U.S. patent application number 10/793673 was filed with the patent office on 2005-09-08 for self-heating and adhesive device.
Invention is credited to Ota, Keizo, Watanabe, Tetsuhiro.
Application Number | 20050196562 10/793673 |
Document ID | / |
Family ID | 34912104 |
Filed Date | 2005-09-08 |
United States Patent
Application |
20050196562 |
Kind Code |
A1 |
Ota, Keizo ; et al. |
September 8, 2005 |
Self-heating and adhesive device
Abstract
The self-heating and adhesive device of the present invention
comprises a gas-permeable sheet layer, an exothermic composition
layer, a gas-impermeable sheet layer, a support, a poultice or gel
layer, and a releasing sheet layer in this order, wherein the
exothermic composition layer is stuffed in a pouch that is made of
the gas-permeable sheet layer and the gas-impermeable sheet layer,
and wherein the support comprises a fibrous layer only or a
gas-impermeable sheet and a fibrous layer and has a moisture
permeability within the range of 0 to 3,000 g/m.sup.2.multidot.24
hours by the Lyssy method.
Inventors: |
Ota, Keizo; (Takefu-shi,
JP) ; Watanabe, Tetsuhiro; (Takefu-shi, JP) |
Correspondence
Address: |
Jonathan P. Osha
Osha Novak & May L.L.P.
1221 McKinney St., Suite 2800
Houston
TX
77010
US
|
Family ID: |
34912104 |
Appl. No.: |
10/793673 |
Filed: |
March 4, 2004 |
Current U.S.
Class: |
428/34.1 |
Current CPC
Class: |
A61F 2007/0261 20130101;
A61F 2007/0203 20130101; Y10T 156/1052 20150115; Y10T 428/13
20150115; A61F 2007/0226 20130101; A61F 7/034 20130101; A61F
2007/0258 20130101; A61F 2007/0257 20130101; A61F 2007/0222
20130101; Y10T 428/14 20150115 |
Class at
Publication: |
428/034.1 |
International
Class: |
B65D 001/00 |
Claims
What we claim are:
1. A self-heating and adhesive device comprising a gas-permeable
sheet layer, an exothermic composition layer, a gas-impermeable
sheet layer, a support, a poultice or gel layer, and a releasing
sheet layer in this order, wherein the exothermic composition layer
is stuffed in a pouch that is made of the gas-permeable sheet layer
and the gas-impermeable sheet layer, and wherein the support
comprises a fibrous layer only or a gas-impermeable sheet and a
fibrous layer and has a moisture permeability within the range of 0
to 3,000 g/m.sup.2.multidot.24hours by the Lyssy method.
2. The device according to claim 1, wherein the fibrous layer is
made of at least one member selected from the group consisting of
an unwoven fabric, a woven fabric, and paper.
3. The device according to claim 1, wherein raw materials of the
fibrous layer comprises at least one member selected from the group
consisting of cotton, a regenerated cellulose, a polyester, a
polypropylene, a polyamide, and an acrylic at least a part of the
raw materials.
4. The device according to claim 1, wherein the support is made of
an unwoven fabric having a basis weight of 20 to 60 g/m.sup.2.
5. An adhesive structure comprising a support, an adhesive poultice
or gel layer, and a releasing sheet layer in this order, wherein
the support comprises a fibrous layer only or a gas-impermeable
sheet and a fibrous layer and has a moisture permeability within
the range of 0 to 3,000 g/m.sup.2.multidot.24hours by the Lyssy
method.
Description
FIELD OF INVENTION
[0001] This invention relates to a self-heating and adhesive device
comprising a layer of an exothermic composition and a layer of an
adhesive poultice or gel.
[0002] Further, this invention relates to an adhesive structure
comprising a layer of an adhesive poultice or gel. This structure
is useful to produce the self-heating and adhesive device.
BACKGROUND
[0003] Self-heating and adhesive devices have been produced, for
example, as follows:
[0004] 1) bonding or heat-sealing a gas-permeable sheet and a
gas-impermeable sheet to make a pouch having an opening;
[0005] 2) stuffing an exothermic composition into the pouch;
[0006] 3) closing the opening of the pouch by bonding or
heat-sealing;
[0007] 4) preparing a composite of a support and an adhesive
poultice or gel whose surface is covered with a releasing
sheet;
[0008] 5) bonding an outer surface of the support to an outer
surface of the gas-impermeable sheet by using an adhesive that has
been applied to the gas-impermeable sheet; and
[0009] 6) cutting off one self-heating and adhesive device.
[0010] The poultice or gel layer is commonly produced by applying
an aqueous composition onto one surface of the support and then
making water-soluble polymers contained in the composition
closslink with crosslinking agents. However, when unwoven fabric is
used as the support, the aqueous composition sometimes permeates
through the unwoven fabric to get to the other side of it during
the application, or after the application and before the completion
of the closslinking. This is disclosed in Japanese Patent
Early-publication No. 2000-119128. If the aqueous composition gets
to the other side of the unwoven fabric, the adhesive force between
the gas-impermeable sheet and the support, i.e., the unwoven
fabric, lowers, which causes insufficient adhesion or the worst
case where the gas-impermeable sheet and the support do not adhere
to each other.
[0011] Self-heating and adhesive devices in which the adhesion
between gas-impermeable sheet and the support is insufficient
cannot be sold. Thus, if the aqueous composition permeates through
the support to get to the other side of it, a yield factor
lowers.
[0012] Japanese Patent Early-publication Nos. Hei. 08-336554, Hei.
