Patent Publication Number: US-2022233737-A1

Title: Air freshener and substance diffusing membrane with removable seal

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. No. 63/141,184, filed on Jan. 25, 2021, the contents of which are hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The field of the disclosure relates generally to air fresheners. More specifically, the disclosure relates to membranes for use with a fragrant material for dispersion through the membrane. 
     Air fresheners can be used to provide an aesthetically pleasing aroma in a desired location. Some known air fresheners use a liquid volatile substance, such as a liquid oil, that is held in an air tight container during use. In use, the volatile substance permeates through a membrane to release the desired aroma. Prior to use, the membrane is sealed by a cover that is removed to expose the membrane and allow the volatile substance to permeate through the membrane. However, the covers for the membranes of known air fresheners may leak, or allow the volatile substance to accumulate between the membrane and the cover, such that the volatile substance may undesirably drip or leak out once the cover is removed. 
     The present disclosure provides a membrane and seal that reduces or eliminates the amount of accumulation of liquid between the membrane and seal prior to use. 
     BRIEF DESCRIPTION 
     It has been recognized that it would be advantageous to develop an air freshener to provide a desired scent. In addition, it has been recognized that fragrant material can pass through the permeable membrane and undesirably pool between the membrane and the liner or cover, to leak from the air freshener as the liner or cover is removed. Furthermore, it has been recognized that it would be advantageous to develop an air freshener that resists spilling, leaking, or pooling of fragrant material that build up between a permeable membrane and a liner or cover prior to use. 
     In one embodiment an air freshener includes a reservoir for storing a liquid fragrant substance, the reservoir has a cavity and an opening to the cavity. A permeable membrane is coupled to the reservoir and has a first surface facing the cavity that covers the opening and a second surface facing away from the cavity. A laminate removable seal includes a metallic layer and a sealing layer, the laminate removable seal is disposed on the second surface of the permeable membrane. The sealing layer is removably adhered to substantially the entirety of the second surface of the permeable membrane. 
     In another embodiment, a method of sealing a reservoir containing a fragrant liquid is disclosed. The reservoir includes a cavity containing the fragrant liquid and an opening to the cavity. The method includes covering the opening with a permeable membrane having a first surface facing the cavity and a second surface facing away from the cavity. The method includes applying a laminate removable seal comprising a metallic layer and a sealing layer to the second surface of the permeable membrane and applying heat and pressure to the laminate removable seal such that the sealing layer is removably adhered across substantially the entirety of the second surface of the permeable membrane. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an air freshener in accordance with an embodiment of the present disclosure. 
         FIG. 2  is a cross-sectional view of scent capsule including a substance diffusing membrane according to the present disclosure. 
         FIG. 3  is an exploded cross-sectional view of an embodiment of a scent capsule including a substance diffusing membrane according to the present disclosure. 
         FIG. 4  is a schematic view of a permeable membrane and removable seal in a press according to the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIGS. 1-3 , an air freshener  10  is shown. The air freshener  10  can be utilized to provide and aesthetically pleasing scent and/or neutralizing agent in a desired area, such as a vehicle. In one embodiment, the air freshener  10  is configured to be secured in a vehicle, such as by being held or clipped to louvers of an air vent, sun visor or the like. In one embodiment, the air freshener  10  can be used with a scent capsule  14  with a releasable seal covering a permeable membrane prior to use. The air freshener  10  can resist leaking or spilling of a fragrant material, including an amount of fragrant material that permeates through the permeable membrane and accumulates between the permeable membrane and the releasable seal defining a leak pool of fragrant material. In addition, the air freshener  10  can provide a simple and adjustable scent release. 
     In one embodiment, the air freshener  10  comprises a scent capsule  14  carried by a housing  18 . The housing  18  can comprise a pair of shells, including a front and/or outer shell  22  and a rear and/or inner shell  24  that together form a cavity therebetween for housing the scent capsule  14 . In other embodiments, the housing  18  may be a single unitary piece having a cavity for housing the scent capsule  14  therein. In one embodiment, the scent capsule  14  can be disposed in the cavities of the shells  22 ,  24  and between the shells. In one embodiment, the desired scent from the scent capsule  14  can escape from between the plates around a perimeter of the air freshener  10 . In addition, or in the alternative, the desired scent from the scent capsule can escape through holes in the housing, or through an open area of the housing  18 , such as on a rear portion of the housing  18 . In one embodiment, the pair of shells, or outer and inner shells  22  and  24 , may be pivotally, rotatably or slidably coupled together to allow the shells  22  and  24  to move apart from one another, or to expose a larger or smaller opening, such as gap  36 , to allow respectively more or less fragrant material to disperse from the scent capsule. 
