Abstract:
An insect repellent compound that includes naturally occurring oil that emits an odor which repels insects is described. The compound is not harmful to animals, to humans or to the environment. The compound may be incorporated into materials such as yarn that is woven to form a mesh. The material may be used for making an animal mask, for screen doors and other applications. A method of making the compound and incorporating it into materials and products is described.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority on the basis of the prior-pending provisional application No. 61/214,528 entitled “Insect Repellent Compound, Material and Animal Mask, and Method for Making Same” filed Apr. 24, 2009. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The field of the current invention generally relates to insect repellent compounds and materials, and applications therefor including animal masks and other protective gear for animals. The field of the current invention also relates to a method of making the foregoing. 
       BACKGROUND OF THE INVENTION 
       [0003]    Insects, such as mosquitoes and flies, are a common irritation for humans and animals alike. Insects can be especially irritating for horses or other animals having large moist eyes that attract flies and other insects. Besides discomfort, insects may also cause infection or spread disease to such animals by biting the animal or crawling on and around the animal&#39;s eyes, or other parts of the animal&#39;s body. 
         [0004]    For example, insects such as flies may pick up bacteria when landing on other animals, garbage, manure piles or other bacteria laden items. Flies may then spread this bacteria to an animal by biting it or by crawling on or around the animal&#39;s eyes or other part of its body. When considering that flies may travel several miles and land many times a day, flies may pick up and transmit a variety of harmful bacteria to a number of animals. 
         [0005]    The discomfort and disease spread by such insects may also negatively impact the people who care for such animals. For example, the bites of insects and/or their presence on a horse&#39;s eyes may cause a sudden reaction by the horse which could injure someone nearby. And where a person is on the horse, insect bites and/or insects crawling on or around the eyes of a horse can distract the horse and cause sudden movements which could injure the rider. 
         [0006]    Different products have been developed to protect horses and other animals from insects. Horse masks, for example, have been developed to physically prevent insects from contacting the eyes or face of a horse. However, those horse masks may be made of heavily woven fabric that may reduce the visibility of the animal wearing them. In addition, they may be cumbersome and uncomfortable for the horse to wear. 
         [0007]    Insect repellent creams, ointments or sprays have also been used as chemical repellents to insects from contacting the face or eyes of animals. Oftentimes, these materials comprise synthetic chemicals that are applied directly to a horse near the horse&#39;s eyes or to the horse mask. 
         [0008]    However, it is undesirable for such repellents, especially those made of synthetic chemicals, to enter an animal&#39;s eyes or other area for which the repellent is not intended. This may unfortunately occur, however, because repellent applied near a horse&#39;s eyes may still migrate too near or into the eyes, or because sprays may be difficult to direct to a specific area. Furthermore, the protection from such materials may last for only a limited time. Accordingly, repeated application may be required to effectively protect the animal, which may prove burdensome for the person applying the repellent material. 
         [0009]    Other existing masks have also comprised an anthelmintic mesh impregnated or otherwise coated with a pesticide or other chemical that resists insects. However, such chemical pesticides may also be harmful to the horse or person caring for the horse, and may also pollute or otherwise harm the environment. 
         [0010]    In view of the foregoing, there exists a need for an animal mask that includes an insect repellent compound that provides safety and comfort to the animals wearing them and safety to the humans caring for such animals. There is also a need for such a compound that repels insects for longer periods of time and that is environmentally friendly. There is also a need for an insect repellent compound for other uses such as with window or door screens for houses or other buildings. 
       SUMMARY OF THE INVENTION 