10-152432, and Hei. 05-170644, each of which discloses an invention
of a self-heating and adhesive device, show that there may be a
support between an adhesive layer such as a poultice layer and a
film or sheet that constitutes a part of an exothermic portion of
the self-heating and adhesive device. However, they do not mention
the permeation of the aqueous composition through the support and
the lowering of the adhesive force that is caused by the
permeation. Japanese Patent Early-publication No. Hei. 05-170644
shows that the support is adhered to the film or sheet that
constitutes a part of an exothermic portion and then the adhesive
layer such as the poultice layer is made on the support. Thus, by
the method that is disclosed in Japanese Patent Early-publication
No. Hei. 05-170644, the problem of the lowering of the adhesive
force between the film or sheet and the support is not caused.
[0013] As a means for preventing the permeation of the aqueous
composition through the support such as an unwoven fabric, it is
proposed that an aqueous composition that will turn to the adhesive
poultice or gel layer and that comprises a closslinking agent in a
larger amount is used to closslink water-soluble polymers faster.
By this means, the permeation of the aqueous composition may be
surely prevented. However, if the closslinking agent is used in a
large amount, the closslinking of the water-soluble polymers takes
place over a long period of time and finally the poultice or gel
layer becomes to nonadhesive. This means that the self-heating and
adhesive device is insufficient in view of the storage
stability.
[0014] An object of this invention is to prevent, by a means in
which an amount of a closslinking agent is not increased,
permeation of an aqueous composition through a support while an
adhesive poultice or gel layer is made and aged.
[0015] Another object of this invention is to maintain the
adhesiveness of the poultice or gel layer for a longer period of
time.
SUMMARY
[0016] The present inventors had extremely studied to attain the
above objects. As a result, they have accomplished the present
invention.
[0017] Namely, the present invention relates to a self-heating and
adhesive device comprising a gas-permeable sheet layer, an
exothermic composition layer, a gas-impermeable sheet layer, a
support, a poultice or gel layer, and a releasing sheet layer in
this order, wherein the exothermic composition layer is stuffed in
a pouch that is made of the gas-permeable sheet layer and the
gas-impermeable sheet layer, and wherein the support comprises a
fibrous layer only or a gas-impermeable sheet and a fibrous layer
and has a moisture permeability within the range of 0 to 3,000
g/m.sup.2.multidot.24hours by the Lyssy method (JIS K 7129, ASTM E
398).
[0018] This device may further comprise at least one adhesive layer
which bonds any two components of the device.
[0019] Also, the present invention relates to an adhesive structure
comprising a support, an adhesive poultice or gel layer, and a
releasing sheet layer in this order, wherein the support comprises
a fibrous layer only or a gas-impermeable sheet and a fibrous layer
and has a moisture permeability within the range of 0 to 3,000
g/m.sup.2.multidot.24hours by the Lyssy method (JIS K 7129, ASTM E
398).
[0020] This structure may further comprise at least one adhesive
layer that bonds any two components of the device.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a sectional view of a first embodiment of the
device according to the present invention.
[0022] FIG. 2 is a sectional view of a second embodiment of the
device according to the present invention.
DETAILED DESCRIPTION
[0023] Hereafter, the present invention is particularly
explained.
[0024] First, with referring to FIGS. 1 and 2, the constitution of
the device of the present invention is explained.
[0025] FIG. 1 is a sectional view of a first embodiment of the
device according to the present invention. The device 100 comprises
a gas-permeable sheet layer 3 on one surface of an exothermic
composition layer 1 and an unwoven fabric layer 15 on the outer
surface of the gas-permeable sheet layer 3, and on another surface
of the exothermic composition layer 1 a gas-impermeable sheet layer
5, an adhesive layer 13, an unwoven fabric layer 7 as a fibrous
layer, a poultice or gel layer 9, and a releasing sheet layer 11 in
this order. The unwoven fabric layer 15, the gas-permeable sheet
layer 3, the exothermic composition layer 1, and the
gas-impermeable sheet layer 5 constitute an exothermic portion 20.
The gas-permeable sheet layer 3 and the gas-impermeable sheet layer
5 constitute a pouch. In this pouch an exothermic composition is
stuffed, which generates heat in the presence of oxygen. In this
embodiment, a support 10 is constituted of only the unwoven fabric
layer 7 as the fibrous layer.
[0026] FIG. 2 is a sectional view of the second embodiment of the
device according to the present invention. This device 200
comprises a gas-permeable sheet layer 3 on one surface of an
exothermic composition layer 1 and an unwoven fabric layer 15 on
the outer surface of the gas-permeable sheet layer 3, and on
another surface of the exothermic composition layer 1 a
gas-impermeable sheet layer 5, an adhesive layer 13, a
gas-impermeable sheet 17, an adhesive layer 19, an unwoven fabric
layer 7 as a fibrous layer, a poultice or gel layer 9, and a
releasing sheet layer 11 in this order. The unwoven fabric layer
15, the gas-permeable sheet layer 3 , the exothermic composition
layer 1, and the gas-impermeable sheet layer 5 constitute an
exothermic portion 20. The gas-permeable sheet layer 3 and the
gas-impermeable sheet layer 5 constitute a pouch. In this pouch an
exothermic composition is stuffed, which generates heat in the
presence of oxygen. In this embodiment, the unwoven fabric layer 7
as a fibrous layer is applied on the gas-impermeable sheet 17 with
the adhesive layer 19 to be a composite that is a support 10. The
unwoven fabric layer 7 may bond to the gas-impermeable sheet 17
without the adhesive layer 19 by, e.g., a melt-bonding such as a
heat-sealing.