     In one embodiment, outer and inner shells  22  and  24  are separated from one another by a gap  36  therebetween, around at least a portion of an outer perimeter of each shell. The gap  36  can extend around at least a portion of, or an entirety of, a lateral perimeter of the air freshener  10  or housing  18 , to allow release of scent from the housing. 
     Although  FIG. 1  shows a housing  18  having a circular shape, in embodiments, the housing  18  may have any shape, such as circular, oval, rectangular, triangular, polygonal or any other shape to allow the air freshener  10  to function as described herein. 
     In one embodiment, the scent capsule  14  comprises a reservoir  78  for containing a fragrant material  82 . The fragrant material  82  can be a liquid, such as an oil, water or alcohol based solution with an added desired fragrance or scent, and in some embodiments a desired color that can correspond to the fragrance or scent. In embodiments, the reservoir  78  can comprise a bowl or vessel  86  with a cavity  94  therein. In one embodiment, the scent capsule  14  has a flange  90  circumscribing the perimeter of vessel  86  and the cavity  94 . 
     In some embodiments, the reservoir  78  and/or vessel  86  can be formed by or can include a sheet, such as a transparent or translucent plastic, having an indentation on one side to form the reservoir  78  or vessel  86  circumscribed by flange  90 . In one embodiment, the reservoir  78  or vessel  86  is formed by vacuum forming a plastic sheet to the desired shape. In another embodiment, the vacuum formed sheet may be die cut to further refine, or detach the reservoir  78  or vessel  86  from the vacuum formed plastic sheet. In some embodiment, reservoir  78  and vessel  86  may be the same part, or may be joined together to form a unitary component. In other embodiments, reservoir  78  and vessel  86  may be separately formed of the same or different materials, and the reservoir  78  may be placed within vessel  86 . 
     The scent capsule  14  or has a front surface  16  and an opposing rear surface  20 . In one embodiment, the scent capsule  14  has a substantially constant thickness. In other embodiments, the thickness of the scent capsule may vary in certain regions thereof to add additional strength or flexibility. In embodiments, the scent capsule may be formed from transparent or at least translucent material, or have at least a portion thereof that is transparent or translucent, such as to allow a user to gauge a quantity of fragrant material  82  held therein. 
     In one embodiment the scent capsule  14  is held within the housing  18  such that at least a portion of the reservoir  78  or vessel  86  is disposed in an aperture  60  of the outer shell  22  such that the reservoir  78  or vessel  86  is visible from an outside of the housing  18 . In some embodiments, the front surface  16  of the scent capsule  14  is sized and configured to be substantially flush with an outer surface of the outer shell  22 . In this embodiment, the fragrant material  82  can be viewed to allow a user to identify an amount of fragrant material  82  left within the scent capsule  14 . In some embodiments, the scent capsule  14  may have gauge markings formed into or printed onto the vessel  86  that allow a user to easily tell how much fragrant material is contained therein. For example, the gauge markings may include “full,” “half,” “empty” and the like, or may alternatively include fluid level markings in milliliters, ounces or the like. In some embodiments, the vessel  86  and the aperture  60  may include matching shapes, such as a circular perimeter to allow the vessel  86  to have a flush appearance when placed into housing  18 . 
     An opening to the cavity of the vessel or reservoir is covered by a permeable membrane  94  defining the vessel  86  between the rear surface  20  of the scent capsule  14  and the permeable membrane  94 . Thus, the vessel  86  is defined by and completely enclosed by the permeable membrane  94 . In one embodiment, the permeable membrane  94  is substantially flat or planar, and extends across the entirety of the opening  26  of the vessel  86 . In one embodiment, the permeable membrane  94  also extends across the flange  90  of the vessel  86 . In another embodiment, the reservoir  78  is formed by the vessel  86  and the permeable membrane  94 . 
     In one embodiment, the permeable membrane  94  is adhered or welded to the flange  90 . In some embodiments, the permeable membrane  94  is adhered to the flange using an adhesive. In other embodiments, the permeable membrane is adhered to the flange  90  without the use of adhesive, and is welded to the flange  90  by heat, friction, induction, crimping or the like. In some embodiments, the permeable membrane is made of HPMV, polyethylene (PE), high density polyethylene (HDPE), polyolefins having random orientation of fibers and the like and combinations thereof. The permeable membrane  94  is configured, for example through material selection and/or mechanical or laser machining, to allow a fragrance of the fragrant material  82 , and/or the fragrant material  82  to disperse or permeate through the permeable membrane  94  over time to release the fragrance into the surrounding air. In one embodiment, the permeable membrane  94  is configured to be substantially permeable to air, gas or vapor, while being substantially impermeable to liquids or oils. 
