U.S. patent application number 11/863880 was filed with the patent office on 2008-04-03 for water resistant undercast liner.
This patent application is currently assigned to BSN MEDICAL, INC.. Invention is credited to John C. Evans.
Application Number | 20080082035 11/863880 |
Document ID | / |
Family ID | 39261915 |
Filed Date | 2008-04-03 |
United States Patent
Application |
20080082035 |
Kind Code |
A1 |
Evans; John C. |
April 3, 2008 |
WATER RESISTANT UNDERCAST LINER
Abstract
The present invention provides an undercast liner for being
applied to an anatomical shape of a patient and overlaid with a
cast material. The undercast liner includes an elongate fabric
having two opposing faces and an intermediate spacer area that both
separates and interconnects the opposed faces. The liner is
constructed at least in part of hydrophobic, water resistant
monofilament yarn for providing enhanced water resistance, light
weight, breathability and resistance to collapse and degradation
due to moisture and bacteria during extended use of the liner. The
liner has sufficient stretch in both a length-wise and width-wise
direction to facilitate conforming the undercast liner around the
anatomical shape without wrinkling during application.
Inventors: |
Evans; John C.; (Lancashire,
GB) |
Correspondence
Address: |
ADAMS INTELLECTUAL PROPERTY LAW, P.A.
Suite 2350 Charlotte Plaza
201 South College Street
CHARLOTTE
NC
28244
US
|
Assignee: |
BSN MEDICAL, INC.
5825 Carnegie Blvd.
Charlotte
NC
28209
|
Family ID: |
39261915 |
Appl. No.: |
11/863880 |
Filed: |
September 28, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60827534 |
Sep 29, 2006 |
|
|
|
Current U.S.
Class: |
602/60 |
Current CPC
Class: |
D04B 21/16 20130101;
Y10T 442/40 20150401; D10B 2509/02 20130101; A61F 13/041 20130101;
D10B 2403/021 20130101; D10B 2509/028 20130101 |
Class at
Publication: |
602/060 |
International
Class: |
A61F 13/02 20060101
A61F013/02 |
Claims
1. An undercast liner for being applied to an anatomical shape of a
patient and overlaid with a cast material, comprising: an elongate
fabric having two opposing faces; an intermediate spacer area that
both separates and interconnects the opposing faces; and wherein
the fabric is constructed at least in part of hydrophobic, water
resistant monofilament yarn for providing enhanced water resistance
and has sufficient stretch in both a length-wise and width-wise
direction to facilitate conforming the undercast liner around the
anatomical shape without wrinkling during application.
2. The undercast liner according to claim 1, wherein the yarn is
selected from the group consisting of polypropylene, polyester,
polyethylene and nylon.
3. The undercast liner according to claim 1, wherein the fabric is
formed by one or more fabric-forming techniques selected from the
group consisting of weaving, knitting non-woven, and stitching.
4. The undercast liner according to claim 1, wherein the fabric is
treated with a finish to provide at least one of: additional water
resistance, anti-bacterial, anti-odor, aromatherapy characteristics
or a combination thereof.
5. The undercast liner according to claim 1, wherein an adhesive
coating is positioned on at least one of the inner and outer faces
to of the fabric to aid in application of the fabric to the
patient.
6. The undercast liner according to claim 5, wherein the adhesive
is preferably a low tack, pressure sensitive adhesive selected from
the group consisting of acrylic and silicone adhesive.
7. The undercast liner according to claim 1, wherein the fabric has
higher elongation in the width direction than in the length
direction for allowing greater stretch during application.
8. The undercast liner according to claim 1, wherein the
monofilament yarn has a diameter of at least 0.03 mm.
9. The undercast liner according to claim 8, wherein the
monofilament yarn has a diameter of between approximately 0.05 and
approximately 0.25 mm.
10. An undercast liner comprising: a fabric having an inner face
and an outer face constructed using a pillar and inlay stitch
wherein the inner face and the outer face are spaced apart to from
a spacer area constructed using a needle V; the fabric being
constructed with yarn having a diameter from approximately 0.03 to
approximately 0.25 mm; and the fabric being formed such that it has
at least 50 courses per meter and weighs between approximately 50
to approximately 400 grams per square meter.