[0027] In the devices 100 and 200, the outermost layer is the
unwoven fabric layer 15. This unwoven fabric layer 15 is not an
essential component of the device according to the present
invention. However, this layer 15 contributes to an improvement of
touch and a maintenance of the form of a device.
[0028] Also, the adhesive layers 13 and 19 are not essential
components of the device according to the present invention. When
an adhesive or tacky composition is used to bond one essential
component to another essential component, an adhesive layer is
made. The adhesive or tacky composition that is used in the present
invention is known in this technical field. One example of it is a
composition of which main component is a styrene-isoprene-styrene
block copolymer.
[0029] The exothermic composition layer of the device according to
the present invention is constituted of an exothermic composition
that generates heat in the presence of oxygen. The components that
are contained in the exothermic composition are not limited as long
as they have been used in the conventional exothermic compositions.
Examples of the components are as follows:
[0030] Examples of chemical exothermic agents include metal powders
such as iron powder, especially reduced iron powder and atomized
iron powder. Examples of reaction auxiliaries include metal halides
such as sodium chloride, potassium chloride, magnesium chloride,
calcium chloride, iron (II) chloride, and iron (III) chloride; and
metal sulfates such as potassium sulfate, sodium sulfate, magnesium
sulfate, copper (II) sulfate, iron (II) sulfate, and iron (III)
sulfate. Examples of water retaining agents include active carbon,
alumina, silica gel, zeolite, wood charcoal, and water-absorptive
polymers. Of course, water is also used. Examples of other
additives include polymers such as carboxymethyl cellulose, acrylic
acid starch, polyethylene, polypropylene, and polystyrene;
bentonite, vermiculite, and pearlite.
[0031] It is preferable that an exothermic composition having a
formula is used such that a metal powder such as iron powder does
not have a tendency of deflection.
[0032] In the present invention, the exothermic composition is
processed to be a form of sheet. The thickness of the sheet may be
5 mm or less, 0.5 to 4 mm, or 1 to 2 mm.
[0033] The pouch that constitutes the exothermic portion of the
device according to the present invention comprises a gas-permeable
sheet in one side and a gas-impermeable sheet in another side.
[0034] An example of the gas-permeable sheet is a gas-impermeable
polymer film having openings, e.g., a moisture-permeable porous
film. In this specification and claims, the term "moisture
permeability" may be used. If moisture can pass through, gas can
also pass through. Namely, one having a moisture-permeability has a
gas-permeability.
[0035] The device of the present invention may have a layer or
layers on or out of the gas-permeable sheet layer. However, the
layer or layers should have a gas-permeability. Examples of the
layers include a woven fabric layer, an unwoven fabric layer, a
knit layer, and a paper layer.
[0036] The gas-permeability of a gas-permeable side of a pouch
affects the exothermic property of the exothermic composition that
is stuffed in the pouch. Thus, it is preferable to select and
process a material or materials that constitute the gas-permeable
side so that the gas-permeable has a moisture-permeability of 200
to 500 g/m.sup.2.multidot.24 hours, especially 250 to 400 g/m.sup.2
.multidot.24 hours by the Lyssy method (JIS K 7129).
[0037] The Lyssy method is compliant to industry standards of many
countries. In, e.g., JIS Z 0208, JIS K 7129, and ASTM E 398, the
measurement by the Lyssy method is conducted at 40.degree. C under
a difference of relative humidities of 90%. More particularly, a
sample to be measured is inserted to the interface of an underneath
chamber that lies under a condition of relative humidity of 100%
and an upper chamber comprising a high-sensitive humidity sensor.
The relative humidity of the upper chamber is maintained at 10%.
Thus, the difference of the relative humidities is 90% (i.e.,
100-10). Then, the time (seconds) to be required for increasing the
relative humidity of the upper chamber from about 9% to about 11%
is measured. By using a standard sample, of which the moisture
permeability is known, the time is measured in the same way under
the same condition. Comparing the data of the sample to be measured
with that of the standard sample, the moisture permeability of the
sample to be measured is decided.
[0038] Methods for processing materials that constitute a
gas-permeable side of a pouch so that the gas-permeable side has a
desirable gas-permeability are known in this technical field.
Examples of the methods include one in which two or more
gas-permeable sheets are used, the sheets are bonded one another,
and the area ratio of the total area of the bonded portions to the
area of the sheet is controlled, and another one by which a porous
film having a desirable gas-permeability is prepared.
[0039] If a moisture-permeable porous film is used as the
gas-permeable sheet, its thickness may be, but not limited thereto,
150 .mu.m or less, 20 to 100 .mu.m, or 40 to 60,.mu.m. If a
gas-permeable layer that is set out the gas-permeable sheet layer
is made of a woven fabric, an unwoven fabric, or paper, the basis
weight of the gas-permeable layer may be, but not limited thereto,
300 g/m.sup.2 or less, 40 to 150 g/m.sup.2, or 60 to 100
g/m.sup.2.
[0040] Examples of a gas-impermeable sheet that can constitute
another side of the pouch, i.e., the gas-impermeable side, include
gas-impermeable polymer films such as polyethylene film. The
thickness of the gas-impermeable polymer film may be, but not
limited thereto, 100 .mu.m or less, 10 to 70 .mu.m, 20 to 50 .mu.m,
or 25 to 40 .mu.m.
[0041] Examples of polymeric materials for the gas-permeable sheet
and the gas-impermeable sheet include a polyethylene, a
polypropylene, a polyester, a polyamide, a poly(vinyl chloride), a
poly(vinylidene chloride), a polyurethane, a polystyrene, an
ethylene-vinyl acetate copolymer, and a polycarbonate.
