Source: http://www.google.com/patents/US5906637
Timestamp: 2014-03-16 21:47:47
Document Index: 82148115

Matched Legal Cases: ['application No. 08', 'application No. 08', 'application No. 08', 'application No. 08', 'application No. 08', 'application No. 08', 'application No. 08', 'application No. 08']

Patent US5906637 - Disposable elastic thermal uniaxial joint wrap - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsThe present invention relates to disposable elastic thermal uniaxial joint wraps having an elastic laminate structure formed from a polymeric mesh and two fabric carrier layers, and one or more heat cells, preferably one or more thermal packs comprising a plurality of individual heat cells, wherein heat...http://www.google.com/patents/US5906637?utm_source=gb-gplus-sharePatent US5906637 - Disposable elastic thermal uniaxial joint wrapAdvanced Patent SearchPublication numberUS5906637 APublication typeGrantApplication numberUS 08/916,083Publication dateMay 25, 1999Filing dateAug 21, 1997Priority dateAug 21, 1997Fee statusPaidAlso published asCA2301290A1, CA2301290C, CN1158982C, CN1271264A, DE69815134D1, DE69815134T2, EP1021144A1, EP1021144B1, US6024761, WO1999009917A1Publication number08916083, 916083, US 5906637 A, US 5906637A, US-A-5906637, US5906637 A, US5906637AInventorsDaniel Louis Barone, Ronald Dean Cramer, Leane Kristine Davis, William Robert OuelletteOriginal AssigneeThe Procter & Gamble CompanyExport CitationBiBTeX, EndNote, RefManPatent Citations (61), Non-Patent Citations (8), Referenced by (37), Classifications (17), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetDisposable elastic thermal uniaxial joint wrapUS 5906637 AAbstract The present invention relates to disposable elastic thermal uniaxial joint wraps having an elastic laminate structure formed from a polymeric mesh and two fabric carrier layers, and one or more heat cells, preferably one or more thermal packs comprising a plurality of individual heat cells, wherein heat is applied to specific areas of the user's body, preferably for the knee and/or elbow, preferably for pain relief. These wraps provide good conformity to user's body to deliver consistent, convenient and comfortable heat application.
What is claimed is: 1. A disposable elastic thermal uniaxial joint wrap comprising:a) a piece of flexible material having a first end and a second end, a body portion fixed between said first end and said second end, a first strap portion, and a second strap portion, wherein at least one of said body portion, first strap portion, and second strap portion, comprises one or more elastic laminate structures, said laminate structures comprising a first carrier layer, a second carrier layer, and a mesh disposed between said carrier layers, said mesh having a plurality of first strands intersecting a plurality of elastic second strands, said first and second strands having softening temperatures at an applied pressure, at least about 10% of said first strands being integrally bonded to said first carrier layer and said second carrier layer by application of a bonding pressure at said softening temperature of said first strands, wherein at least one of said body portion, first strap portion, and second strap portion is stretchable along a longitudinal axis of said piece of flexible material; b) one or more heat cells comprising an exothermic composition spaced apart and fixedly attached across said body portion; and c) a fastening means to hold said piece of flexible material around a user's knee or elbow. 2. A disposable elastic thermal uniaxial joint wrap according to claim 1 wherein at least 50% of said first strands are integrally bonded to said first carrier layer and said second carrier layer.