       [0011]    A first aspect of the invention involves a material such as a resin or compound that emits an insect repellent odor and that may be coated on, incorporated into or otherwise applied to an article, such as a mesh or netting, that is used to manufacture protective gear for an animal, such as a mask, blanket or fly mesh, to protect and provide comfort to animals. The repellent material may also be coated on, incorporated into or otherwise applied to other items such as window and door screens to repel insects from houses and other buildings. 
         [0012]    In another aspect of the invention, the insect repellent includes a naturally occurring oil that is not harmful to animals, to humans caring for the animals or to the environment. For example, an embodiment of the insect repellent may include a naturally occurring citrus oil that emits an insect repellent odor. Other suitable repellent materials may include odor emitting oils such as mint, fennel, clove, lavender, eucalyptus, citronella, pelargonium, basil, thyme or other naturally occurring ingredients. 
         [0013]    Another aspect of the invention involves the ingredients of the insect repellent material. An embodiment suitable for animal masks, blankets or fly mesh, and window or door screens, involves PVC, DINP plasticizer, epoxy soybean oil, additives such as CaCO 3 , an oil extract such as orange citrus oil, lubricant OPE, an ultraviolet resistant ingredient, antioxidant, auxiliary antioxidant, stabilizer and pigment. Another embodiment may use other ingredients such as epoxy soybean oil or rosin or mint essential oil which may be effective to repel termites. 
         [0014]    Another aspect of the invention involves the preparation of the ingredients comprising the resin or compound or other type of repellent material. For example, the ingredients may be mixed in a blender to form a powder. The powder may then be granulated. 
         [0015]    Another aspect of the invention involves a method of incorporating the insect repellent resin or compound or other type of repellent material into an article. For example, the resin or compound may be drawn onto a yarn, which yarn is then woven into a mesh fabric for use in animal masks, blankets, fly mesh or other applications. When the yarns are woven together, they may be hot set to fasten the warp and weft yarns together. 
         [0016]    In another aspect of the invention, the odor emitting orange citrus or other oil used in the repellent material provides an odor for increased length of time. For example, the resin or compound is preferably resistant to the temperatures associated with manufacturing the product. The product is also preferably packaged to seal in the odor during shipping or shelf life. Accordingly, odor will remain with the product after manufacturing and shipping so that an odor is emitted to repel insects for an increased length of time. 
         [0017]    Another aspect of the invention involves an animal mask made of a lower density mesh material impregnated with the resin or compound of the current invention. The lower density mesh is more comfortable for the animal to wear, provides better visibility and ventilation and also decreases manufacturing costs. 
         [0018]    Another aspect of the invention involves providing a mask, blanket, fly mesh or other product that includes a naturally occurring, environmentally friendly oil or other material to resist insects. In this manner, the use of pesticides or other chemicals that may harm the environment are avoided. 
         [0019]    One embodiment of the invention involves an animal mask for repelling insects, comprising a mesh material that is configured to cover a part of the animal and that includes an insect repellent material. The insect repellent material includes a naturally occurring extract essential oil. The insect repellent material includes a citrus oil. The insect repellent material includes an oil of mint, fennel, clove, lavender, eucalyptus, citronella, pelargonium, basil or thyme. The mesh comprises a plurality of yarns, and the yarns comprise an inner core and an outer coating that includes the insect repellent material. The yarns are hot set. The insect repellent material comprises PVC, a plasticizer, a naturally occurring extract essential oil, an antioxidant and a stabilizer. The animal mask further comprises fleece attached to at least some of the edges of the animal mask. The mask is configured to fit over part of the animal&#39;s head including the eyes. The mask is configured to fit over a part of a horse&#39;s head including the eyes. 
