Tacky allergen trap and filter medium, and method for containing allergens

Abstract

An allergen trap is provided. The allergen trap includes a woven or nonwoven substrate having at least one strata. The trap is impregnated with or otherwise treated with a tacky adhesive by which allergens may be trapped. An example of an allergen is a dust mite. The tacky adhesive, in turn, may be treated with a miticide or activated carbon.

1 . A unitary tacky material comprising:
 (A) a woven or nonwoven multistrata substrate, each stratum of the substrate containing
 (i) a matrix of fibers, 
 (ii) optionally, a binder; and 
   (B) a tacky adhesive.   
     
     
         2 . The unitary tacky material of  claim 1 , wherein the substrate is an airlaid nonwoven material. 
     
     
         3 . The unitary tacky material of  claim 1 , wherein the substrate further comprises a scrim being of a spunbond material, a meltblown material, a wetlaid or airlaid nonwoven material, a textile, a woven or nonwoven synthetic material. 
     
     
         4 . The unitary tacky material of  claim 1 , wherein at least a portion of the matrix of fibers of one stratum of the multistrata substrate are impregnated with the tacky adhesive. 
     
     
         5 . The unitary tacky material of  claim 1 , wherein the substrate comprises cellulose fibers. 
     
     
         6 . The unitary tacky material of  claim 1 , wherein the substrate consists essentially of synthetic materials. 
     
     
         7 . The unitary tacky material of  claim 1 , wherein the tacky material is present in one or more intermediate layers between the strata of the multistrata substrate. 
     
     
         8 . The unitary tacky material of  claim 1 , wherein each of the strata of the multistrata is at least partially impregnated with a same or different tacky adhesive. 
     
     
         9 . The unitary tacky material of  claim 8 , wherein the strength of the tacky adhesive impregnating one stratum of the multistrata substrate is different from the strength of the tacky adhesive impregnating another stratum of the multistrata substrate. 
     
     
         10 . The unitary tacky material of  claim 1 , wherein the strata of the multistrata substrate are melded together by heat. 
     
     
         11 . The unitary tacky material of  claim 1 , further comprising a miticide. 
     
     
         12 . The unitary tacky material of  claim 1 , wherein the substrate has a basis weight of from about 35 gsm to about 500 gsm. 
     
     
         13 . The unitary tacky material of  claim 12 , wherein the substrate contains from about 30 weight percent to about 95 weight percent matrix fibers and from about 5 weight percent to about 70 weight percent of a binder wherein the weight percentages are based on the total weight of the nonwoven substrate. 
     
     
         14 . The unitary tacky material of  claim 13 , wherein the substrate contains from about 50 weight percent to about 95 weight percent matrix fibers and from about 5 weight percent to about 50 weight percent of a binder. 
     
     
         15 . The unitary tacky material of  claim 1 , wherein the matrix fibers of the substrate comprise cellulosic fibers, synthetic fibers, or a mixture of cellulosic fibers and synthetic fibers. 
     
     
         16 . The unitary tacky material of  claim 1 , wherein the binder is a latex or other liquid binder, a bicomponent or other fiber binder, a powdered or pelletized synthetic binder, or a combination thereof. 
     
     
         17 . The unitary tacky material of  claim 1 , wherein the substrate has a density of from about 0.035 g/cm 3  to about 0.10 g/cm 3 . 
     
     
         18 . The unitary tacky material of  claim 1 , wherein the tacky adhesive is on the surface of the substrate. 
     
     
         19 . The unitary tacky material of  claim 18 , wherein the material further comprises a release layer adhered to the tacky adhesive. 
     
     
         20 . The unitary tacky material of  claim 19 , wherein the release layer is paper, fiber, metal foil, polymeric film, or a combination thereof. 
     
     
         21 . The unitary tacky material of  claim 20 , wherein the release layer is a polymeric film that is one of polyolefin, polyethylene, polyester, and plasticized vinyl films. 
     
     
         22 . The unitary tacky material of  claim 20 , wherein the release layer is either a woven or nonwoven fiber which has been treated on a surface with a release agent. 
     
     
         23 . The unitary tacky material of  claim 1 , wherein the tacky adhesive is present in an amount from about 5 gsm to about 300 gsm. 
     
     
         24 . The unitary tacky material of  claim 1 , wherein the tacky material has a basis weight of from about 40 gsm to about 1300 gsm. 
     
     
         25 . The unitary tacky material of  claim 1 , wherein the tacky adhesive is coextensively contiguous with a major surface of one of the strata of the multistrata substrate. 
     
     
         26 . The unitary tacky material of  claim 1 , wherein the tacky adhesive is coextensively contiguous with the one or more selected areas of the substrate. 
     
     
         27 . The unitary tacky material of  claim 1 , wherein the tacky adhesive is a pressure sensitive adhesive. 
     
     
         28 . The unitary tacky material of  claim 27 , wherein the pressure sensitive adhesive is an acrylate, a polyurethane, a poly-alpha-olefin, a silicone, or a self-tacky or tackified natural or synthetic rubber. 
     
