U.S. patent application number 10/813675 was filed with the patent office on 2005-06-23 for anti-bacterial medical waterproof material and sheet made of the same.
Invention is credited to Ichiba, Hiromi, Kawada, Yoshiari, Taniguchi, Yoshimichi.
Application Number | 20050132754 10/813675 |
Document ID | / |
Family ID | 34266424 |
Filed Date | 2005-06-23 |
United States Patent
Application |
20050132754 |
Kind Code |
A1 |
Taniguchi, Yoshimichi ; et
al. |
June 23, 2005 |
Anti-bacterial medical waterproof material and sheet made of the
same
Abstract
A waterproof material of a circular knitted fabric woven from a
first yarn and a second yarn. The first yarn is a nylon filament
containing ultra-micro silver ions and the second yarn is a
polyester yarn. The fabric is made of approximately 20 to 40% of
the first yarn and 60-80% of the second yarn. An antibacterial
waterproof sheet has a multilayer construction for controlling
bacterial growth, eliminating odor and resisting wear and includes
a polyurethane film having an upper and lower side forming an
innermost layer. A layer of polyurethane adhesive is disposed on
each upper and lower side of the film. A layer of knitted material
is disposed on each layer of adhesive forming opposed outer layers
of the sheet. The knitted material is woven from the first yarn and
a second yarn. The silver powder ions are 1 micron or less.
Inventors: |
Taniguchi, Yoshimichi;
(Kasugai Prefecture, JP) ; Kawada, Yoshiari;
(Nakamuraku, JP) ; Ichiba, Hiromi; (Esmond,
RI) |
Correspondence
Address: |
NIXON PEABODY, LLP
401 9TH STREET, NW
SUITE 900
WASHINGTON
DC
20004-2128
US
|
Family ID: |
34266424 |
Appl. No.: |
10/813675 |
Filed: |
March 31, 2004 |
Current U.S.
Class: |
66/202 |
Current CPC
Class: |
D10B 2503/06 20130101;
A47C 31/007 20130101; D04B 1/14 20130101 |
Class at
Publication: |
066/202 |
International
Class: |
D04B 007/16 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 28, 2003 |
JP |
2003-280677 |
Claims
What is claimed is:
1. A waterproof material comprising a knitted fabric woven from a
first yarn and a second yarn, the first yarn being a nylon filament
containing ultra-micro silver ions and the second yarn being a
polyester yarn.
2. The material of claim 2, wherein the fabric is made of
approximately 20 to 40% of the first yarn and 60-80% of the second
yarn.
3. The material of claim 1, wherein the material has a gauge of 28
to 32 stitches.
4. An antibacterial waterproof sheet made of the material of claim
1.
5. The material of claim 1, wherein the silver powder ions are 1
micron or less.
6. An antibacterial waterproof sheet having a multilayer
construction for controlling bacterial growth, eliminating odor and
resisting wear, comprising: a polyurethane film having an upper and
lower side forming an innermost layer; a layer of polyurethane
adhesive disposed on each upper and lower side of the film; and a
layer of knitted material disposed on each layer of adhesive
forming opposed outer layers of the sheet, the knitted material
being woven from a first yarn and a second yarn, the first yarn
being a nylon filament containing ultra-micro silver ions and the
second yarn being a polyester yarn.
7. The sheet of claim 6, wherein the material is made of
approximately 20 to 40% of the first yarn and 60-80% of the second
yarn.
8. The sheet of claim 7, wherein the material has a gauge of 28 to
32 weaves of fiber.
9. The sheet of claim 6, wherein the polyurethane film has a
thickness of about 0.05 to 0.15 mm.
10. The sheet of claim 6, wherein the silver powder ions are 1
micron or less.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an anti-bacterial
waterproof material made of a circular knitted fabric woven with a
nylon yarn containing an ultra-micro powder of silver effective in
controlling the growth of various bacteria from the moisture
associated with patient use, and more particularly, to a medical
sheet made of the material of the present invention.
[0003] 2. Description of the Related Art
[0004] As our society ages, the number of the bedridden elderly is
increasing annually. Many of these patients require an additional
medical waterproof sheet placed beneath their lower back on a bed
or other support surface.