[0042] The gas-permeable sheet and the gas-impermeable sheet are
not limited to monolayer films, but may be multilayer films.
[0043] At least one of the gas-permeable sheet and the
gas-impermeable sheet may have a heat-seal property. If the
gas-permeable sheet or the gas-impermeable sheet is made of a
multilayer film, a layer that faces other sheet may have a
heat-seal property. An example of a polymer film that shows the
heat-seal property is a metallocene polyethylene film, which can be
used in the present invention. The peripheries of the gas-permeable
sheet and the gas-impermeable sheet that constitute the pouch may
also be bonded each other with an adhesive or tacky
composition.
[0044] The device of the present invention has, out the
gas-impermeable sheet layer that constitute the pouch, i.e., in a
side that faces to a human body, a poultice or gel layer and a
support that supports the poultice or gel layer. One sided of the
support faces to the gas-impermeable sheet layer that constitutes
the pouch. The poultice or gel layer functions as an adhesive or
tacky layer when the device is applied onto a human body.
Therefore, before use, the poultice or gel layer is covered with a
releasing sheet.
[0045] As shown in FIG. 1, in the first embodiment of the device
according to the present invention the support 10 comprises the
fibrous layer 7 only. As shown in FIG. 2, in the second embodiment
of the device according to the present invention the support 10
comprises the gas-impermeable sheet 17 and the fibrous layer 7. In
the latter case, one side of the gas-impermeable sheet 17 faces the
gas-impermeable sheet layer 5 that constitutes the pouch.
[0046] The feature of the present invention is that the support has
a moisture-permeability within the range of 0 to 3,000
g/m.sup.2.multidot.24hours by the Lyssy method (JIS K 7129). The
poultice or gel layer contains water. Therefore, if the support has
a high moisture-permeability, the bonding between the support and
the gas-impermeable sheet layer may become insufficient. However,
if the support has a moisture-permeability within the above range,
the water that is contained in the poultice or gel layer does not
get to or slightly get to, by passing through the support, the
adhesive layer lain between the support and the gas-impermeable
sheet layer. Thus, the support can be bonded to the gas-impermeable
sheet layer with a sufficient adhesive force.
[0047] If the support comprises a fibrous layer only, its
moisture-permeability is 3,000 g/m.sup.2.multidot.24hours or less,
and may be 2,000 g/m.sup.2.multidot.24hours or less, or 1,500 to
1,900 g/m.sup.2.multidot.24hours.
[0048] If the support comprises a fibrous layer only, its
moisture-permeability depends on the kind of the raw materials, the
conditions after processing, the thickness, and the like. The
fibrous layer may be made of at least one member selected from the
group consisting of an unwoven fabric, a woven fabric, and paper.
The fibrous layer may be made of an unwoven fabric, e.g., a
melt-blow unwoven fabric. The unwoven fabric may have a basis
weight in the range of 20 to 60 g/m.sup.2, 30 to 50 g/m.sup.2, or
35 to 45 g/m.sup.2. When the basis weight is large, the
moisture-permeability may be low. However, a too thick unwoven
fabric tends to give a uncomfortable touch.
[0049] The raw materials for the fibrous layer may comprise, at
least a part of it, at least one member selected from the group
consisting of a polyester, a polypropylene, a polyamide (e.g., a
nylon), and an acrylic. The raw materials may consist of at least
one member selected from the group consisting of a polyester, a
polypropylene, a polyamide (e.g., a nylon), and an acrylic.
[0050] If the support comprises a gas-impermeable sheet and a
fibrous layer, the moisture-permeability of the support is near 0
g/m.sup.2.multidot.24hours because of the presence of the
gas-impermeable sheet. Therefore, in this case the raw materials,
thickness, and the like of the fibrous layer can be selected from
view points of, e.g., a touch, heat-conductivity, and an easiness
in the production of the poultice or gel layer (an easiness in the
coating or application of, e.g., a poultice composition).
[0051] Examples of the gas-impermeable sheet that constitutes the
support include gas-impermeable polymer films, e.g., a polyethylene
film. The thickness of the gas-impermeable sheet may be 60 .mu.m or
less, 10 to 40 .mu.m, or 20 to 30 .mu.m.
[0052] The fibrous layer that is used for the support with the
gas-impermeable sheet may be made of at least one member selected
from the group consisting of an unwoven fabric, a woven fabric, and
paper. The fibrous layer may be made of an unwoven fabric, e.g., a
spun-lace or melt-blow unwoven fabric. The unwoven fabric may have
a basis weight in the range of 10 to 40 g/m.sup.2, 15 to 35
g/m.sup.2, or 20 to 30 g/m.sup.2
[0053] In the case where the fibrous layer is used for the support
with the gas-impermeable sheet, the raw materials for the fibrous
layer may comprise, at least a part of it, at least one member
selected from the group consisting of cotton, a regenerated
cellulose (e.g., rayon), a polyester, a polypropylene, a polyamide
(e.g., a nylon), and an acrylic. The raw materials may comprise, at
least a part of it, at least one member selected from the group
consisting of a polyester, a polypropylene, a polyamide (e.g., a
nylon), and an acrylic. The raw materials may consist of at least
one member selected from the group consisting of a polyester, a
polypropylene, a polyamide (e.g., a nylon), and an acrylic.
[0054] The support that is a composite of the gas-impermeable sheet
and the fibrous layer may be prepared by melt-bonding the
gas-impermeable sheet and the fibrous layer or bonding them with a
adhesive or tacky composition. In the latter case, an adhesive
layer is prepared between them.