26. A disposable elastic thermal uniaxial joint wrap according to claim 21 wherein said thermal pack comprises at least one continuous layer of a coextruded material having a first side of polypropylene and a second side of a low melt temperature copolymer, wherein said continuous layer is semirigid at a temperature of about 25 substantially less rigid at a temperature of above about 25
As used herein, "elastic" refers to that property of a material whereby the material, when subjected to a tensile force, will stretch or expand in the direction of the force and will essentially return to its original untensioned dimension upon removal of the force. More specifically, the term "elastic" is intended to mean a directional property wherein an element or structure has a recovery to within about 10% of its original length Lo after being subjected to a percent strain ε.sub.% of greater than 50%. As used herein, percent strain ε.sub.% is defined as:
&#949;.sub.% = (L.sub.f -L.sub.o)/L.sub.o !*100
The above described benefits can be achieved by selecting a first strand material having a softening temperature which is lower than the softening temperature of second strands 26 relative to the processing pressures used to form laminate structures 66 and/or 67. As used herein, the phrase "softening temperature" is intended to mean the minimum temperature at which a material begins to flow under an applied pressure to facilitate integral bonding of the material to a carrier layer or layers. Typically, heat is applied to a material to achieve a softening temperature. This generally results in a decrease in the viscosity of the material which may or may not involve a "melting" of the material, the melting being associated with a latent heat of fusion. Thermoplastic materials tend to exhibit a lowering in viscosity as a result of an increase in temperature allowing them to flow when subjected to an applied pressure. It will be understood that as the applied pressure increases, the softening temperature of a material decreases and therefore a given material can have a plurality of softening temperatures because the temperature will vary with the applied pressure. For ease of manufacturing and processing, and when utilizing generally polymeric materials for strands 24 and 26, it is preferred that the softening temperature of first strands 24 be lower, at least about 10 20 when both materials are subjected to the same applied pressure (e.g., the processing pressure). As used herein, the phrase "bonding pressure", is intended to mean the pressure which facilitates the integral bonding of first strands 24 to carrier layers 37 and 38, without integrally bonding second strands 26 to carrier layers 37 and 38, when both strands are at the softening temperature of first strands 24 but below the softening temperature of second strands 26. In addition to the selection of first and second strand materials for softening temperature point, second strands 26 are preferably formed from a material which renders second strands 26 appropriately elastic such that laminate structures 66 and/or 67 provide a structural direction, along the direction of second strands 26, which is also appropriately elastic as desired.
The softening temperature of carrier layers 37, 38, 40, and/or 41 (at the subject processing pressures) should be greater than any of the processing temperatures applied to elastic member 36 and/or 39 in forming laminate structures 66 and/or 67. In addition, carrier layers 37, 38, 40, and/or 41 of the present invention preferably have a modulus of less than about 100 gm force per cm at a unit strain ε.sub.μ of at least about 1 (i. e., L.sub.f =2 when it is formed into laminate structure 66 and/or 67. As used herein, the term "modulus" is intended to mean the ratio of an applied stress σ to the resulting unit strain ε.sub.μ, wherein stress σ and strain ε.sub.μ are:
&#963;=F.sub.a /W
&#949;.sub.&#956; =(L.sub.f -L.sub.o)/L.sub.o
F.sub.a =Applied force
W=Orthogonal dimension of the element or structure subjected too the applied force F.sub.a (typically the structure width)
For example, a 20 gram force applied orthogonally across a 5 cm wide fabric would have a stress σ of 4 grams force per cm. Further, if the original length L.sub.o in the same direction as the applied force F.sub.a were 4 cm and the resulting elongated length L.sub.f were 12 cm, the resulting unit strain ε.sub.μ would be 2 and the modulus would be 2 grams force per cm.
First carrier layer 37 is juxtaposed adjacent to first elastic member 36 which is juxtaposed adjacent to second carrier layer 38 such that when fed around first surface 148, as seen in FIG. 5, first elastic member 36 is disposed between first carrier layer 37 and second carrier layer 38. Preferably, first strands 24 of first elastic member 36 are juxtaposed adjacent inner surface 50 of first carrier layer 37 and second strands 26 are juxtaposed adjacent inner surface 52 of second carrier layer 38. First carrier layer 37 is preferably oriented adjacent first surface 148. First surface 148 is heated to a temperature T.sub.1, which, in combination with the feed rate of juxtaposed first carrier layer 37, first elastic member 36, and second carrier layer 38 over first surface 148, raises the temperature of first strands 24 to, or above, their softening temperature. Because of the low applied pressure P.sub.d at gap 156, first strands 24 and second strands 26 undergo little if any deformation thereat.
