U.S. patent application number 12/343624 was filed with the patent office on 2010-06-24 for treated cuff.
Invention is credited to Michael P. Mathis, Roger B. Quincy, III, Anthony S. Spencer, Ali Yahiaoui.
Application Number | 20100154105 12/343624 |
Document ID | / |
Family ID | 42263968 |
Filed Date | 2010-06-24 |
United States Patent
Application |
20100154105 |
Kind Code |
A1 |
Mathis; Michael P. ; et
al. |
June 24, 2010 |
TREATED CUFF
Abstract
The present invention is generally directed to an elastic woven
cuff having an alcohol repellency rating of 10, the cuff having
fluoro-chemical monomer deposited onto the surface of the cuff
Inventors: |
Mathis; Michael P.; (Powder
Springs, GA) ; Quincy, III; Roger B.; (Cumming,
GA) ; Spencer; Anthony S.; (Woodstock, GA) ;
Yahiaoui; Ali; (Roswell, GA) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.;Tara Pohlkotte
2300 Winchester Rd.
NEENAH
WI
54956
US
|
Family ID: |
42263968 |
Appl. No.: |
12/343624 |
Filed: |
December 24, 2008 |
Current U.S.
Class: |
2/455 ; 139/383B;
139/420R; 2/243.1; 2/69; 66/171; 66/202 |
Current CPC
Class: |
D06M 15/277 20130101;
D06M 2200/11 20130101; D06M 10/10 20130101; A41D 13/1209 20130101;
D06M 14/22 20130101; D06M 14/28 20130101; D06M 10/025 20130101;
D06M 2200/10 20130101; D06M 10/08 20130101; D06M 14/04 20130101;
D06M 2200/12 20130101; A41D 27/10 20130101; D06M 14/10
20130101 |
Class at
Publication: |
2/455 ; 2/69;
2/243.1; 66/171; 66/202; 139/420.R; 139/383.B |
International
Class: |
A41D 13/00 20060101
A41D013/00; A41D 1/00 20060101 A41D001/00; A41D 27/00 20060101
A41D027/00; D04B 1/24 20060101 D04B001/24; D04B 39/00 20060101
D04B039/00; D03D 15/00 20060101 D03D015/00; D03D 49/00 20060101
D03D049/00 |
Claims
1. A protective garment comprising: a sleeve having attached
thereto a woven cuff; the woven cuff having an alcohol repellency
rating of 10, the cuff having fluoro-chemical monomer graft
polymerized onto at least a portion of the woven cuff.
2. The protective garment of claim 1, the fluoro-chemical monomer
graft polymerized onto the cuff being perfluorodecyl acrylate.
3. The protective garment of claim 2, the fluoro-chemical monomer
being graft polymerized onto the cuff by an RF plasma process.
4. The protective garment of claim 1, the protective garment
comprising a surgical gown.
5. The protective garment of claim 1, the woven cuff being
elastic.
6. An elastic woven cuff having an alcohol repellency rating of 10,
the cuff having fluoro-chemical monomer graft polymerized onto the
cuff.
7. The cuff of claim 6, the cuff comprising polyester fiber.
8. The cuff of claim 6, the fluoro-chemical monomer graft
polymerized onto the cuff being perfluorodecyl acrylate.
9. The cuff of claim 6, the fluoro-chemical monomer being graft
polymerized onto the cuff by an RF plasma process.
10. A method for forming a protective garment comprising the steps
of: providing a yarn; subjecting the yarn to a plasma process which
graft polymerized a fluoro-chemical monomer to the yarn; forming
the yarn into a knitted cuff; attaching the knitted cuff to a
sleeve, the cuff having an alcohol repellency rating of 10;
attaching the sleeve to a body of a garment.
11. The method of claim 10, the step of subjecting the yarn to a
plasma process includes the step of subjecting the yarn to an RF
plasma process.
12. The method of claim 10, the fluoro-chemical monomer graft
polymerized to the cuff being perfluorodecyl acrylate.
13. The method of claim 10, including the step of forming the yarn
into an elastic woven cuff.