11. An undercast liner according to claim 10, wherein the fabric
weighs between approximately 100 to approximately 250 grams per
square meter and a has a nominal thickness when not compressed or
under tension of approximately 1.5 to approximately 3.5 mm.
12. An undercast liner according to claim 10, the fabric being
treated with at least one of a fluorochemical, silicone, other
water repellant finish, and a combination thereof for improving
drainage and providing faster drying.
13. An undercast liner for being applied to an anatomical shape of
a patient and overlaid with a cast material, comprising: a tubular
fabric having two opposing faces and an intermediate spacer area
that both separates and interconnects the opposing faces; the
fabric is constructed at least in part of hydrophobic, water
resistant monofilament yarn for providing enhanced water
resistance, light weight, breathability and resistance to collapse
and degradation due to moisture and bacteria during extended use of
the liner; and the fabric has sufficient stretch in both a
length-wise and width-wise direction to facilitate conforming the
undercast liner around the anatomical shape during application.
14. An undercast liner according to claim 10 wherein the fabric
includes a water repellant finish to improve drainage and provide
faster drying.
15. An undercast liner for being applied to an anatomical shape of
a patient and overlaid with a cast material is provided,
comprising: an elongate fabric in roll form, the fabric having two
opposing faces and an intermediate spacer area that both separates
and interconnects the opposing faces; the fabric is constructed at
least in part of hydrophobic, water resistant monofilament yarn;
and the fabric has sufficient stretch in both a length-wise and
width-wise direction to facilitate conforming the undercast liner
around the anatomical shape during application.
16. An undercast liner according to claim 15, wherein the
monofilament yarn has a diameter of between approximately 0.05 and
approximately 0.25 mm.
17. An undercast liner according to claim 15, wherein the liner is
constructed using a pillar and inlay stitch on the inner and outer
faces and a needle V in the spacer area.
18. An undercast liner according to claim 16, wherein the yarn has
a diameter of approximately 0.03 to approximately 0.25 mm.
19. An undercast liner according to claim 16, wherein the fabric is
formed with at least 50 courses per meter and weighs between
approximately 50 to approximately 400 grams per square meter.
20. An undercast liner according to claim 16, wherein the liner
weighs between approximately 100 to approximately 250 grams per
square meter and has a nominal thickness when not compressed or
under tension of approximately 1.5 to approximately 3.5 mm.
Description
[0001] This application claims priority to U.S. Provisional Patent
Application No. 60/827,534, filed Sep. 29, 2006.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an undercast liner of the type
used to protect and cushion the skin of a patient from the
relatively rigid material of a cast, such as those constructed of
plaster of Paris or synthetic cast tape. The liner allows the
patient to carry out routine activities such as bathing, showering,
swimming, and the like without fear of the liner getting wet.
[0003] Traditional cast padding is constructed from a simple
stockinette and padding material made from cotton or synthetic
fibers, and offers poor or no water resistant capability. Cotton
and some synthetic paddings actually absorb and retain large
quantities of water. A cast is typically worn for a period of 6-8
weeks. During this period of time, traditional casts having a
water-absorbent stockinette can promote skin maceration,
discomfort. Traditional cast paddings can also breed odor causing
bacteria as perspiration and water from washing and bathing
migrates to and through the stockinette. The stockinette remains
wet or damp for an extended period of time, causing the problems
mentioned above.
[0004] The present invention provides a more conformable,
water-resistant liner at a reduced cost as compared to water
resistant products already available in the market. The present
invention is directed to a construction that overcomes the
drawbacks of water-resistant undercast liners such as that found in
U.S. Pat. Nos. 5,102,711 and 5,277,954. For example, the
monofilament structure of the liner has higher elongation in the
width direction and provides a higher stretch during application
that results in a better conforming liner which can be easily
molded around a limb. Due to the improved padding/cushioning as
compared to other liner and padding products known in the prior
art, the undercast liner of the present invention requires fewer
layers during application. The present invention may also have an
adhesive coating incorporated on either or both surfaces. The tacky
surface, when applied away from the skin, adheres to itself
sufficiently to form a smoother underlayer for a cast.