     
         29 . The unitary tacky material of  claim 27 , wherein the pressure sensitive adhesive is an essentially non-tacky adhesive tackified with a resin. 
     
     
         30 . The unitary tacky material of  claim 29 , wherein the pressure sensitive adhesive is a substantially non-tacky acrylate tackified with a rosin ester, an aliphatic resin, or a terpene resin. 
     
     
         31 . The tacky material of  claim 1 , formed in the shape of a polygon with an edge circumference of from about 30 cm to about 15 meters. 
     
     
         32 . The tacky material of  claim 31 , wherein the edge circumference is from about 1 meter to about 15 meters. 
     
     
         33 . The tacky material of  claim 31 , wherein the edge circumference is shaped to cover an upper surface of a mattress. 
     
     
         34 . The tacky material of  claim 33 , wherein the material has four sides with angles between the sides of about 90°. 
     
     
         35 . A filter element for filtering a fluidized stream of materials comprising:
 (A) a filter housing, and   (B) a tacky material containing matrix fibers, and optionally, a binder, and a tacky adhesive, the tacky material being affixed within the filter housing.   
     
     
         36 . The filter element of  claim 35  sized to fit a residential air conditioning unit. 
     
     
         37 . The filter element of  claim 35 , wherein the tacky adhesive has an absorbent or adsorbent adhered to it. 
     
     
         38 . The filter element of  claim 37 , wherein the adsorbent is activated carbon. 
     
     
         39 . The filter element of  claim 35 , further comprising a pesticide, allergen neutralizer or an insect growth regulator. 
     
     
         40 . The filter element of  claim 39 , wherein the pesticide, allergen neutralizer or insect growth regulator is dissolved or suspended in the binder. 
     
     
         41 . The filter element of  claim 39 , wherein the pesticide, allergen neutralizer or insect growth regulator is adhered to the tacky adhesive. 
     
     
         42 . The filter element of  claim 35 , wherein the substrate has a basis weight of from about 35 gsm to about 75 gsm, and the material retained in a Dust Capture Performance Test is about 25 percent or greater. 
     
     
         43 . The filter element of  claim 35 , wherein the substrate has a basis weight of from about 80 gsm to about 125 gsm, and the material retained in a Dust Capture Performance Test is about 50 percent or greater. 
     
     
         44 . The filter element of  claim 35 , wherein dust mite allergen and feline allergen in an Allergen Barrier Test are reduced by about 90 percent or more. 
     
     
         45 . The filter element of  claim 35 , wherein the MERV is from about 7 to about 8 at an airflow rate of about 472 CFM. 
     
     
         46 . The filter element of  claim 35 , wherein the total basis weight of the tacky material is from about 200 gsm to about 220 gsm. 
     
     
         47 . The filter element of  claim 35 , wherein the MERV is about 10 at an airflow rate of about 472 CFM. 
     
     
         48 . A unitary tacky material produced by a process comprising:
 (A) producing or providing one or more strata of a woven or nonwoven substrate which contains
 (i) matrix fibers, and 
 (ii) optionally, a binder; and 
   (B) adhering a tacky adhesive to at least one stratum of the one or more strata of the substrate.   
     
     
         49 . The process of  claim 48 , wherein step (A) and step (B) are performed in a series of unitary steps in a continuous process. 
     
     
         50 . The process of  claim 48 , wherein a tacky adhesive is adhered to a previously formed substrate in a converting process. 
     
     
         51 . The process of  claim 48 , wherein a tacky adhesive is adhered to the substrate by spraying, rolling, printing or foaming. 
     
     
         52 . The process of  claim 48 , wherein the tacky adhesive is sprayed from an aerosol can or a pump spray. 
     
     
         53 . A process for immobilizing and containing pests including allergen producing pests comprising passing air through a tacky material which contains matrix fibers and, optionally, a binder, and a tacky adhesive. 
     
     
         54 . A process for filtration of a fluidized stream of materials comprising passing a fluidized stream of materials through a filter element of  claim 35 . 
     
     
         55 . The process of  claim 54 , wherein the fluidized stream comprises a fluidizing medium and suspended particulate matter or dissolved matter. 
     
     
         56 . The process of  claim 54 , wherein the fluidizing medium is air or another gas or mixture of gases. 
     
     
         57 . The process of  claim 54  wherein the suspended particulate matter contains dust, allergens, or a mixture thereof. 
     
     
         58 . The process of  claim 54 , wherein the fluidizing medium is a liquid. 
     
     
         59 . A method for containing allergens adjacent an allergen-bearing article, comprising:
 providing a tacky material, the tacky material comprising a woven or nonwoven substrate which contains matrix fibers and, optionally, a binder, and a tacky adhesive;   placing the tacky material adjacent the allergen-bearing article;   trapping allergens moving into or out of the allergen-bearing article within the tacky material;   removing the tacky material from the allergen-bearing article; and   disposing of the allergen-bearing article.   
     
     
         60 . The method of  claim 59 , wherein:
 the allergens are dust mites;   the allergen-bearing article is a mattress; and   the step of placing the tacky material adjacent the allergen-bearing article comprises spreading the tacky material over at least an upper surface of the mattress.