         [0020]    Another embodiment of the invention involves an animal mask for repelling insects, comprising a mesh material that is configured to cover at least a part of the animal&#39;s head including the eyes, and that comprises a plurality of yarns; wherein the yarns include an inner core and an outer coating that includes an insect repellent material including a naturally occurring extract essential oil. The naturally occurring extract essential oil is a citrus oil. The naturally occurring extract essential oil is an oil of mint, fennel, clove, lavender, eucalyptus, citronella, pelargonium, basil or thyme. The mask is configured to fit over a part of a horse&#39;s head including the eyes. 
         [0021]    Another embodiment of the invention involves an insect repellent, comprising PVC; a plasticizer DINP; epoxy soybean oil; a calcium carbonate additive; a naturally occurring extract oil; a lubricant; UV resistant material; an antioxidant; and a stabilizer. The naturally occurring oil is a citrus oil. The naturally occurring oil is an oil of mint, fennel, clove, lavender, eucalyptus, citronella, pelargonium, basil or thyme. The ingredients undergo a mixing cycle for about 9 to about 15 minutes at a temperature of between about 80 degrees C. to about 110 degrees C. The naturally occurring extract oil is added to the mix near the end of the mixing cycle. The mixture is granulated. 
         [0022]    Further aspects, objects, and desirable features, and advantages of the invention will be better understood from the following description considered in connection with the accompanying drawings in which various embodiments of the disclosed invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration only and are not intended to limit the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]      FIG. 1  shows a horse wearing a horse mask comprising a mesh fabric having an insect repellent coating according to an embodiment of the present invention. 
           [0024]      FIG. 2  is an enlarged view of the coated mesh fabric of  FIG. 1 . 
           [0025]      FIG. 3  is an enlarged view of a single piece of yarn from the mesh fabric of  FIG. 2 . 
           [0026]      FIG. 4  is a cross-sectional view of a single piece of yarn taken along the plane indicated by  4 - 4 . 
           [0027]      FIG. 5  is a flow chart of a process for making a mesh fabric according to an embodiment of the current invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    Embodiments of the invention will now be described with reference to the figures. To facilitate the description, any reference numeral representing an element in one figure will represent the same element in any other figure. 
         [0029]      FIG. 1  shows a horse  10  wearing a mask  100  comprising a mesh fabric  120  according to an embodiment of the current invention.  FIG. 1  also shows the horse&#39;s eye  12  (shown under the mask  100 ), nose  14 , ears  16 ,  18 , neck  20 , jaw  22 , and forehead  24 . The current invention is not limited to horses but may be used with other animals. The current invention is not limited to animal masks, but may be used with animal blankets that may cover the horse&#39;s or other animal&#39;s body, fly mesh and other gear. 
         [0030]    The horse mask  100  may be tailored from a mesh fabric  120 , netting or other suitable material to fit the head of a horse  10  or other animal. The edges of the mask  100  may extend to near the ears  16 ,  18 , nose  14  and neck  20  of the horse  10 . The mask  100  of the current invention preferably accommodates animals having different head shapes and sizes, and different spacing between eyes, nose, ears and other parts of its body. To this end, the mask  100  may be adjustable through the use of velcro straps or other fasteners that allow the mask  100  to be tightened or loosened. The mask  100  may also be configured to accommodate a certain type or size of animal. 
         [0031]    Fleece edges  102 ,  104 ,  106  may be added around the edges of the mask  100  to provide comfort to the animal  10  by avoiding any abrasive edge of the mesh  120  or other material from contacting the animal. To this end, it is preferred that the mask  100  is configured to avoid irritating the animal&#39;s eyes or skin, and to also avoid causing hair loss on the animal. 
         [0032]      FIG. 2  is an enlarged view of the mesh fabric  120  of  FIG. 1 . As shown, the mesh fabric  120  is preferably comprised of warp yarns  122  and weft yarns  124  that may be generally perpendicular to each other. In the embodiment shown in  FIG. 2 , the weft yarn  124  is preferably drawn alternatively over and under the warp yarns  122  to form the mesh fabric  120 . Alternative weaving patterns may also be used and the current invention is not limited to the weaving pattern shown in  FIG. 2 . 