14. A method for forming a protective garment comprising the steps
of: providing a yarn; forming the yarn into a knitted cuff;
subjecting the knitted cuff to a plasma process which graft
polymerizes a fluoro-chemical monomer to the cuff, the cuff having
an alcohol repellency rating of 10; attaching the knitted cuff to a
sleeve; attaching the sleeve to a body of a garment.
15. The method of claim 14, the step of subjecting the yarn to a
plasma process includes the step of subjecting the yarn to an RF
plasma process.
16. The method of claim 14, the fluoro-chemical monomer graft
polymerized to the cuff being perfluorodecyl acrylate.
17. The method of claim 14, including the step of forming the yarn
into an elastic woven cuff.
Description
BACKGROUND OF THE INVENTION
[0001] Sterile surgical gowns are designed to greatly reduce, if
not prevent, the transmission of liquids and biological
contaminants through the gown. In surgical procedure environments,
such liquid sources include the gown wearer's perspiration, blood,
saliva, blood plasma, alcohol, drugs and saline. Because surgical
gowns require a high degree of liquid repellency to prevent
strike-through of these and other liquids, disposable gowns for use
under these conditions are, for the most part, made primarily from
liquid repellent fabrics.
[0002] Surgical gowns are generally loose fitting, with portions of
the gown such as the cuffs designed to fit closely and comfortably
about the wearer. Such elastic cuffs may be formed from a variety
of fabrics such as cotton, knits and polyester knits. The cuff
which is preferred by many medical personnel is a loosely knitted
cuff formed of a polyester material which provides comfort while
maintaining a close fit to the wearer's wrist. These cuffs provide
good freedom of movement and blood circulation in the wrist and
hand, which helps to limit muscle fatigue in this area. While such
cuffs may provide a comfortable form-fit about the wrist, they do
not function well as a barrier to strikethrough.
[0003] To overcome this deficiency, the cuffs are commonly overlaid
with a glove which acts as a highly effective barrier to fluids.
Unfortunately, movement of the wearer creates opportunities for the
glove to move away from its optimum position over the cuff, making
the glove-gown interface an area that is prone to strike-through.
Additionally, perspiration may be formed within the gown sleeve and
collect in the cuff area. As the amount of perspiration retained in
the cuff increases, the liquid may migrate to the cuff/glove
interface. Strike-through may occur when liquids generated during
the surgical procedure contact the wearer's perspiration at the
interface of the gown, glove and cuff. Liquids on the outer surface
of the gown sleeve may also travel down the sleeve and contact the
perspiration-laden cuff before or during the removal of the glove
or gown.
[0004] Due to the strong preference of medical personnel for this
type of loosely-woven cuff, solutions to the glove/gown interface
do not address the cuff itself. Rather, the woven elastic cuff is
seen as an impediment to be overcome in the glove/gown interface
and is not viewed as part of the solution.
[0005] As such, there remains a need for surgical gowns having
cuffs which provide excellent barrier protection while maintaining
the comfort levels which medical personnel have come to expect.
SUMMARY OF THE INVENTION
[0006] In accordance with one embodiment of the present invention,
an elastic woven cuff is treated with a fluoro-chemical monomer and
has an alcohol repellency rating of 10. In some embodiments, the
fluoro-chemical monomer is a perfluorodecyl acrylate (PFDEA) and
may be applied to the elastic woven cuff by a radio frequency
plasma process.
[0007] In another embodiment of the present invention, a polyester
yarn may be treated with a fluorinated compound to achieve an
alcohol repellency rating of 10, the yarn being suitable for use in
an elastic woven cuff.
[0008] The invention also encompasses a method of forming a
protective garment that includes the steps of providing a yarn and
forming the yarn into a knitted cuff. The knitted cuff, or in some
embodiments, the yarn which is to be formed into the knitted cuff,
is subjected to a plasma process which applies a fluoro-chemical
monomer to the cuff, the cuff having an alcohol repellency rating
of 10. The cuff is then attached to a sleeve which is attached to a
protective garment.