[0005] Typical waterproof sheets used in medical facilities, such
as nursing homes and hospitals are placed in the center of a
mattress of a bedridden patient to prevent sweat, bodily fluid
and/or waste of the patient from penetrating the mattress or
support.
[0006] At the core of these conventional waterproof sheets is a
polyurethane film to which a fabric is attached. This polyurethane
film blocks the moisture of the patient's fluids from penetrating
into the mattress or support.
[0007] However, these conventional waterproof sheets do not
eliminate odor, are not anti-bacterial and are not designed to
control the growth of bacteria such as MRSA, staphylococcus aureus,
pneumobacillus and E.coli bacteria. See Japanese Unexamined Patent
Application 7-39564.
[0008] Thus, there is a need for a medical anti-bacterial
waterproof material that can be used as a sheet or other item which
can control bacterial growth and/or eliminate odor.
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to provide a
waterproof material that can be made into a sheet or other product
for medical use to eliminate odor and bacterial growth.
[0010] Another object of the present invention is to produce a low
cost, easily assembled waterproof sheet of a circular knitted
fabric woven with a nylon yarn containing an ultra-micro powder of
silver ions to control bacterial growth and eliminate odor.
[0011] In accomplishing these and other objects of the present
invention there is provided a waterproof material comprising a
knitted fabric woven from a first yarn and a second yarn, the first
yarn being a nylon filament containing ultra-micro silver ions and
the second yarn being a polyester yarn. The fabric is made of
approximately 20 to 40% of the first yarn and 60-80% of the second
yarn.
[0012] In accomplishing these and other objects of the present
invention there is provided an antibacterial waterproof sheet
having a multilayer construction for controlling bacterial growth,
eliminating odor and resisting wear, comprising a polyurethane film
having an upper and lower side forming an innermost layer. A layer
of polyurethane adhesive is disposed on each upper and lower side
of the film. A layer of knitted material is disposed on each layer
of adhesive forming opposed outer layers of the sheet. The knitted
material is woven from a first yarn and a second yarn. The first
yarn is a polyester yarn and the second yarn is a nylon filament
containing ultra-micro silver ions.
[0013] These and other objects, features, aspects, and advantages
of the present invention will become more apparent from the
following detailed description of the preferred embodiment relative
to the accompanied drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a length of nylon yarn containing the
ultra-micro powder of silver ions used in the material of the
present invention.
[0015] FIG. 2 is a perspective view of the fabric of the present
invention.
[0016] FIG. 3 is a perspective view of an anti-bacterial waterproof
sheet made of the fabric and according to the present
invention.
[0017] FIG. 4 is a cross-section of the sheet of FIG. 3 taken along
line I-I.
[0018] FIG. 5 is a perspective view of a mattress with the
anti-bacterial waterproof sheet of the present invention placed
thereon.
[0019] FIG. 6 is a perspective view of a pillow with the
anti-bacterial waterproof sheet of the present invention placed
thereon.
[0020] FIG. 7 is a perspective view of a bed with the
anti-bacterial waterproof sheet of the present invention placed
thereon.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0021] Referring to FIGS. 1-3, the waterproof antibacterial
material of the present invention is made of a circular knitted
fabric 14 having a gauge of 28-32 weaves of fiber, one measurement
of fiber equals one weave, 1 gauge of fiber. The fabric is circular
knitted to increase softness, elasticity and flexibility.
[0022] The knitted fabric is woven, approximately 20% to 40%, with
a first nylon yarn 10 having a length of 70D/24F to 140D/48F. Nylon
yarn is desirable because of its hydrophilic properties, improving
fluid absorption. Moreover, higher price and health concerns are
limited by maximizing the content of the fabric to 20-40% nylon
yarn. Use of a nylon yarn in excess of 40% can irritate or damage
sensitive skin.
[0023] The yarn 10 is shown in FIG. 1 and is a filament containing
ions of ultra-micro silver powder 12. The silver powder ions 12 are
preferably 1 micron or smaller in size. Fabric 12 is comprised
approximately 60-80% of a second 100% polyester yarn having a
length of 70D/24F to 140D/48F for example, 450 meters with a
quantity of 0.05 grams or 1 denier. This yarn material facilitates
the generation of the silver ions from the ultra-micro silver
powder 12. It should be appreciated that other yarns having the
appropriate gauge and properties can be used.