[0055] There is a poultice or gel layer on the fibrous layer that
is just the support or that constitutes the support. The
composition that is used to prepare the poultice or gel layer
comprises a polymer or polymers such as a poly(vinyl pyrrolidone),
a poly(vinyl alcohol), a poly(acrylic acid), a polyacrylate, an
acrylic acid starch, a hydroxyethyl cellulose, and a carboxy
methylcellulose; an excipient, filler, or vehicle such as kaolin
and titanium oxide; a closslinking agent such as a polyvalent metal
salt, a polyvalent metal hydroxide, and a polyvalent metal oxide; a
polyhydric alcohol such as glycerol, sorbitol, and propylene
glycol; a surfactant; a preservative or stabilizer; and other
components that have been conventionally used in this technical
field. The composition may comprise a polymer having a carboxyl
group such as poly(acrylic acid) and as a closslinking agent for
the polymer a polyvalent metal salt (e.g., aluminium hydroxide and
magnesium metasilicate aluminate).
[0056] Examples of the compositions that constitute the poultice or
gel layer include poultice compositions. The poultice compositions
are commonly hydrophilic and contain water in an amount of about 50
to 60% by weight. The composition that constitutes the poultice or
gel layer may also be a medicament-releasable composition. The
composition of this type comprises any medicament such as
indomethacin, a resolvent for the medicament such as castor oil and
alcohols, and an excipient, filler, or vehicle such as various
polymers and clay minerals. The medicament-releasable composition
may be hydrophilic or lipophilic. Further, the composition that
constitutes the poultice or gel layer may be a hydrogel composition
comprising, e.g., a polysaccharide as its main component, which
also comprises or does not comprise a medicament.
[0057] In the present invention, the thickness of the poultice or
gel layer is not particularly limited. From the view points of heat
conductive property and touch, it may be 2 mm or less, 0.2 to 1.5
mm, or 0.5 to 1 mm.
[0058] The device of the present invention is applied to a human
body only by the adhesive force of the poultice or gel layer.
Therefore, the layer should have an adhesive force that enables the
device to be held on the human body. However, if the adhesive force
is too strong, skin may be injured when the device is stripped. The
poultice or gel layer may have an adhesive of Ball Nos. 3 to 9,
Ball Nos. 5 to 9, Ball Nos. 7 to 9, or Ball No. 8 or 9 according to
JIS Z 0237 (2000) [Test Method for Adhesive Tape and Adhesive
Sheet], namely, a Ball Tack Method Using Slope, at the angle of the
slope of 30 degrees.
[0059] Before use, the surface of the poultice or gel layer is
covered with a releasing sheet. Namely, before use one of the
outermost layers of the device is a releasing sheet layer. The
materials of the releasing sheet layer are not limited as long as
they have been conventionally used for a sheet to cover a layer of,
e.g., a poultice composition. For example, various plastic films
and composites of a plastic film and paper can be used as the
releasing sheet layer. On the releasing sheet layer, a release
coating agent of a silicone, alkyl acrylate, or fluorine type may
be coated.
[0060] The total thickness of the gas-impermeable sheet layer that
constitutes one side of the pouch and the support (if an adhesive
layer exist, its thickness is also added) affects the conduction of
heat that the exothermic composition generates to the poultice or
gel layer. From the view point of heat conductivity, the total
thickness of the gas-impermeable sheet layer and the support may be
100 to 500 .mu.m, 100 to 400 .mu.m, or 150 to 300 .mu.m.
[0061] The device of the present invention is stored in a bag. The
bag is made of a moisture-resistant gas-impermeable material.
Because the bag is made of a gas-impermeable material, the
exothermic agent contained in the exothermic composition does not
cause a chemical reaction, thus the device can be stored without
the generation of heat. After the bag is opened, air (especially,
oxygen) gets in from the gas-permeable side of the pouch and
reaches to the exothermic agent. Thus, a chemical reaction starts
and the heat is generated.
[0062] An example of the material for the bag is a laminate of an
aluminium thin layer and a polymer film.
[0063] The present invention also relates to an adhesive structure
comprising a support, an adhesive poultice or gel layer, and a
releasing sheet layer in this order, wherein the support comprises
a fibrous layer only or a gas-impermeable sheet and a fibrous layer
and has a moisture permeability within the range of 0 to 3,000
g/m.sup.2.multidot.24hours by the Lyssy method (JIS K 7129). This
structure has a form of sheet, commonly a long sheet, and can be
used to prepare the device of the present invention. The parts that
are expressed by the numeral 30 in FIGS. 1 and 2 are derived from
this structure.
[0064] The details of the elements or components of this structure
are the same as those that have been explained about the device of
the present invention.
[0065] This structure is made by, e.g., applying or coating a
composition that is used to prepare a poultice or gel layer on a
fibrous layer of a support by using a coater of a added gravure
printing system, a screen printing system, or the like to prepare
the poultice or gel layer. At about the same time of the
preparation of the poultice or gel layer, the surface of the
poultice or gel layer is covered with a releasing sheet. Or, first,
a composition that is used to prepare a poultice or gel layer is
cast on a film. Next, a polymer contained in the composition is
crosslinked. Thus, the composition turns into a membrane. Then, the
membrane is transferred onto a fibrous layer and then the surface
of the poultice or gel layer is covered with a releasing sheet.