[0009] Other features and aspects of the present invention are
described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth more particularly in the remainder of the
specification, which makes reference to the appended figures in
which:
[0011] FIG. 1 is a photograph of a cuff according to one embodiment
of the present invention; and
[0012] FIG. 2 is a photograph of a cuff according to the prior
art.
[0013] Repeat use of reference characters in the present
specification and drawings is intended to represent same or
analogous features or elements of the invention.
DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS
[0014] Reference now will be made in detail to various embodiments
of the invention, one or more examples of which are set forth
below. Each example is provided by way of explanation, not
limitation of the invention. In fact, it will be apparent to those
skilled in the art that various modifications and variations may be
made in the present invention without departing from the scope or
spirit of the invention. For instance, features illustrated or
described as part of one embodiment, may be used on another
embodiment to yield a still further embodiment. Thus, it is
intended that the present invention cover such modifications and
variations.
[0015] The present invention is generally directed to an improved
cuff for use in a protective garment such as a surgical gown. The
present invention is a unique approach to reducing the
opportunities for strike-through at the glove/gown interface by
dramatically increasing the liquid repellency of the loosely-woven
cuff which is preferred by many medical personnel. More
specifically, this invention is directed to loosely woven elastic
cuffs which have improved barrier properties to fluids as a result
of grafting fluorinated moieties via a plasma process onto and
through the preferred woven cuff.
[0016] While a variety of woven cuffs may be utilized in the
present invention, woven elastic cuffs which are preferably used in
medical garments are available from Straus Knitting Mills, Inc.
(St. Croix Falls, Wis.). The term "elastic", as used herein, refers
to a material that, upon application of a stretching force, is
stretchable in a direction, and which upon release of the
stretching force, returns to approximately its original dimension.
For example, a stretched material may have a stretched length that
is at least 50% greater than its relaxed unstretched length, and
which will recover to within at least 50% of its stretched length
upon release of the stretching force. A hypothetical example would
be a 2.54-cm sample of a material that is stretchable to at least
3.81 centimeters and which, upon release of the stretching force,
will recover to a length of not more than 3.175 centimeters.
Desirably, the material contracts or recovers at least 50%, and
even more desirably, at least 80% of the stretched length. In a
preferred embodiment, polyester staple fiber is woven into a four
ply tubular knit cuff having a relatively open knitted structure.
These elastic cuffs function to secure the gown sleeve onto a
user's wrist without applying such a significant retracting force
to the wearer's wrist.
[0017] Various references are available which describe, in detail,
plasma fluorination processes. For example, US 20030134515 and EP 1
557 489 disclose plasma fluorination processes. RF plasma
fluorination processes have been primarily investigated for
filtration needs and for oil and water repellency. Materials which
have previously been evaluated are unlike the loosely woven elastic
cuff of the present invention, in that the woven elastic cuff is
entirely unsuitable for most filtration and repellency
applications.
[0018] The plasma fluorination process to treat the polyester cuffs
for repellency to fluids encountered in medical applications
involves generating radio frequency (RF) plasma in a vacuum chamber
that is filled with a gas that can be sustained in a plasma state,
such as helium or argon. A fluorinated gas, such as a
fluoro-acrylic monomer, is flash-evaporated into the chamber, and
the plasma initiates the graft polymerization of the fluoro-acrylic
monomer onto the surfaces of the cuff, including pores, seams and
stitching holes, that can be reached by the activated
fluoro-chemistry.