         [0033]      FIG. 3  shows an enlarged view of a single fiber or yarn strand  130  taken from the mesh fabric  120  of  FIG. 2 .  FIG. 4  is a cross-sectional view of the single fiber or yarn strand  130  taken along the plane indicated by  4 - 4 . 
         [0034]    The fiber or yarn  130  preferably includes an inner core  132  that may be coated by an outer coating  140  that may comprise and/or include the insect repelling material, e.g., resin or compound, of the current invention. In a preferred embodiment, the inner core  132  may comprise polyethylene terephthalate (PET) for its strength and abrasion resistance. Alternatively, the inner core  132  may comprise other natural or synthetic fibers, such as olefin. In one embodiment, the inner core  132  may be 150 D to 1500 D, and have a diameter of about 0.28-0.8 mm. However, the invention is not limited to these characteristics or dimensions. Furthermore, the insect repelling resin or compound may be applied to materials other than yarn and other than in an outer coating configuration. To this end, the insect repellent material may be applied to horse blankets, fly mesh and other protective gear. 
         [0035]    The composition and preparation of the insect repelling material, e.g., the resin or compound that may comprise the outer coating  140  or other insect repellent configuration, are now described. In a preferred embodiment, the material may comprise approximately 100 equal parts of polyvinyl chloride (PVC), approximately 38 equal parts of a plasticizer such as diisononyl phthalate (DINP), approximately 5 equal parts of epoxy soybean oil, approximately 10 equal parts of additives such as calcium carbonate (CaCO 3 ), approximately 0.4 equal parts of orange extract essential oil, approximately 0.5 equal parts of lubricant such as OPE, approximately 1.5 equal parts of an ultraviolet (UV) resistant ingredient, approximately 0.3 equal parts of antioxidant, approximately 0.6 equal parts of auxiliary antioxidant and approximately 3 equal parts of stabilizer and a small equal parts of pigment. The current invention is not limited to the components and ratios listed above, but alternatively, the ratios between different components may be varied. 
         [0036]    In a preferred embodiment, the PVC may be grade S-65. The plasticizer DINP may be of a type manufactured by ExxonMobil Chemical, and preferably softens the resin or compound. The epoxy soybean oil may be used as a PVC plasticizer and/or to generally increase performance. The CaCO 3  additive preferably helps reduce cost and strengthens the PVC. The lubricant may be used to help increase the flexibility of the material including the resin or compound. The UV resistant ingredient may be UV 326 manufactured by Ciba. Preferably, the UV resistant material protects against cracking, fading or other effects of the sun that may be experienced as the product of the current invention is used outdoors. The antioxidant may be Ciba 1010 manufactured by Ciba, and the auxiliary antioxidant may be Ciba 168 manufactured by Ciba. Preferably, these materials may prolong the odor emitting characteristic of the oil. The lubricant may be OPE, i.e., oxidized polyethylene wax. The stabilizer may be a Ca/Zn liquid equalizer, such as Baerostab 9875 manufactured by Baerlocher. The stabilizer may help avoid the PVC breaking down from heat. The pigment may be added so that the resulting resin or compound has a certain color, e.g., black, if desired. The invention is not limited to the foregoing materials and manufacturers, and other alternatives or replacements may be used with the current invention. The foregoing list is for example purposes only. 
         [0037]    A preferred embodiment may include orange extract essential oil, or citrus oil, because its odor generally repels insects. As such, it is a preferred ingredient to protect horses or other animals that wear the mask  100 , or other protective gear such as a blanket or fly mesh. Orange extract essential oil is also preferred because it is a natural occurring product that does not harm the animal wearing the mask  100 , the people who may care for animals or the environment. 
         [0038]    Alternatively, other natural essential oils may be used since they also repel insects such as mosquitoes and flies. These may include oils of citrus, mint, fennel, cloves, lavender, eucalyptus, citronella, pelargonium, basil or thyme. 
         [0039]    Table 1 is a summary of ingredients for the above-described preferred coating embodiment or other insect repellent material configuration. Again, the ingredients in this table are only for example purposes only and the invention is not limited thereto. 
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Summary of Preferred Coating Ingredients 
               