[0066] One example of the method for preparing the device of the
present invention is as follows:
[0067] First, a gas-permeable sheet and a sheet composite
comprising a gas-impermeable sheet layer, an adhesive layer, and a
releasing paper are prepared. The gas-permeable sheet and the sheet
composite are arranged so that the gas-permeable sheet faces the
gas-impermeable sheet layer
[0068] If a self-heating and adhesive device 100 or 200 shown in
FIG. 1 or 2 is to be prepared, in which an unwoven fabric layer 15
is made on a gas-permeable sheet layer 3, instead of the
gas-permeable sheet, a sheet composite comprising the gas-permeable
sheet layer 3 and the unwoven fabric layer 15 is used. These two
sheet composites are arranged so that the gas-permeable sheet layer
faces the gas-impermeable sheet layer.
[0069] The gas-permeable sheet and the sheet composite or the two
sheet composites (hereafter, "sheet composites") are heat-sealed in
their lateral direction, and then both sides are heat-sealed in
their longitudinal directions. Thus, a room is made. An exothermic
composition is stuffed in this room. Again, the sheet composites
are heat-sealed in their lateral direction and then in both sides
in their longitudinal directions to make a room. Again, an
exothermic composition is stuffed in this room. The room in which
the exothermic composition is stuffed is pressed. Thus, the
exothermic composition turns into a layer. A series of the
operations are repeated. Thus, rooms in which the exothermic
composition is stuffed are obtained in a continuous form.
[0070] Aside from this, the structure of the present invention,
namely, an adhesive structure comprising a support, an adhesive
poultice or gel layer, and a releasing sheet layer in this order is
prepared. This structure has also a sheet form.
[0071] The releasing paper is peeled off, and to the adhesive layer
thus exposed the adhesive structure of the present invention is
bonded. To the adhesive layer the fibrous layer as the support in
the adhesive structure is bonded, if the support comprises the
fibrous layer only. To the adhesive layer the gas-impermeable sheet
of the support in the adhesive structure is bonded, if the support
comprises the fibrous layer and the gas-impermeable sheet. Thus,
the devices of the present invention are obtained in a continuous
form.
[0072] Next, one device is cut off by making a cut at the lateral
heat-sealed portion. At once, the device is put into a bag that is
made of an oxygen-impermeable material and the opening of the bag
is closed. These operations are repeated.
[0073] Just before the device of the present invention is used, the
device is get out from the bag, the releasing sheet layer is peeled
off, and the device is applied on a part of a human body.
EXAMPLES
[0074] Hereafter, examples of the present invention will be
explained. However, the scope of the present invention is not
limited by these examples.
Example 1
[0075] An exothermic composition was prepared according to the
formula shown in Table 1. A composition that would be used to
prepare a poultice layer was also prepared according to the formula
shown in Table 2.
1 TABLE 1 Raw materials Amounts (wt. %) Iron powder 60 Active
carbon 5 Carboxymethyl cellulose 2 Acrylic acid starch 2 Sodium
chloride 2 Water 29 Total 100
[0076]
2 TABLE 2 Raw materials Amounts (wt. %) Poly(vinyl alcohol) 3.000
Acrylic acid starch 1.000 Carboxymethyl cellulose 1.000 Kaolin
11.000 Titanium oxide 1.000 Sorbitan monolaurate 0.050 Tartaric
acid 0.300 Poly(acrylic acid) 8.000 Liquid paraffin 1.000 Sorbitol
3.000 Sorbitan (polyoxyethylene) 0.050 monopalmitate Butyl
para-hydroxybenzoate 0.050 Methyl para-hydroxybenzoate 0.050
Propylene glycol 0.050 Poly(sodium acrylate) 5.000 Dried alminium
hydroxide gel 0.060 Magnesium metasilicate 0.015 aluminate Sodium
edetate (EDTA-Na) 0.015 Conc. Glycerol 12.000 Water balance Total
100.000
[0077] A sheet composite (I) was used in which a layer of an
adhesive, of which main component was SIS (styrene-isoprene-styrene
block copolymer), was made on a commercially available,
gas-impermeable polyethylene film (thickness: 40 .mu.m) and in
which the surface of the layer of the adhesive was covered by a
releasing paper. Also, a sheet composite A comprising a
gas-permeable porous polyethylene film (manufactured by Kojin;
thickness: 50 .mu.m) and a polyester (100%) spun-lace unwoven
fabric (manufactured by Asahikasei; basis weight: 90 g/m.sup.2) was
used. The sheet composite A has a moisture-permeability of 250
g/m.sup.2 .multidot.24hours by the Lyssy method (JIS K 7129).
[0078] The machine that was used to determine the
moisture-permeability was type L80-4000, manufactured by Lyssy. The
temperature was 40.degree. C., and the relative humidity was
90%.
[0079] The sheet composite (I) was lapped over the sheet composite
A so that the gas-impermeable polyethylene film of the sheet
composite (I) faced the gas-permeable porous polyethylene film of
the sheet composite A and they were heat-sealed in their lateral
direction. Next, both sides were heat-sealed in their longitudinal
direction. Thus, a room was made. The exothermic composition (20 g)
that had been prepared according to the formula of Table 1 was
stuffed in this room. Again, the sheet composite (I) and the sheet
composite A were heat-sealed in their lateral direction and then in
both sides in their longitudinal directions to make a room. Again,
the same exothermic composition (20 g) was stuffed in this room.
The room in which the exothermic composition had been stuffed was
pressed. Thus, the exothermic composition turned into a layer
having a thickness of about 1.5 mm. A series of the operations were
repeated. Thus, an exothermic structure having continuous rooms in
which the exothermic composition was stuffed was obtained.