Additionally, it provides a non-slip effect under the cast tape and
keeps the liner in position to facilitate easier application of the
cast tape.
[0005] One of the problems with conventional cast padding as well
as commercially available water resistant padding is that the
padding collapses underneath a cast over the duration of 4-6 weeks
as water and perspiration are absorbed into the structure. This
reduction in thickness and resultant increase in density retards
moisture transfer by both wicking and evaporation, and lessens the
protection offered by the padding.
[0006] A water-resistant undercast liner such as disclosed and
claimed in this application can help alleviate skin maceration
problems which generally require additional treatment or therapy
and eliminates the need for frequent cast changes. The present
invention accommodates bathing, showering and contact with water
without significant penetration of water into the padding,
therefore keeping the skin relatively dry. In addition, the padding
of the present invention provides improved conformability,
cushioning, breathability, ease of application and a low profile as
compared to a traditional undercast liner.
[0007] One embodiment of the invention uses a knitted spacer fabric
having highly resilient monofilament yarns that allow the padding
to keep its shape and loft when applied under an orthopedic cast.
This feature also ensures less layers are needed than typical
paddings used in this field. The materials and structure of the
present invention offer excellent drainage and drying properties
due to low surface area and low surface energy. The present
invention can be used with an adhesive applied to one side, away
from the skin, that permits a more effective non-slip effect,
however, the knitted spacer material can be used with no adhesive
layer.
[0008] The present invention is a very cost effective method of
avoiding skin maceration problems arising from wearing an
orthopedic cast over a period of weeks. The present invention will
avoid the need for frequent cast changes arising for getting the
orthopedic cast and padding wet. The present invention affords the
opportunity to shower and bath and keep the skin clean with water
without damaging the padding and also allows removal of the
orthopedic cast using a cast saw without fear of cutting through
the padding so improving comfort and safety.
SUMMARY OF THE INVENTION
[0009] Therefore, it is an object of the invention to provide a
water resistant undercast liner.
[0010] It is another object of the invention to provide an
undercast liner that is comfortable when worn under a plaster or
synthetic cast.
[0011] It is another object of the invention to provide an
undercast liner that is relatively thin and thus provides a low
profile undercast liner layer when properly overlapped during
application.
[0012] It is another object of the invention to provide an
undercast liner that is relatively open and therefore
breathable.
[0013] It is another object of the invention to provide an
undercast liner that is resistant to collapse during extended
use.
[0014] It is another object of the invention to provide an
undercast liner that promotes drainage of water from the cast/liner
if wetting does occur.
[0015] It is another object of the invention to provide an
undercast liner that is highly resilient.
[0016] It is another object of the invention to provide a
breathable undercast orthopedic padding.
[0017] It is another object of the invention to provide a
breathable orthopedic undercast padding that is comfortable when
worn against the skin under a plaster or synthetic cast, brace,
splint or other orthopedic device.
[0018] It is another object of the invention to provide an
orthopedic padding that is breathable and easy to clean.
[0019] It is another object of the invention to provide a
breathable orthopedic padding that is resilient, low profile and
protects boney prominences when fitted under a cast or splint.
[0020] These and other objects of the present invention are
achieved by providing a breathable orthopedic undercast-padding
product that comprises a knitted spacer fabric using monofilament
yarns in an open construction.
[0021] According to one preferred embodiment of the invention, the
knitted spacer fabric has between 4 and 20 courses per inch.
[0022] According to yet another preferred embodiment of the
invention the wales per inch are between 6 and 28 per inch.
[0023] According to yet another preferred embodiment of the
invention the spacer fabric is constructed using 4 to 6 bars.
[0024] According to yet another preferred embodiment of the
invention the construction of the spacer fabric uses monofilament
yarns.
[0025] According to yet another preferred embodiment of the
invention the Monofilament yarns are Nylon, Polyester or
Polypropylene materials.
[0026] According to yet another preferred embodiment of the
invention a Multifilament yarn could be incorporated into the
structure.
[0027] According to yet another preferred embodiment the
multifilament yarns are between 0.03 and 1.2 mm in diameter.
