning and sanitizing system  10  as shown in  FIG. 2 . Attached to the frame  16  is an electrical generator  17  which receives fuel from the electrical generator fuel tank  18 . The electrical generator  17  provides electricity to operate the various components of the mattress cleaning and sanitizing system  10 . Optionally, electricity could be provided by the electrical power supply of a building in which the mattress cleaning and sanitizing system is contained. A steam generator  7  attached to the frame  16  provides steam for the steam manifold (not shown) through a steam supply line  15 . The mattress receives UV irradiation by a plurality of lower UV light assemblies  2   a , upper UV lights assemblies  2   b  and side UV light assemblies  13  which receive power from a UV light assembly power supply  1 . The mattress to be treated is cleaned by dry steam from a steam manifold (not shown) which receives steam from a steam generator  7  through a steam supply line  15 . Odors are removed from the mattress by dispersing ozone around the mattress from an ozone generator  14 . Debris from the mattress is removed by a vacuum through a vacuum plenum  22  from a plurality of vacuum fans  5 . The debris removed by the vacuum is collected and isolated from the mattress cleaning and sanitizing system  10  through a vacuum exhaust plenum/filter assembly  4 . A plurality of upper infrared heaters  6   b  and lower infrared heaters  6   a  provides heat which is distributed over the mattress by heat chamber convection fans  12 . The infrared heaters  6   a ,  6   b  collectively generate up to 19,114 BTU&#39;s per hour of heat which produces temperatures of up to 265 degrees. The infrared heaters  6   a ,  6   b  will evaporate any moisture created by the dry steam while also killing any surviving bed bugs and dust mites. The mattress is moved through the mattress cleaning and sanitizing system  10  by a mattress conveyor system  8  on the rollers  28  and raised or lowered to the proper height by a mattress elevator system  9  by actuators  24  connected by actuator rods  29  to the conveyor system  8 . 
         [0029]    Another view of the mattress cleaning and sanitizing system  10  with some of the mattress conveyor system  8  removed for clarity is shown in  FIG. 3 . Attached to the frame  16  of the mattress cleaning and sanitizing system  10  are: 1) a UV light assembly power supply  1 , 2) lower UV light assemblies  2   a , 3) upper UV light assemblies  2   b , 4) side UV light assemblies  13 , 5) a vacuum exhaust plenum  4 , 6) vacuum fans  5 , 7) vacuum plenum  22 , 8) ozone generator  14 , 9) lower infrared heaters  6   a , 10) upper infrared heaters  6   b , 11) steam generator  7 , 12) steam supply line  15 , 13) electrical generator  17 , 14) electrical generator fuel supply  18 , 15) heat chamber convection fans  12 , 16) conveyor track  27  of the mattress conveyor system  8  and 17) the actuators  24  connected to the conveyor platform by corresponding actuator rods  29  of the mattress elevator system  9 . 
         [0030]    In another embodiment, the mattress cleaning and sanitizing system  10  may be attached to a vehicle such as a truck  20  to take the mattress cleaning and sanitizing system  10  to the facility which needs mattress cleaning as shown in  FIG. 4 . The various components of the mattress cleaning and sanitizing system  10  are attached to the frame  16  which is affixed to a truck  20 . The components of the mattress cleaning and sanitizing system  10  shown include: 1) UV light assembly power supply  1 , 2) power distribution panel  11 , 3) vacuum fans  5 , 4) vacuum exhaust plenum  4 , 5) vacuum plenum  22 , 6) side UV light assembly  13 , 7) the plurality of rollers  28  of the mattress conveyor system  8 , 8) actuators  24  and actuator rods  29  of the mattress elevator system  9 , 9) lower infrared heaters  6   a , 10) upper infrared heaters  6   b , 11) heat chamber convection fans  12 , 12) steam supply line  15 , 13) electrical generator  17 , electrical generator fuel tank  18 , 14), a pre-treatment table  19 . The pre-treatment table  19  provides a work surface on which the mattress can be placed to enable the operator to focus on specific problems on the mattress. 
         [0031]    Another view of the mattress cleaning and sanitizing system  10  affixed to a truck  20  is shown in  FIG. 5 . The components of the mattress cleaning and sanitizing system  10  attached through the frame  16  to a truck  20  and shown are the: 1) mattress conveyor system  8  including the conveyer platform  30  and rollers  28 , 2) mattress elevator system  9 , 3) mattress elevator system  9  including the actuators  24  and actuator rods  29  connected to the mattress conveyor platform  30 , 4) power distribution panel  11 , 4) ultraviolet light power supply  1 , 5) side UV light assembly  13 , 6) lower infrared heater  6   a , 7) upper infrared heater  6   b , 8) vacuum fans  5 , 9) vacuum exhaust plenum  4 , 10) vacuum plenum  22 , 11) ozone generator  14 , 12) steam generator  7 , 13) steam supply line,  15  14) pre-treatment table  19  and 15) thermal limiters  31 . The components of the mattress cleaning and sanitizing system  10  may be operated through the master control panel  21  located at the rear of the truck and in a location convenient to the pre-treatment table  19 . 