[0080] Aside from this, an adhesive structure a was prepared. A
polypropylene (100%) melt-blow unwoven fabric (manufactured by
Kurare; basis weight: 40 g/m.sup.2) having a moisture-permeability
of 1,890 g/m.sup.2 .multidot.24hours by the Lyssy method (JIS K
7129) was used. On this unwoven fabric, the composition having the
formula of Table 2 was applied in an amount of 500 g/m.sup.2 to
prepare a layer and then the surface of the layer was covered with
a releasing sheet.
[0081] The releasing paper of the exothermic structure was peeled
off, and to the adhesive layer thus exposed the unwoven fabric of
the adhesive structure a was bonded. Thus, continuous self-heating
and adhesive poultice devices were obtained.
[0082] Next, by making a cut at the lateral heat-sealed portion,
one device as shown in FIG. 1 was cut off. At once, the device was
put into a bag that was made of an oxygen-impermeable material and
the opening of the bag was closed.
[0083] The thickness of one side of the self-heating and adhesive
poultice devices, i.e., the total thickness of the gas-impermeable
polyethylene film, the adhesive (SIS) layer, and the polypropylene
melt-blow unwoven fabric, was 270 .mu.m.
[0084] The self-heating and adhesive poultice devices (100 pieces)
were examined about the adhesive bonding between the
gas-impermeable polyethylene film and the polypropylene melt-blow
unwoven fabric. None was insufficiently bonded.
Example 2
[0085] A sheet composite (II) was used in which a layer of an
adhesive, of which main component was SIS (styrene-isoprene-styrene
block copolymer), was made on a commercially available,
gas-impermeable polyethylene film (thickness: 25 .mu.m) and in
which the surface of the layer of the adhesive was covered by a
releasing paper. Also, a sheet composite A comprising a
gas-permeable porous polyethylene film (manufactured by Kojin;
thickness: 50 .mu.m) and a polyester (100%) spun-lace unwoven
fabric (manufactured by Asahikasei; basis weight: 90 g/m.sup.2) was
used. The sheet composite A has a moisture-permeability of 250
.mu.m.sup.2.multidot.24hours by the Lyssy method (JIS K 7129).
[0086] The sheet composite (II) was lapped over the sheet composite
A so that the gas-impermeable polyethylene film of the sheet
composite (II) faced the gas-permeable porous polyethylene film of
the sheet composite A and they were heat-sealed in their lateral
direction. Next, both sides were heat-sealed in their longitudinal
directions. Thus, a room was made. The exothermic composition (20
g) that had been prepared according to the formula of Table 1 was
stuffed in this room. Again, the sheet composite (II) and the sheet
composite A were heat-sealed in their lateral direction and then in
both sides in their longitudinal directions to make a room. Again,
the same exothermic composition (20 g) was stuffed in this room.
The room in which the exothermic composition had been stuffed was
pressed. Thus, the exothermic composition turned into a layer
having a thickness of about 1.5 mm. A series of the operations were
repeated. Thus, an exothermic structure having continuous rooms in
which the exothermic composition was stuffed was obtained.
[0087] Aside from this, an adhesive structure b was prepared.
[0088] To prepare the adhesive structure b, a sheet composite B was
used in which by using a layer of an adhesive, of which main
component was SIS (styrene-isoprene-styrene block copolymer), a
commercially available, gas-impermeable polyethylene film
(thickness: 25 .mu.m) and a polyester (100%) spun-lace unwoven
fabric (manufactured by Asahikasei; basis weight: 20 g/m.sup.2) was
bonded. The sheet composite B has a moisture-permeability of about
0 g/m.sup.2.multidot.24hours by the Lyssy method (JIS K 7129).
[0089] On the unwoven fabric of the sheet composite B, the
composition having the formula of Table 2 was applied in an amount
of 500 g/m.sup.2 to prepare a layer and then the surface of the
layer was covered with a releasing sheet. Thus, the adhesive
structure b was prepared.
[0090] The releasing paper of the exothermic structure was peeled
off, and to the adhesive layer thus exposed the gas-impermeable
polyethylene film of the adhesive structure b was bonded. Thus,
continuous self-heating and adhesive poultice devices were
obtained.
[0091] Next, by making a cut at the lateral heat-sealed portion,
one device as shown in FIG. 2 was cut off. At once, the device was
put into a bag that was made of an oxygen-impermeable material and
the opening of the bag was closed.
[0092] The thickness of one side of the self-heating and adhesive
poultice devices, i.e., the total thickness of the gas-impermeable
polyethylene film, the adhesive (SIS) layer, the gas-impermeable
polyethylene film, the adhesive (SIS) layer, and the polyester
spun-lace unwoven fabric (basis weight: 20 g/m.sup.2), was 175
.mu.m.
[0093] The self-heating and adhesive poultice devices (100 pieces)
were examined about the adhesive bonding between two sheets of the
gas-impermeable polyethylene films. None was insufficiently
bonded.
Comparative Example 1
[0094] The exothermic structure having continuous rooms in which
the exothermic composition was stuffed was made by the same way as
that shown in Example 1.
[0095] Aside from this, an adhesive structure c was prepared. A
rayon/polyester (60%/40%) spun-lace unwoven fabric (manufactured by
Asahikasei; basis weight: 40 g/m.sup.2) having a
moisture-permeability of 3,900 g/m.sup.2.multidot.24hours by the
Lyssy method (JIS K 7129) was used. On this unwoven fabric, the
composition having the formula of Table 2 was applied in an amount
of 500 g/m.sup.2 to prepare a layer and then the surface of the
layer was covered with a releasing sheet.