After juxtaposed first carrier layer 37, first elastic member 36, and second carrier layer 38 pass through gap 156, second carrier layer 38 is preferably oriented adjacent second surface 150 and disposed between second surface 150 and first elastic member 36 and first carrier layer 37. Second surface 150 is preferably heated to a temperature T.sub.2, which in combination with the feed rate of juxtaposed first carrier layer 37, first elastic member 36, and second carrier layer 38 over second surface 150, raises the temperature of second strands 26 to their softening temperature. Juxtaposed first carrier layer 37, first elastic member 36, and second carrier layer 38 then pass through interference nip 154, wherein first strands 24 are integrally bonded to first carrier layer 37 and second carrier layer 38 by the application of first strand bonding pressure P.sub.b from second and third surfaces 150 and 152 at nip 154. Resilient third surface 152 provides bonding pressure P.sub.b which is uniformly applied to first strands 24 between second strands 26 due to the conforming nature of resilient third surface 152. More preferably, the application of pressure P.sub.b from third surface 152 and heat flux from second surface 150 at temperature T.sub.2 is sufficient to deform first strands 24 into substantially flat shaped and integrally bonded first strands 25. Most preferably, the application of pressure and heat flux is sufficient to deform first strands 24 into integrally bonded first strands 25 which are substantially coplanar with inner surface 50 of first carrier layer 37 and second carrier layer 38.
In contrast, at least about 25%, preferably at least about 50%, more preferably at least about 75%, most preferably about 100%, of second strands 26 are deformed into a substantially elliptical shape at nip 154 because pressure P.sub.b is fully applied to second strands 26 by second surface 150. The elliptical cross-sectional shape of second strands 27 is desirable if the undeformed cross section of the second strands 26 would otherwise produce a "nubby" or rough feel when laminate structures 66 and/or 67 are worn about the body. Preferably, the post-nip structural thickness I of laminate structures 66 and/or 67 is about 50% of the pre-nip structural thickness S of juxtaposed first carrier layer 37, first elastic member 36, and second carrier layer 38.
Based upon the foregoing described nip process, it has been found that the following will form satisfactory laminate structures 66 and/or 67 having an elastic structural direction along the direction of laminate second strands 27: first, second, third, and fourth carrier layers 37, 38, 40 and 41 preferably comprise a carded nonwoven formed from thermally bonded polypropylene and having a 32 gram per m.sup.2 basis weight, a fiber size of about 2.2 denier per filament, a caliper of between about 0.01 cm to about 0.03 cm, a modulus of about 100 grams force per cm at a unit strain ε.sub.μ of 1 (such a fabric being marketed by Fibertech, Landisville, N.J., as Phobic Q-1); and first and second elastic members 36 and 39 comprise a mesh wherein first strands 24 are formed from polyethylene and second strands 26 are formed from a styrene or butadiene block copolymer (such a mesh being manufactured by Conwed, Minneapolis, Minn. and marketed as T50018). Specifically, the juxtaposed Phobic Q-1 fabric, T50018 mesh, and Phobic Q-1 fabric, having a pre-formed structural thickness S of from about 0.09 cm to about 0.13 cm, preferably from about 0.10 cm to about 0.12 cm, more preferably about 0.11 cm, are fed at a rate of from about 6 to about 14, more preferably from about 7 to about 12, most preferably from about 8 to about 10 meters per minute, over first surface 148 which is heated to a temperature T.sub.1 of from about 71 C. to about 141 about 139 greater than or about 0.13 cm. Preferably, second surface 150 is heated to a temperature T.sub.2 of from about 71 preferably from about 130 preferably from about 137 juxtaposed fabrics and mesh pass over second surface 150 and through inference nip 154. Pressure P.sub.b at nip 154 is preferably from about 55 to about 85 kilograms per centimeter, more preferably from about 70 to about 75 kilograms per centimeter. After the juxtaposed fabrics and mesh emerge from nip 154, the resulting thermal bonded elastic laminates 66 and/or 67 have a thickness I of from about 0.05 cm to about 0.09 cm, preferably from about 0.06 cm to about 0.08 cm, more preferably about 0.07 cm.