             
          
           
               
                 Component 
                 Possible 
                   
                 Equal 
               
               
                 Description 
                 Manufacturer 
                 Grade 
                 Parts 
               
               
                   
               
             
          
           
               
                 PVC 
                   
                 S-65 
                 100 
               
               
                 Plasticizer DINP 
                 ExxonMobil 
                   
                 38 
               
               
                   
                 Chemical 
               
               
                 Epoxy Soybean Oil 
                   
                   
                 5 
               
               
                 Additives CaCO 3   
                   
                   
                 10 
               
               
                 Orange Extract Essential Oil 
                   
                   
                 0.4 
               
               
                 Lubricant 
                   
                 OPE Oxidized 
                 0.5 
               
               
                   
                   
                 Polyethylene Wax 
               
               
                 UV resistant ingredient 
                 Ciba 
                 UV 326 
                 1.5 
               
               
                 Antioxidant 
                 Ciba 
                 Ciba 1010 
                 0.3 
               
               
                 Auxiliary Antioxidant 
                 Ciba 
                 Ciba 168 
                 0.6 
               
               
                 Stabilizer 
                 Baerlocher 
                 Baerostab 9875 
                 3 
               
               
                 Pigment 
                   
                   
                 small 
               
               
                   
               
             
          
         
       
     
         [0040]    The orange extract essential oil, or other natural essential oils, used in connection with the insect repellent material, e.g., outer coating  140  on the fiber or yarn  130 , preferably emits an odor over time so that the mask  100 , tailored from the mesh fabric  120  comprising the preferred coating, repels insects such as mosquitoes and flies. 
         [0041]    The current invention may also be used in other applications where repelling insects is desired. For example, a window or door screen of a farm building or house may comprise a mesh fabric  120  including an orange extract essential oil or other natural essential oils. The insect repellent material may also be applied to other non-mesh type materials. For example, the insect repellent materials may be applied to horse blankets, e.g., coated on blanket fibers or otherwise applied to the blanket. 
         [0042]    Some insects are more sensitive to certain odors. For example, termites are repelled by the odor of rosin or mint. Accordingly, in another embodiment of the invention, a carpet mat may include a mesh fabric or yarn with a coating comprising the components shown in Table 2 suitable for repelling termites. Again, the ingredients in this table are only for example purposes only and the invention is not limited thereto. 
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Summary of Preferred Coating Ingredients for a Carpet Mat 
               
             
          
           
               
                 Component 
                 Possible 
                   
                 Equal 
               
               
                 Description 
                 Manufacturer 
                 Grade 
                 Parts 
               
               
                   
               
             
          
           
               
                 PVC 
                   
                 S-65 
                 100 
               
               
                 Plasticizer DINP 
                 ExxonMobil 
                   
                 36 
               
               
                   
                 Chemical 
               
               
                 Epoxy Soybean Oil 
                   
                   
                 5 
               
               
                 Additives CaCO 3   
                   
                   
                 50 
               
               
                 Rosin Essential Oil 
                   
                   
                 0.4 
               
               
                 Lubricant 
                   
                 OPE Oxidized 
                 0.5 
               
               
                   
                   
                 Polyethylene Wax 
               
               
                 UV resistant ingredient 
                 Ciba 
                 UV 326 
                 1.5 
               
               
                 Antioxidant 
                 Ciba 
                 Ciba 1010 
                 0.3 
               
               
                 Auxiliary Antioxidant 
                 Ciba 
                 Ciba 168 
                 0.6 
               
               
                 Stabilizer 
                 Baerlocher 
                 Baerostab 9875 
                 3 
               
               
                 Pigment 
                   
                   
                 small 
               
               
                   
               
             
          
         
       
     
         [0043]    In another embodiment, a floor cushion may include a mesh fabric or yarn with a coating comprising the components shown in Table 3 for repelling termites. 
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Summary of Preferred Coating Ingredients for a Floor Cushion 
               
             
          
           
               
                 Component 
                 Possible 
                   
                 Equal 
               
               
                 Description 
                 Manufacturer 
                 Grade 
                 Parts 
               
               
                   
               
             
          
           
               
                 PVC 
                 Qilu 
                 S1000 
                 100 
               
               
                   
                 Petrochemical 
               
               
                 Plasticizer DINP 
                 UPC Group 
                   
                 38 
               
               
                 Epoxy Soybean Oil 
                   
                   
                 5 
               
               
                 Additives CaCO 3   
                   
                   
                 8 
               
               
                 Mint Essential Oil 
                   
                   
                 0.4 
               
               
                 Lubricant 
                   
                 OPE Oxidized 
                 0.5 
               
               
                   