[0019] A variety of monomer compounds may be used in the present
invention, including, for example, fluorinated compounds. Exemplary
fluorinated monomers include 2-propenoic acid,
2,2,3,3,4,4,5,5,6,6,7,7,8,8,8-pentadecafluorooctyl ester;
2-propenoic acid,
2-methyl-2,2,3,3,4,4,5,5,6,6,7,7,8,8,8-pentadecafluorooctol ester;
2-propenoic acid, pentafluoroethyl ester; 2-propenoic acid,
2-methyl-pentafluorophenyl ester; 2,3,4,5,6-Pentafluorostyrene;
2-Propenoic acid, 2,2,2-trifluoroethyl ester; and 2-propenoic acid,
2-methyl-2,2,2-trifluoroethyl ester. Other suitable monomers
include those fluoroacrylate monomers having the general structure
of:
CH.sub.2.dbd.CROCO(CH.sub.2).sub.x(CnF.sub.2n+1)
wherein n is an integer ranging from 1 to 12, x is an integer
ranging from 1 to 8, and R is H or an alkyl group with a chain
length varying from 1 to 16 carbons. Specifically, perfluorodecyl
acrylate, 1H,1H,2H,2H-heptadecafluorodecyl acrylate and
3,3,4,4,5,5,6,6,7,7,8,8,9,9,10,10,10-heptadecafluorodecyl
methacrylate are also suitable for use in the present invention. In
many instances, the fluoroacrylate monomer may be comprised of a
mixture of homologues corresponding to different values of n.
Monomers of this type may be readily synthesized by one of skill in
the chemical arts by applying well-known techniques. Additionally,
many of these materials are commercially available. Specifically,
suitable fluoro-acrylic monomers include TG-10, TG-20 or TG-30,
which are available from Daikin Americas, Inc. (Decatur, Ala.). If
desired, perfluordecyl acrylate may be utilized and is available
from Apollo Chemical Company, LLC (Burlington, N.C.).
[0020] In selected embodiments, the formed cuff, or if desired, the
material that will be formed into a cuff (such as yarn or thread),
may be subjected to a high-energy pre-treatment such as a glow
discharge from a corona or plasma treatment system. The high energy
treatment may function to "clean" the cuff or cuff forming material
from "loose" or weak boundary layers made of contaminants and short
chain oligomers. The high energy treatment can also generate
radicals on the surface of the cuff or cuff forming material, which
can subsequently enhance surface attachment and uniformity of the
fluorinated monomer.
[0021] The strength of the high energy treatment may be varied in a
controlled manner by known means across at least one dimension of
the fibrous web. For example, a corona apparatus having a segmented
electrode may be employed, in which the distance of each segment
from the sample to be treated may be varied independently. As
another example, a corona apparatus having a gap-gradient electrode
system may be utilized; in this case, one electrode may be rotated
about an axis which is normal to the length of the electrode. Other
methods also may be employed; see, for example, "Fabrication of a
Continuous Wettability Gradient by Radio Frequency Plasma
Discharge", W. G. Pitt, J. Colloid Interface Sci., 133, No. 1, 223
(1989); and "Wettability Gradient Surfaces Prepared by Corona
Discharge Treatment", J. H. Lee, et al., Transactions of the 17th
Annual Meeting of the Society for Biomaterials, May 1-5, 1991, page
133, Scottsdale, Ariz.
[0022] In a particular embodiment, the plasma fluorination process
to treat the loosely woven polyester cuffs for repellency to fluids
involves generating plasma in a chamber using radio frequency (RF).
Initially, a vacuum is used to evacuate the chamber to about
10.sup.-2 torr. The chamber, which includes a powered electrode, is
then filled with the desired amount of a gas that can sustain
plasma, such as, for example, argon. Upon application of an RF
field to the powered electrode, a plasma is established which acts
as a charge carrier between the electrodes. The plasma is typically
visible as a colored cloud. A fluoro-acrylic monomer is
flash-evaporated into the chamber.
[0023] The plasma initiates the graft polymerization of the
fluoro-acrylic monomer onto the surfaces of the cuffs, including
pores that are easily reached by the activated fluoro-chemistry.
The reaction can vary from about 10 seconds to about 30 minutes or
longer if necessary, depending on the size of the reactor and the
number of cuffs loaded inside the plasma reactor. Alternatively,
other fluorinated gases and fluorine precursors can be used in the
plasma treatment process.