[0028] According to yet another object of the invention a
multifilament yarn could be used with a decitex range of 33 to
156.
[0029] According to yet another embodiment of the invention the
multifilament yarn could be Nylon, Polyester, Polypropylene, or any
synthetic fiber.
[0030] According to yet another preferred embodiment of the
invention the multifilament yarns would be knitted on the surface
of the padding.
[0031] According to yet another embodiment of the invention the
knitted structure should be between 1 mm and 10 mm in
thickness.
[0032] According to yet another preferred embodiment of the
invention the weight of the padding material should be between 40
and 160 gsm.
[0033] According to yet another preferred embodiment of the
invention the padding material should have a lengthways stretch of
between 0 (zero) and 100 percent.
[0034] According to yet another preferred embodiment of the
invention the surface of the padding is coated with an
adhesive.
[0035] According to yet another preferred embodiment of the
invention the adhesive is applied at a coating level of 3 to 50 gsm
by weight.
[0036] According to yet another preferred embodiment of the
invention the padding could be used with no adhesive layer.
[0037] In accordance with one embodiment of the invention, an
undercast liner for being applied to an anatomical shape of a
patient and overlaid with a cast material is provided, and
comprises an elongate fabric having two opposing faces and an
intermediate spacer area that both separates and interconnects the
opposed faces. The liner is constructed at least in part of
hydrophobic, water resistant monofilament yarn for providing
enhanced water resistance, light weight, breathability and
resistance to collapse and degradation due to moisture and bacteria
during extended use of the liner. The liner has sufficient stretch
in both a length-wise and width-wise direction to facilitate
conforming the undercast liner around the anatomical shape without
wrinkling during application.
[0038] According to another embodiment of the invention, the yarn
is selected from the group consisting of polypropylene, polyester,
polyethylene, and nylon.
[0039] According to another embodiment of the invention, liner is
formed by one or more fabric-forming techniques selected from the
group consisting of weaving, knitting, non-woven, and
stitching.
[0040] According to another embodiment of the invention, the fabric
is treated with at least one finish for providing additional water
resistance, anti-bacterial, anti-odor, or aromatherapy
characteristics to improve the functionality of the liners or
enhance the cast-wearing experience for the patient.
[0041] According to another embodiment of the invention, the liner
includes an adhesive coating on at least one of the inner and outer
faces to aid in application to the patient by adhering to itself
and thus maintaining placement of partially overlying layers
relative to each other as the liner is applied.
[0042] According to another embodiment of the invention, the liner
has higher elongation in the width direction than in the length
direction for allowing greater stretch during application.
[0043] According to another embodiment of the invention, the
adhesive is preferably a low tack, pressure sensitive adhesive
selected from the group consisting of acrylic and silicone
adhesive.
[0044] According to another embodiment of the invention, the
monofilament yarn has a diameter of at least 0.03 mm.
[0045] According to another embodiment of the invention, the
monofilament yarn has a diameter of between approximately 0.05 and
approximately 0.25 mm.
[0046] According to another embodiment of the invention, an
undercast liner is provided, wherein the liner is constructed using
a pillar and inlay stitch on the inner and outer faces and a needle
V in the spacer area, and the yarn has a diameter of approximately
0.03 to approximately 0.25 mm. The liner is formed with at least 50
courses per meter and weighs between approximately 50 to
approximately 400 grams per square meter.
[0047] According to another embodiment of the invention, the liner
weighs between approximately 100 to approximately 250 grams per
square meter and has a nominal thickness when not compressed or
under tension of approximately 1.5 to approximately 3.5 mm.
[0048] According to another embodiment of the invention, the liner
includes a fluorochemical, silicone or other water repellant finish
to improve drainage and provide faster drying.
[0049] According to another embodiment of the invention, an
undercast liner for being applied to an anatomical shape of a
patient and overlaid with a cast material is provided, and
comprises a tubular fabric having two opposing faces and an
intermediate spacer area that both separates and interconnects the
opposed faces. The liner is constructed at least in part of
hydrophobic, water resistant monofilament yarn for providing
enhanced water resistance, light weight, breathability and
resistance to collapse and degradation due to moisture and bacteria
during extended use to the liner. The liner has sufficient stretch
in both a length-wise and width-wise direction to facilitate
conforming the undercast liner around the anatomical shape during
application.