In addition to forming a laminate structure of the present invention via the is above described nip process, such laminate structures can also be formed by a process providing a first plate 150 and a second plate 160, such as shown in FIG. 6. In contrast to the process discussed previously, first plate surface 149 preferably is substantially non-resilient, while second plate surface 151 is substantially resilient. First plate surface 149 is preferably heated to temperature T.sub.1. A bonding pressure P.sub.f is applied to the juxtaposed fabrics and mesh by moving first plate surface 149 toward second plate surface 151 appropriately. Because temperature T.sub.1 heats first strands 24 to their softening temperature for the applied bonding pressure P.sub.f, application of the bonding pressure P.sub.f integrally bonds first strands 24 to carrier layers 37 and 38. More preferably, application of the bonding pressure P.sub.f also deforms first strands 24 into a substantially flat shape which is also coplanar with carrier layer inner surfaces 50 and 52. Most preferably, application of bonding pressure P.sub.f also deforms second strands 26 into a substantially elliptical shape.
Using the Phobic Q-1 fabrics and T50018 mesh combination described above, satisfactory laminate structures 66 and/or 67 having first strands 24 integrally bonded to first and second carrier layers 37 and 38 can be provided if first plate 158 is heated to a temperature T.sub.1 of from about 110 P.sub.f of between 350 to 700 grams force per cm.sup.2 is applied between first plate 158 and second plate 160 for from about 10 to about 20 seconds.
It is believed that properly selecting the strand density, strand cross-sectional area, and/or the melt index of first strands 24 (if first strands 24 are formed of a polymer) is necessary in order to provide laminate structures 66 and/or 67 having an elastic structural direction along the direction of the second strands 27. Improper selection of strand density, strand cross-sectional area, and/or melt index of first strands 24 can result in a laminate structure wherein portions of integrally bonded first strands 25 can overlap or merge together in laminate structures 66 and/or 67. Such merging or overlap of integrally bonded first strands 25 can result in only small portions of laminate second strands 27 being able to extend or elongate when subjected to a tensile force, as opposed to the elongation being distributed along substantially the entire length of substantially all of laminate second strands 27 absent this overlap. To minimize this condition, the strand density, strand cross-sectional area, and/or melt index of first strands 24 should be selected such that integrally bonded first strands 25 have a strand coverage S.sub.c of less than about 50%. As used herein, the phrase "strand coverage" is intended to be a measure of the amount of surface area of first carrier layer inner surface 50 and second carrier layer inner surface 52 which is in contact with integrally bonded first strands 25 of the present invention. Strand coverage SC is defined as:
The melt index of a polymer measures the ability of the polymer to flow when subjected to a given temperature or pressure. A polymer having a low melt index will be more viscous (and therefore not flow as readily) at a given temperature than a polymer having a higher melt index. Thus, it is believed that first strands 24 comprising a polymer having a high melt index will have a greater tendency to merge or overlap during application of a given pressure and heat flux than first strands 24 comprising a polymer having a lower melt index and subjected to the same pressure and heat flux. Because of this variability, the polymer forming first strands 24 can be selectively chosen, in conjunction with the strand density and strand cross-sectional area, to provide a predetermined melt index such that first strands 24 are integrally bonded to first and second carrier layer 37 and 38 with a strand coverage S.sub.c of about 50 percent. In addition, varying the polymer melt index can also be especially useful where it is desired to increase the density of first and second carrier layers 37 and 38 while maintaining the same processing conditions. In this situation, the polymer of first strands 24 can be changed to provide a higher melt index such that first strands 24 can more easily penetrate and bond with carrier layer 37, 38, 40, and/or 41 when subjected to the predetermined pressure and heat flux. Consequently, the same level of integral bonding can be achieved without changing the processing conditions despite the increased density of carrier layers 37, 38, 40, and/or 41.