         [0032]    A side view of the mattress cleaning and sanitizing system  10  attached to a truck  20  is shown in  FIG. 6 . The components of the mattress cleaning and sanitizing system  10  shown include the pre-treatment table  19 , master control panel  21 , power distribution panel  11 , ultraviolet power supply  1 , side UV light assembly  13 , vacuum fan  5 , vacuum exhaust plenum/filter assembly  4 , steam manifold  23 , steam supply line  15 , steam generator  7 , ozone generator  14 , mattress conveyor system  8 , mattress elevator system  9 , lower infrared heater  6   a  and upper infrared heaters  6   b.    
         [0033]      FIG. 7  is a top view of the mattress cleaning and sanitizing system  10  attached to the frame  16  and affixed to a truck  20  showing the steam generator  7 , steam supply line  15 , electric generator fuel tank  18 , lower infrared heaters  6   a , upper infrared heaters  6   b , heat chamber convection fans  12 , mattress conveyor system  8 , mattress elevator system  9 , vacuum exhaust plenum/filter assembly  4 , vacuum fans  5 , vacuum plenum  22 , ozone generator  14 , UV light power supply  1 , power distribution panel  11  and pre-treatment table  19 . 
         [0034]      FIG. 8  is a rear view of the mattress cleaning and sanitizing system  10  attached to a frame  16  and affixed to a truck  20  showing the pre-treatment table  19 , master control panel  21 , electrical generator  17 , lower infrared heaters  6   a , mattress conveyor system  8 , mattress elevator system  9 , vacuum plenum  22 , power distribution panel  11 , UV light assembly power supply  1 , vacuum fans  5  and vacuum plenum exhaust  4 . 
         [0035]    A better view of the steam manifold  23  is shown in  FIG. 9  in which many of the components of the mattress cleaning and sanitizing system  10  have been removed. Also shown are the frame  16  to which are attached the UV assembly power supply  1 , mattress conveyor system  8  including the rollers  28 , conveyor track  27  and mattress holder  32 , mattress elevator system  9  including the actuators  24  and actuator rods  29 , lower infrared heaters  6   a , upper infrared heaters  6   b , steam supply line  15 , steam generator  7  and electrical generator  17 . 
         [0036]    The mattress conveyor system  8  and mattress elevator system  9  are shown in  FIG. 10 . Both mattress conveyor system  8  and mattress elevator system  9  are connected to the frame  16 . A mattress to be cleaned and sanitized is placed on the mattress conveyor system and held in position by a plurality of mattress holders  32 . The mattress is moved along the conveyor track  27  by a screw drive  25  which moves a plurality of mattress holders  26  in contact with the mattress. The plurality of mattress holders  26  driven by the screw drive  25  travels along the conveyor track  27  and moves the mattress from one station to another for cleaning and sanitizing. In another embodiment the mattress holders  26  may be moved along the conveyor track by a number of methods including, by way of example, a cable/pulley system. 
         [0037]    A better view of the mattress conveyor system  8  may be seen in  FIG. 11  in which most of the components of the mattress cleaning and sanitizing system have been removed. Two parallel rows of rollers  28  upon which the mattress travels are attached to the conveyor platform  30 . A conveyor track  27  is positioned between the two rows of rollers  28 . A pair of parallel mattress movement connectors  26  move along the conveyor track  27  driven by a screw drive  25 . The mattress to be cleaned and sanitized is held in place in connection with the mattress movement connectors  26  by a pair of mattress holders  32  located on a travel bar  33  running between the mattress movement connectors  26  and connected to the screw drive  25 . The length of the travel bar  33  is adjustable so that the mattress holders  32  may be fitted to different size mattresses. 
         [0038]    The system and method for cleaning and sanitizing mattresses disclosed herein is susceptible to many different embodiments. The size and number of the various components can vary to accomplish the same goals with respect to other items constructed from or covered by a fabric such as pillows, blankets, chair and sofa cushions, pet beds, rugs, draperies, clothing, luggage and a myriad of other items. The fabric from which the items to be cleaned and sanitized are constructed or covered may be of natural components such as wool, cashmere, mohair, rabbit and other animal fur, cotton, flax, hemp and other plant materials as well as artificial components such as nylon, rayon, polyester, plastic, vinyl, glass, metal, acrylic and spandex. All of these other embodiments are incorporated into this specification as limited by the claims appended hereto.