[0024] As shown in FIGS. 3 and 4, an antibacterial waterproof sheet
20 can be made using the material of the present invention.
Referring to FIG. 4, the fabric 20 is applied to a polyurethane
film 18 with a compatible polyurethane adhesive 16. Film 18 has a
preferable thickness of 0.5 to 0.15 mm. The adhesive 16 is applied
to the fabric which is then heated and pressed onto film 18.
[0025] The sheet is formed in a continuous motion, for example, by
use of a pressure roller and pressure belt. Pressure within the
range of 2.5 to 3.0 kg/m.sup.2, a heating temperature range of 75
to 85.degree. C., and a speed of 0.9 to 1.0 m/min can be used to
form the sheet.
[0026] A layer of fabric 20 is disposed on each side of film 18.
Due to the multilayer construction, both sides of sheet 20 can be
used for convenience, economy and practicality.
[0027] Accordingly, the waterproof sheet of the present invention
has a multi-layer construction and enhanced resistance to bacterial
growth, odor and wear from repeated washing and drying. In use, the
sheet will prevent the moisture of sweat, bodily fluids or waste
from infiltrating the mattress, futon or other support upon which
it is placed.
[0028] The properties of the medical waterproof sheet of the
present invention has been determined as follows:
[0029] Water resistance: 1500 mm or more (JISL 1092)
[0030] Water vapor permeability: 1,000 g/m.sup.2/24 hrs or more
(JISL 1099)
[0031] Full thickness: 0.5 to 0.75 mm (dial gauge)
[0032] Full weight: 200 to 330 g/m.sup.2 (10 cm.times.10 cm
conversion)
[0033] Cleaning: sample sheet withstood 100 washings with water (no
dry cleaning)
[0034] FIGS. 5-7 illustrate working examples of the antibacterial
medical waterproof sheet according to the present invention. As
shown in FIGS. 5 and 7, sheet 20 is placed at the center of a
mattress 30, with both ends tucked thereunder. FIG. 7 illustrates
the sheet of the present invention on mattress 30 of bed 36. FIG. 6
illustrates the sheet of the present invention as used on a pillow
32.
[0035] It should be appreciated that the waterproof sheet 20 of the
present invention is not limited to medical applications, be can
also be used in other environments and applications. Moreover, a
pillow or mattress can be cover on its entire surface with the
fabric of the present invention. Other contemplated uses and/or
applications for the fabric and sheet of the present invention can
include a cover for a stretcher, a pillowcase or protective cover
for a carpet/rug to protect the same from moisture and stain.
[0036] The fabric and sheet of the present invention is especially
effective in controlling the growth of various bacteria, including
MRSA, staphylococcus aureus, pneumobacillus and E.coli bacteria. It
also prevents odors associated with bacterial growth. Various
anti-bacterial tests were conducted.
1TABLE 1 [Test Item] Anti bacterial test [Bacteria] MRSA
Methicillin resistant Staphylococcus aureus IID 1677 [Test Method]
Standardized test method [Test Results] Planted bacteria count [A]
2.4 .times. 10.sup.4 Log A 4.4 Bacteria count on untreated fabric
[B] 1.3 .times. 10.sup.7 Log B 7.1 (Untreated fabric: Standard
cotton fabric) Log B - Log A = 2.7 > 1.5 ... Test was effective.