     In order to prevent the premature release of the fragrant material  82  through the permeable membrane  94 , a removable seal  100  is sealed over permeable membrane  94  to prevent or substantially prevent fragrance release until removed. Thus, the removable seal  100  is disposed over the permeable membrane  94  prior to use and removable therefrom to initiate use. To prevent pooling of fragrant material  82  between the permeable membrane  94  and the removable seal  100 , the removable seal  100  is adhered to the permeable membrane  94  across an entirety of the outer surface  104  of the permeable membrane  94 . In one embodiment, the removable seal is a laminate structure having at least a first layer  106  and a second layer  108 . In one embodiment, the first layer  106  is made of a foil, such as a metallic foil or the like/ The second layer  108  may be made from of polyethylene (PE) or high-density polyethylene (HDPE) and the like. 
     It is important that although the removable seal  100  is adhered to the permeable membrane  94  across an entirety of the outer surface  104  of the permeable membrane  94 , it must still be easily removable by a user when desired in order to begin use of the air freshener  10 . In one embodiment, the removable seal  100  includes a tab  102  to aid in removing the removable seal from the permeable membrane  94 . In the embodiment shown in  FIG. 3 , the second layer  108  is adhered directly to the permeable membrane  94 . 
     Accordingly, in one embodiment, to adhere the releasable seal  100  to the permeable membrane  94 , a process is used to eliminate the use or need for any adhesives. In this embodiment, the permeable membrane  94  is coated with a layer of amorphous silica. In one suitable embodiment, the amorphous silica is poured directly onto the permeable membrane  94 , and then excess amorphous silica is removed using a cloth, brush or the like. In such embodiments, it the amorphous silica may be in the form of a fine silt. In one embodiment, the amorphous silica is substantially pure amorphous silica having no added binders, solvents or additives. It should be noted that “substantially pure” may mean that some small amount of impurities are present such that it does not affect the binding of the amorphous silica to the permeable membrane and the second layer  108  and allows the air freshener  10  to function as described herein. After the amorphous silica layer has been coated onto the permeable membrane  94 , the removable seal is then adhered thereto according to the disclosure herein. 
     In one embodiment, to adhere the amorphous silica coated permeable membrane  94  to the removable seal  100 , a suitable pressure and or temperature is applied to one or both of the removable seal  100  and the permeable membrane  94  while the second layer  108  is in contact with the outer surface  104  of the permeable membrane  94 . With reference to  FIG. 4 , in this embodiment, the removable seal  100  and the permeable membrane  94  are placed onto a base  110  of a press  112 . The press  112  applies a force in the direction F A  to the first layer  106  of the removable seal  100 . Accordingly, the permeable membrane  94  is thus sandwiched between the base  110  and the second layer  108  of the removable seal  100 . The force in the direction F A  is applied by the press for a predetermined period of time that allows for the amorphous silica coated permeable membrane  94  to fully adhere across the entirety of upper surface  104  to the second layer  108 . In embodiments, the time period of the applied force may range from about 0.02 to 5 seconds. In another embodiment, heat may be applied to one or both of the base  110  or press  112  during the force being applied. The temperatures of the press  112  and the base  110  may be controlled to be within a range of from. In another embodiment, the temperature may be controlled to change, increase or decrease during the application of the force, and in other embodiments the heat may be applied for a predetermined amount of time that may be less than, equal to, or greater than the time period for which the force is applied. In any such embodiment, the applied force and/or pressure should be sufficient to adhere the amorphous silica coated permeable membrane  94  to the removable seal  100 , such that an entirety of the upper surface  104  of the permeable membrane  94  is adhered to the second layer  108  of the removable seal  100 . After the adhering process is complete, the bonded permeable membrane  94  and removable seal  100  structure is removed from the press  112 . 
     In one embodiment, subsequent to the above described adhering process, the bonded permeable membrane  94  and removable seal  100  structure is then adhered to the flange  90  of the housing  18  as described herein. In another embodiment, permeable membrane  94  may be adhered to the flange  90  of the housing  18  prior to bonding the permeable membrane  94  to the removable seal  100 . In embodiments, the permeable membrane  94  is adhered to the flange using an adhesive. In other embodiments, the permeable membrane is adhered to the flange  90  without the use of adhesive, and is welded to the flange  90  by heat, friction, induction, crimping or the like. 
     As described herein, the removable seal  100  is releasably secured to the permeable membrane  94 . When the customer receives the air freshener  10 , he or she can remove the removable seal  100  covering the permeable membrane  94  to begin the scent release. In one embodiment, the tab  102  can extend from the removable seal  100 , and beyond the housing, such as between the pair of shells, to be grasped and pulled by a user in order to remove the seal from the scent capsule. 
     This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.