                   
                 Polyethylene Wax 
               
               
                 UV resistant ingredient 
                 Ciba 
                 UV 531 
                 1.5 
               
               
                 Antioxidant 
                 Ciba 
                 Ciba 1010 
                 0.3 
               
               
                 Auxiliary Antioxidant 
                 Ciba 
                 Ciba 168 
                 0.6 
               
               
                 Stabilizer 
                 Baerlocher 
                 Baerostab 9398 
                 4 
               
               
                 Pigment 
                   
                   
                 small 
               
               
                   
               
             
          
         
       
     
         [0044]    It should be noted that the invention is not limited to the specific ingredients and ratios listed above. 
         [0045]    A preferred process for preparing the resin or coating, for coating the fiber or yarn and for preparing the mesh fabric  120  of the current invention is now described with reference to  FIG. 5 . 
         [0046]    In step  210 , the components of the resin or coating, such as those in Tables 1, 2 or 3 above, or other suitable ingredients, may be mixed for approximately 9 to 15 minutes at a temperature in the range of about 80° C. to 110° C. until the ingredients are mixed to form a dried powder. It is preferred that a high-speed blender be used and that the ingredients be fully mixed. Other durations and temperatures may also be used. The orange extract essential oil (or other oil) is preferably resistant to high temperatures so that the oil does not lose a significant portion of its odor emitting characteristic during the mixing process. Furthermore, the oil is preferably added to the blender near the end of the mixing step and/or just prior to the next granulating step  220 . This preferably helps reduce volatility during mixing and may help the oil retain its odor emitting characteristic. It is preferred that the oil lose less than 20% of its odor emitting characteristic during mixing. This preferably results in the mesh fabric  120  providing an insect repelling odor for an increased time, such as for three to twelve months. 
         [0047]    In step  220 , the mixed dried powder may be granulated into PVC granule through a PVC granulating extruder. This may occur at a temperature in the range of about 100° C. to 180° C. 
         [0048]    In step  230 , the PVC coating may be drawn on a core fiber or yarn through a single-screw extruder. In one embodiment, the core fiber or yarn may preferably be 150-1500 D. In one embodiment, the coated fiber or yarn preferably has an outer diameter of 0.28 mm to 0.8 mm, though the dimensions of the core fiber and coated fiber may vary. 
         [0049]    In step  240 , the coated fibers or yarns may be divided on a bobbin to weaving spindles by a sectional warping machine. 
         [0050]    In step  250 , the coated fibers or yarns may be weaved on spindles to form a mesh. In one embodiment, the warp density is 8 to 60 yarn/inch and the weft density is 8 to 56 yarn/inch with a rapier loom. The density may vary according to the article being made, e.g., horse masks or horse blankets. 
         [0051]    In step  260 , the mesh fabric may be hot-set at a temperature in the range of about 100° C. to 190° C. to fasten the warp and weft yarn together to form a mesh fabric. It is again preferred that the orange or other oil is temperature resistant so that it may retain a significant portion of its odor emitting characteristic during the manufacturing process. 
         [0052]    In step  270 , the mesh fabric or product comprising the mesh is sealed in appropriate packaging to prevent the orange extract essential or other oil integrated in the mesh fabric from sublimation during shipping, storage or shelf life. This preferably contributes to increasing the length of time that the product of the current invention may emit an insect repelling odor. 
         [0053]    While various embodiments of a mesh fabric and its respective composition have been presented in the foregoing disclosure, numerous modifications, alterations, alternate embodiments, and alternate materials may be contemplated by those skilled in the art and may be utilized in accomplishing the various aspects of the present invention. For example, the insect repellent material may be applied to other fabrics and materials other than mesh. The insect repellent material may also be applied in manners other than extruding onto yarns. Furthermore, the invention is not limited for use with horses, but may alternatively be used with other domestic or farm animals. Thus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the invention as claimed below.