[0050] According to another embodiment of the invention, the liner
includes a water repellant finish to improve drainage and provide
faster drying.
[0051] According to another embodiment of the invention, an
undercast liner for being applied to an anatomical shape of a
patient and overlaid with a cast material is provided, and
comprises an elongate fabric in roll form having two opposing faces
and an intermediate spacer area that both separates and
interconnects the opposed faces. The liner is constructed at least
in part of hydrophobic, water resistant monofilament yarn for
providing enhanced water resistance, light weight, breathability
and resistance to collapse and degradation due to moisture and
bacteria during extended use of the liner. The liner has sufficient
stretch in both a length-wise and width-wise direction to
facilitate conforming the undercast liner around the anatomical
shape during application.
[0052] According to another embodiment of the invention, the
monofilament yarn has a diameter of between approximately 0.05 and
approximately 0.25 mm.
[0053] According to another embodiment of the invention, the liner
is constructed using a pillar and inlay stitch on the inner and
outer faces and a needle V in the spacer area. The yarn has a
diameter of approximately 0.03 to approximately 0.25 mm, and the
liner is formed with at least 50 courses per meter and weighs
between approximately 50 to approximately 400 grams per square
meter.
[0054] According to another embodiment of the invention, the liner
weighs between approximately 100 to approximately 250 grams per
square meter and has a nominal thickness when not compressed or
under tension of approximately 1.5 to approximately 3.5 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] Some of the objects of the invention have been set forth
above. Other objects and advantages of the invention will appear as
the invention proceeds when taken in conjunction with the following
drawings, in which:
[0056] FIG. 1 is a perspective view of a roll of an undercast liner
according to one embodiment of the invention;
[0057] FIG. 2 is a view illustrating application of the undercast
liner to the wrist and forearm;
[0058] FIGS. 3 and 4 illustrate preparation of a cast tape for
application over the undercast liner;
[0059] FIGS. 5 and 6 illustrate application of the cast tape to the
undercast liner;
[0060] FIG. 7 illustrates the completed cast;
[0061] FIG. 8 illustrates a liner in the form of a circular sleeve;
and
[0062] FIG. 9 shows the sleeve in place on an arm prior to
application of a cast tape bandage.
DETAILED DESCRIPTION OF THE INVENTION
[0063] Referring now specifically to the drawings, a undercast
liner according to the present invention is illustrated in FIG. 1
and shown generally at reference numeral 10. While the undercast
liner 10 can be formed in any desired width or length, the
undercast liner 10 shown in FIGS. 1, 2, and 3 is about 7.5 cm
(about 3 in.) wide and is formed into a roll during manufacture for
shipping and storage until use. The undercast liner 10 is easily
applied from the roll, as shown in FIG. 2. The liner 10 includes
two opposing faces 11, 12 and an intermediate spacer area 13 that
both separate and interconnect the faces 11, 12, as described in
further detail below. The undercast liner 10 can be formed in a
tubular form or in an elongate padding form in a roll.
[0064] The liner 10 can be constructed using any suitable organic
or inorganic monofilament yarn, preferably a hydrophobic/water
resistant monofilament yarn such as polypropylene, polyester,
polyethylene and nylon. The monofilament yarn used for constructing
the liner 10 preferably has a diameter of at least 0.03 mm. The
liner 10 is constructed in a spacer fabric construction to provide
sufficient cushioning and breathability, and it has been found that
the use of a monofilament hydrophobic yarn on both faces 11, 12 and
in the spacer area 13 provides enhanced water resistance, light
weight, breathability and resistance to collapse and degradation
due to moisture and bacteria during extended use.
[0065] The liner 10 is formed using any suitable fabric forming
technology such as weaving, various knitting techniques such as,
for example, weft knitting and warp knitting, non-woven, stitching,
or a combination of these techniques. Preferably, the structure
should provide some stretch in both the length-wise and width-wise
directions, and facilitate conforming the undercast liner 10 around
an anatomical shape during application.