[0024] The level of liquid repellency achieved by plasma
fluorination the cuff will depend upon the amount of acrylic
monomer (e.g. perfluorodecyl acrylate) that has been deposited and
graft copolymerized on the surface of the woven cuff. As shown in
FIG. 1, a droplet of synthetic blood has been placed on a treated
cuff to demonstrate the liquid repellency of the treated cuff. The
synthetic blood shown in FIG. 1 was the synthetic blood which is
required for use in ASTM F-1670-98, Standard Test Method for
Resistance of Material Used in Protective Clothing to Penetration
by Synthetic Blood. The droplet has maintained a rounded shape and
has not `flattened out`, indicating resistance to penetration into
the cuff material. In FIG. 2, which shows a cuff that has not been
treated according to the present invention, the droplet of
synthetic blood has penetrated the un-treated cuff, as shown by the
flattened profile of the droplet.
[0025] To produce a plasma fluorinated cuff similar to that shown
in FIG. 1, 30 sccm (standard cubic centimeters per minute) of argon
gas and 15 ml/hr of the fluorinated acrylic monomer perfluorodecyl
acrylate were simultaneously introduced into a plasma chamber to a
pressure of about 5 mtorr. A pulsed glow discharge plasma was
generated at 100 Watts and at 100 Hz for a reaction time of 10
minutes. After the reaction was completed, the vacuum chamber was
purged with 500 sccm of argon for two minutes until atmospheric
pressure was reached. The samples were removed from the plasma
chamber and tested for liquid repellency.
[0026] To determine the appropriate repellency of the cuff, the
Worldwide Strategic Partners standard test number WSP 80.8 (05)
entitled "Standard Test Method for Alcohol Repellency of Nonwoven
Fabrics" should be used. The term "nonwoven web" generally refers
to a web having a structure of individual fibers or threads which
are interlaid, but not in an identifiable manner as in a knitted
fabric. Although the cuff is a woven fabric rather than a nonwoven
fabric, this test may still be used effectively to determine the
fluid repellency of the cuff. The terms "woven" and "knitted" are
used interchangeably with respect to the present invention, and are
intended to include materials which have an identifiable interlaid
pattern of fibers or threads.
[0027] The test method is used to measure the resistance of
nonwoven fabrics to wetting and penetration by alcohol and
alcohol/water solutions. Drops of standard test liquids, consisting
of a selected series of water/alcohol solutions, are placed on the
test material and observed for penetration or wetting. The alcohol
repellency rating is the highest numbered test liquid which does
not penetrate the fabric.
[0028] If there is a conflict between the test as discussed in this
document and the test specification, the test specification is to
be followed.
[0029] Alcohol solutions having decreasing surface tensions with
increasing alcohol concentrations are utilized in the test, and are
listed below in Table 1. The alcohol repellency rating determined
in WSP 80.8 (05) serves as a rough estimate of the overall surface
repellency of the test material.
TABLE-US-00001 TABLE 1 Standard Test Solutions Alcohol Repellency
Composition by Weight Rating No. Percent Alcohol Percent Water 0 0
100 1 10 90 2 20 80 3 30 70 4 40 60 5 50 50 6 60 40 7 70 30 8 80 20
9 90 10 10 100 0
[0030] The alcohol repellency rating of the fabric is the highest
numbered test liquid which will not penetrate the fabric within a
period of five minutes. The cuff will show complete resistance to
penetration by a given test liquid, which is indicated by a
spherical drop which shows no tendency to penetrate the cuff, such
as is shown in FIG. 1.
[0031] In yet another embodiment of the invention, a method of
forming a protective garment includes the steps of providing a yarn
and forming the yarn into a knitted cuff. The knitted cuff, or in
some embodiments, the yarn which is to be formed into the knitted
cuff, is subjected to a plasma process which applies a
fluoro-chemical monomer to the cuff, the cuff having an alcohol
repellency rating of 10. The yarn from which the cuff is made can
be treated as a single filament within a continuous RF plasma
process, if desired. The cuff is then attached to a sleeve which is
attached to a protective garment.
[0032] While the invention has been described in detail with
respect to the specific embodiments thereof, it will be appreciated
that those skilled in the art, upon attaining an understanding of
the foregoing, may readily conceive of alterations to, variations
of, and equivalents to these embodiments. Accordingly, the scope of
the present invention should be assessed as that of the appended
claims and any equivalents thereto.
* * * * *