[0096] The releasing paper of the exothermic structure was peeled
off, and a trial of bond of the unwoven fabric of the adhesive
structure c to the adhesive layer thus exposed was made. However,
this trial did not become successful because moisture that had been
contained in the poultice composition permeated and get to the
other side (i.e., a side that was to be bonded) through the
spun-lace unwoven fabric.
Comparative Example 2
[0097] Continuous self-heating and adhesive poultice devices were
made by the same way as that shown in Example 1, except that the
composition that would be used to prepare a poultice layer was
prepared according to the formula shown in Table 3. The
self-heating and adhesive poultice device was put into a bag that
was made of an oxygen-impermeable material and the opening of the
bag was closed.
3 TABLE 3 Raw materials Amounts (wt. %) Poly(vinyl alcohol) 3.000
Acrylic acid starch 1.000 Carboxymethyl cellulose 1.000 Kaolin
11.000 Titanium oxide 1.000 Sorbitan monolaurate 0.050 Tartaric
acid 0.300 Poly(acrylic acid) 8.000 Liquid paraffin 1.000 Sorbitol
3.000 Sorbitan (polyoxyethylene) 0.050 monopalmitate Butyl
para-hydroxybenzoate 0.050 Methyl para-hydroxybenzoate 0.050
Propylene glycol 0.050 Poly(sodium acrylate) 5.000 Dried alminium
hydroxide gel 0.080 Magnesium metasilicate 0.040 aluminate Sodium
edetate (EDTA-Na) 0.030 Conc. Glycerol 12.000 Water balance Total
100.000
[0098] Experimental Test 1
[0099] Self-heating and adhesive poultice devices were examined
about their temperature-retaining properties. The machine that was
used for the experimental test 1 and the examination method are
shown hereafter.
[0100] Test Machine
[0101] The machine comprises a heating device and a temperature
controlled tank of a water circulation system.
[0102] (1) Heating Device
[0103] The material for the heating device is SUS 304 (thickness: 3
mm) regulated in JIS G 4303 (hot rolled stainless steel). It has a
form of a box and the sizes are 300 mm (length).times.600 mm
(width).times.100 mm (height). On the upper surface of the heating
device, a plate that is made of an acrylic resin and has a
thickness of 6 mm is fixed with screws. Surfaces other than the
upper surface is covered by a heat insulating material that is made
of an expanded polystyrene and has a thickness of 30 mm. Inside the
heating device, warm water circulates.
[0104] (2) Temperature Controlled Tank of Water Circulation
System
[0105] This is a tank through which warm water can circulate in a
flow rate of 19 to 21 liter per minute.
[0106] In this examination test, the water temperature was
controlled so that the temperature on the acrylic resin plate was
35 to 37.degree. C.
[0107] Examination Method
[0108] (1) The self-heating and adhesive poultice device of Example
1 or 2 was taken out of the bag.
[0109] (2) The releasing sheet was peeled off and the poultice
layer was applied onto the acrylic resin plate (at a temperature of
35 to 37.degree. C.). A thermometer was put in between the poultice
layer and the acrylic resin plate.
[0110] (3) The temperature was determined at regular time
intervals.
[0111] The results are shown in Table 4.
4 TABLE 4 Temperature change (.degree. C.) Highest 0 min. 30 min. 1
hour 2 hours 3 hours 4 hours 5 hours 6 hours 7 hours 8 hours
temperature (.degree. C.) Example 1 32.9 43.0 43.1 42.8 42.2 41.6
41.2 40.8 40.8 40.9 43.1 Example 2 32.8 42.3 42.3 42.0 41.3 40.8
40.3 39.9 40.0 40.1 42.3
[0112] As is clear from the results shown in Table 4, the
self-heating and adhesive poultice devices of the present invention
show good heat conductivity. Thus, the temperature of the poultice
layer, where contacts a human body, was maintained within an
appropriated range for a long period of time, i.e., over eight
hours.
[0113] Experimental Test 2
[0114] The self-heating and adhesive poultice devices of Examples 1
and 2, and Comparative Example 2 were used.
[0115] The device that was enclosed in the bag was stored at room
temperatures. After three days, the device was taken out of the
bag. The releasing sheet was peeled off and then the adhesive force
of the poultice layer was determined according to JIS Z 0237
(2000), i.e., the Test Method for Adhesive Tape and Adhesive Sheet
(angle of the slope: 30 degrees; balls used: Nos. 1-9).
[0116] The reason why the devices were stored for three days at
room temperatures is to stabilize the condition of closslinking of
the water-soluble polymers.
[0117] The same operations were repeated, except that self-heating
and adhesive poultice devices that were stored at room temperatures
for forty five days and those that were stored at 40.degree. C. for
fifteen days were used.
[0118] The results are shown in Table 5.
5 TABLE 5 3 days after 45 days after preparation preparation 15
days after (stored at room (stored at room preparation
temperatures) temperatures (stored at 40.degree. C.) Example 1 9+*
9+* 9+* Example 2 9+* 9+* 9+* Comparative 9+* 5 6 Example 2 *The
ball did not move even after five seconds, which is a period of
time that is regulated in JIS 0237 (2000).
[0119] As is clear from the results shown in Table 5, the adhesive
forces of the self-heating and adhesive poultice devices of the
present invention are not reduced due to their storage. In
contrast, the adhesive forces of the conventional self-heating and
adhesive poultice device, i.e., Comparative Example 2 (in which the
amount of the closslinking agent is increased to prevent the
permeation of the composition for the poultice layer to the other
side of the unwoven fabric), is reduced with the lapse of time.
[0120] The present invention is defined or limited only by the
following claims.
* * * * *