[0066] The liner 10 can be treated with one or more finishes to
provide additional water resistance, anti-bacterial and/or
anti-odor characteristics, or aromatherapy to improve the
functionality or enhance the cast-wearing experience for the
patient. Alternatively, the liner 10 can be fabricated from
modified/treated monofilament yarns incorporating suitable fillers
or finishes to improve the performance of the liner 10.
[0067] The liner 10 may also be provided with an adhesive coating
on one or both faces 11, 12 to aid in application to the patient.
The adhesive is preferably any suitable low tack, pressure
sensitive adhesive, such as an acrylic or silicone adhesive. The
adhesive aids in application by adhering to itself and thus
maintaining the exact placement of the layers relative to each
other as the liner 10 is applied by the cast technician.
[0068] In one preferred embodiment, the liner 10 is constructed as
a spacer fabric using polypropylene monofilament and a low tack,
pressure sensitive adhesive on one surface. The monofilament yarn
has a diameter of at least 0.03 mm, and preferably between
0.05-0.25 mm. Preferably, the liner 10 requires no additional
finish or water repellency treatment.
[0069] More specifically, the preferred embodiment of the liner 10
is constructed of a polypropylene monofilament yarn on a double
needle bed knitting machine, and can be knitted on either a warp
knitting Raschel machine or a Crochet knitting machine. The liner
10 is preferably constructed using a pillar and inlay stitch on the
surfaces 11, 12 and a 3 or 5 needle V in the spacer area 13. The
yarn has a diameter of 0.03-0.25 mm. The fabric for the liner 10 is
formed with at least 50 courses per meter preferably 200-850
courses per meter. The liner 50 weighs between 50-400 grams per
square meter, and more preferably between 100-250 grams per square
meter. The liner 10 has a nominal thickness when not compressed or
under tension of approximately 1.5-3.5 mm.
[0070] Alternatively, an undercast liner may be constructed as a
spacer fabric with at least one of the yarns being a multifilament
or spun yarn in order to provide even more patient comfort. The
liner may be treated with suitable fluorochemical, silicone or
other water repellant finish to improve drainage and provide faster
drying.
[0071] Referring now to FIG. 2, the undercast liner 10 is applied
to the injured limb in a conventional manner. As noted above, the
stretch provided by the undercast liner 10 permits a fast,
accurate, closely-conforming application without wrinkles or
creases.
[0072] As is shown in FIGS. 3-7, after application of the undercast
liner 10, a conventional cast tape 20 is wetted, FIG. 3, excess
water removed by wringing, FIG. 4, and applied to the injured limb,
FIGS. 5-7, taking care in the usual manner to avoid overlapping the
undercast liner 10 on opposite ends, leaving a short width of
exposed undercast liner 10.
[0073] Referring now to FIG. 8, a circular knit liner 30 is shown,
preferably with the same preferred constructions described above.
The liner 30 includes an outer face 31, an inner face 32 and a
spacer area 33 that both separates and interconnects the two faces
31, 32, as shown in FIG. 1. Instead of wrapping, the liner 30 is
pulled onto the limb as shown in FIG. 9, in the same manner as a
conventional stockinette. Thereafter, a cast tape 20 is applied in
a conventional manner.
[0074] A further embodiment includes a knitted spacer fabric
constructed from monofilament yarns. The monofilament yarns may be
of the type selected from Nylon, Polypropylene or Polyester yarns
or a mixture thereof.
[0075] The monofilament yarns may be between 0.03 mm and 1.5 mm in
diameter.
[0076] The substrate may have a thickness of between 0.5 and 10
mm.
[0077] The substrate weight may be between 40 and 160 grams per
square meter.
[0078] The substrate may have between 4 and 20 courses per
inch.
[0079] The substrate is between 6 and 28 wales per inch.
[0080] The substrate may contain a multifilament yarn.
[0081] The substrate may be used in a bandaging product or in a
compression bandage, and may incorporate elastic yarns.
[0082] An undercast liner is described above. Various details of
the invention may be changed without departing from its scope.
Furthermore, the foregoing description of the preferred embodiment
of the invention and the best mode for practicing the invention are
provided for the purpose of illustration only and not for the
purpose of limitation--the invention being defined by the
claims.
* * * * *