Based upon the foregoing, it is believed that first strands 24 should preferably be aligned so as to provide a strand density of from about 2 to about 10 strands per centimeter in conjunction with a strand cross-sectional area of from about 0.0005 cm.sup.2 to about 0.03 cm.sup.2, more preferably from about 3 to about 6 strands per centimeter in conjunction with a strand cross-sectional area of from about 0.001 cm.sup.2 to about 0.005 cm.sup.2, so that merger or overlap of integrally bonded first strands 25 in laminate structure 66 and/or 67 can be avoided. A melt index of from about 2 to about 15 (as measured per ASTM D1238) in conjunction with the above-described strand density and strand cross-sectional area values has been found to be satisfactory. With regard to second strands 26, it is believed that the strand density, strand cross-sectional area, and modulus of second strands 26 can also affect the elastic properties of laminate structures 66 and/or 67 (i. e., the modulus of laminate structures 66 and/or 67) in the direction along the second strands 26 (i. e., along irection D of FIG. 4). For example, as the strand density and/or the strand cross-sectional area of second strands 26 increases, the modulus of laminate structures 66 and/or 67 will decrease. For laminate structures 66 and/or 67 to be incorporated into the wraps of the present invention, it is desirable that a modulus of from about 100 to about 250 grams force per cm, at a strain ε.sub.μ of about 1 be provided. It is believed that providing second strands 26 having a strand density of from about 2 to about 5, a cross-sectional area of from about 0.003 cm.sup.2 to about 0.02 cm.sup.2, and comprising a styrene butadiene block copolymer will provide laminate structures 66 and/or 67 having the preferred modulus in a direction along second strands 26. The modulus of laminate structures 66 and/or 67 can be measured by techniques known in the art. For example, the modulus of laminate structures 66 and/or 67 can be measured using a universal constant rate of elongation tensile tester, such as Instron Model #1122, manufactured by Instron Engineering Corp., Canton, Mass.
The attachment of layers to form body-facing laminate 92, outer surface laminate 93 and, finally, wrap 10 may be achieved by any number of attachment means known in the art. These include, but are not limited to, hot melt adhesive including spiral sprays, meltblown, control coat, and the like, latex adhesives applied via spray, printing gravure, and the like, thermal bonding, ultrasonic, pressure bonding, and the like. One particular method that has been used successfully is hot melt adhesive layer 60 available as 70-4589 from National Starch and Chemical Co., Bridgewater, N.J., applied via a spiral hot melt system at a rate of from about 0.5 to about 25 mg/cm.sup.2.
Thermal pack 22 may be made of any number of thermoplastic materials; however, it is preferred that base material 70 and/or cover material 72 be made of thermoplastic materials which are semirigid at a temperature of about 25 substantially less rigid, at a temperature above about 25 Different materials may be capable of satisfying the specified requirement provided that the thickness is adjusted accordingly. Such materials include, but are not limited to, polyethylene, polypropylene, nylon, polyester, polyvinyl chloride, polyvinylidene chloride, polyurethane, polystyrene, saponified ethylene-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, natural rubber, reclaimed rubber, synthetic rubber, and mixtures thereof. These materials may be used alone or coextruded with a low melt temperature polymer including, but not limited to, ethylene vinyl acetate copolymer, low density polyethylene, and mixtures thereof. Such materials are also capable of containing exothermic composition 74 and limiting oxygen flow into pocket 76 and provides sufficient rigidity to prevent wrap 10 from folding or bunching during use, preventing unacceptable stretching of structures of the continuous layer during processing or use, and deterring easy access to the heat cell contents.
Oxygen permeability can be provided by selecting materials for the base material 70 and/or cover material 72 that have the specifically desired permeability properties. The desired permeability properties may be provided by microporous films or by films which have pores or holes formed therein. The formation of these holes/pores may be via extrusion cast/vacuum formation or by hot needle aperturing. Oxygen permeability can also be provided by perforating at least one of the base material 70 and cover material 72 with aeration holes using, for example, an array of pins having tapered points and diameters of from about 0.2 mm to about 2 mm, preferably from about 0.4 mm to about 0.9 mm. Oxygen diffusion into heat cell 75 during oxidation of the exothermic composition 74 typically ranges from about 0.01 cc O.sub.2 /min./5 cm.sup.2 to about 15.0 cc O.sub.2 /min./5 cm.sup.2 (at 21 O.sub.2 /min./5 cm.sup.2 to about 3 cc O.sub.2 /min./5 cm.sup.2 (at 21
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