Active bactericidal level = Log A - Log C Active bacteriostatic
level = Log B - Log C Bacteria count Active bactericidal Active
bacteri- Sample Log C level ostatic level With silver yarn 1.3 3.1
5.8
[0037]
2TABLE 2 [Test Item] Anti bacterial test [Bacteria] Staphylococcus
aureus ATCC 6538P [Test Method] JIS L1902 quantitative test
(standardized test method) [Test Results] Planted bacteria count
[A] 2.3 .times. 10.sup.4 Log A 4.4 Bacteria count on untreated
fabric [B] 1.3 .times. 10.sup.7 Log B 7.1 (Untreated fabric:
Standard cotton fabric) Log B - Log A = 2.7 > 1.5 ... Test was
effective. Active bactericidal level = Log A - Log C Active
bacteriostatic level = Log B - Log C Bacteria count Active
bactericidal Active bacteri- Sample Log C level ostatic level
Polyester 100% 5.5 -1.1 1.6 Polyester 100% 1.3 3.1 5.8 (with
silver)
[0038]
3TABLE 3 [Test Item] Anti bacterial test [Bacteria] Klebsiella
pneumoniae ATCC 4352 [Test Method] Standardized test method [Test
Results] Planted bacteria count [A] 1.9 .times. 10.sup.4 Log A 4.3
Bacteria count on untreated fabric [B] 2.9 .times. 10.sup.7 Log B
7.5 (Untreated fabric: Standard cotton fabric) Log B - Log A = 3.2
> 1.5 ... Test was effective. Active bactericidal level = Log A
- Log C Active bacteriostatic level = Log B - Log C Bacteria count
Active bactericidal Active bacteri- Sample Log C level ostatic
level With silver yarn 1.3 3.0 6.2
[0039]
4TABLE 4 [Test Item] Anti bacterial test [Bacteria] Escherichia
coli NBRC 3301 [Test Method] Standardized test method [Test
Results] Planted bacteria count [A] 2.1 .times. 10.sup.4 Log A 4.3
Bacteria count on untreated fabric [B] 3.1 .times. 10.sup.7 Log B
7.5 (Untreatcd fabric: Standard cotton fabric) Log B - Log A = 3.2
> 1.5 ... Test was effective. Active bactericidal level = Log A
- Log C Active bacteriostatic level = Log B - Log C Bacteria count
Active bactericidal Active bacteri- Sample Log C level ostatic
level With silver yarn 1.3 3.0 6.2
[0040]
5 1 [A] Bacteria count on untreated sample immediately after
planting (Log A) [B] Bacteria count on untreated sample after 18
hour incubation (Log B) [C] Bacteria count on treated sample after
18 hour incubation (Log C) 2 Staphylococcus Klebsiella Escherichia
Pseudomonas MRSA aureus pneumoniae coli aeruginosa Active
bacteriostatic level 5.8 5.8 6.2 6.2 1.9 Log B-Log C Effectiveness
in controlling 1/630,000 1/630,000 1/1,600,000 1/1,600,000 1/80
bacterial growth (compared to untreated fabric) Criteria for
evaluating bacteria growth/odor control: (Log for staphylococcus
aureus must be 2.2 or higher; generally 1/160 or less) 3
Staphylococcus Klebsiella Escherichia Pseudomonas MRSA aureus
pneumoniae coli aeruginosa Active bactericidal level 3.1 3.1 3.0
3.0 -0.9 Log A-Log C Effectiveness in bactericidal 1/1,260 1/1,260
1/1,000 1/1,000 8 times activity (compared to initial bacteria
count) Criteria for evaluating sterilization: Active bactericidal
level must be: Log C < Log AC 0 (bacteria count must be less
than initial count) 4 The SEK (Japan Textile Evaluation Technical
Council) mark specifies the following. [Bacteria to be Tested]
include: Bacterial growth control treatment Specific
Antibacterial/anti General application Bacteria to be tested for
bacteria growth/odor control odor treatment application (medical)
Staphylococcus IID 1677 (MRSA) -- -- .quadrature. Staphylococcus
aureus ATCC 6538P (*) .quadrature. .quadrature. .quadrature.
Klebsiella pneumoniae ATCC 4352 (*) -- .quadrature. .quadrature.
Eseherichia coli IFO 3301 (*) -- .quadrature. .quadrature.
Pseudomonas aeruginosa IFO 3080 (*) -- .quadrature. .quadrature.
Note: .quadrature.: Required: .quadrature.: Optional: --: Not
applicable
[0041] Although the present invention has been described in
relation to particular embodiments thereof, many other variations
and modifications and other uses will become apparent to those
skilled in the art. It is preferred therefore, that the present
invention be limited not by the specific disclosure herein, but
only by the appended claims.
* * * * *