U.S. patent application number 17/688563 was filed with the patent office on 2022-08-18 for perineal thermal pack with improved liquid containment.
The applicant listed for this patent is Allegiance Corporation. Invention is credited to Aaron DEDERICH, Walter H. ISAAC, Varsha KALYANKAR, Taylor MAROHL, Andrew T. NIKOLAI, Hallie M. SCHMIDT, Nichole L. WILHELM.
Application Number | 20220257412 17/688563 |
Document ID | / |
Family ID | 1000006318802 |
Filed Date | 2022-08-18 |
United States Patent
Application |
20220257412 |
Kind Code |
A1 |
ISAAC; Walter H. ; et
al. |
August 18, 2022 |
PERINEAL THERMAL PACK WITH IMPROVED LIQUID CONTAINMENT
Abstract
Devices for providing thermal therapy to the perineal and rectal
areas of a patient are described. The device is particularly useful
for containing gushing lochia flow. Different embodiments of the
device can be used to provide either hot or cold therapy to the
patient. The inventive thermal pack of the current invention
comprises a thermal pouch, pad and a backing layer.
Inventors: |
ISAAC; Walter H.;
(Lindenhurst, IL) ; KALYANKAR; Varsha; (Kenosha,
WI) ; WILHELM; Nichole L.; (Columbus, OH) ;
NIKOLAI; Andrew T.; (Chicago, IL) ; SCHMIDT; Hallie
M.; (Highland Park, IL) ; MAROHL; Taylor;
(Green Bay, WI) ; DEDERICH; Aaron; (Menomonee
Falls, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Allegiance Corporation |
Waukegan |
IL |
US |
|
|
Family ID: |
1000006318802 |
Appl. No.: |
17/688563 |
Filed: |
March 7, 2022 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15654459 |
Jul 19, 2017 |
11298260 |
|
|
17688563 |
|
|
|
|
62364092 |
Jul 19, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F 2013/53908
20130101; A61F 2007/0018 20130101; A61F 7/10 20130101; A61F
13/47236 20130101; A61F 2013/51078 20130101; A61F 2013/51021
20130101; A61F 2013/5103 20130101; A61F 2013/5104 20130101; A61F
2013/51045 20130101; A61F 2007/0226 20130101; A61F 7/02 20130101;
A61F 7/00 20130101; A61F 2013/530065 20130101; A61F 2013/1517
20130101; A61F 2007/0258 20130101; A61F 13/51305 20130101; A61F
2013/530481 20130101; A61F 13/539 20130101; A61F 2007/0214
20130101 |
International
Class: |
A61F 7/02 20060101
A61F007/02; A61F 7/00 20060101 A61F007/00; A61F 7/10 20060101
A61F007/10; A61F 13/472 20060101 A61F013/472; A61F 13/513 20060101
A61F013/513; A61F 13/539 20060101 A61F013/539 |
Claims
1-55. (canceled)
56. A device for applying thermal therapy to a patient, comprising:
a pad comprising a single absorbent core; an overwrap; a backing
layer; and a thermal pouch overlying the absorbent core; wherein
the overwrap is over the pad and the thermal pouch, wherein the
overwrap and pad comprise at least one embossed channel, and
wherein the device does not comprise an additional absorbent
core.
57. The device of claim 56, wherein the pad comprises a hot melt
glue.
58. The device of claim 56, wherein the overwrap is attached to the
pad and the thermal pouch.
59. The device of claim 58, wherein the overwrap is attached to the
pad beyond a perimeter of the thermal pouch.
60. The device of claim 56, wherein the at least one channel is
located between an edge of the pad and the thermal pouch.
61. The device of claim 60, wherein the at least one channel
follows a perimeter of the pad.
62. The device of claim 56, wherein the at least one embossed
channel is continuous.
63. The device of claim 56, wherein the overwrap comprises at least
a first layer, and wherein the first layer is nonwoven.
64. The device of claim 63, wherein the overwrap further comprises
a second layer, wherein the second layer is an acquisition
distribution layer.
65. The device of claim 56, wherein the overwrap has at least one
slit.
66. The device of claim 56, wherein the thermal pouch is attached
above the pad and below the overwrap.
67. The device of claim 66, wherein the pad is compressed where the
thermal pouch is attached.
68. The device of claim 66, wherein the pad is thinner where the
thermal pouch is attached.
69. The device of claim 56, wherein the absorbent core extends
above a bottom layer of the thermal pouch.
70. The device of claim 56, wherein the backing layer is
folded.
71. The device of claim 56, further comprising an adhesive layer
and a release liner attached to the backing layer.
72. A device for applying thermal therapy to a perineal area of a
patient, the device comprising: a pad comprising an absorbent core;
an overwrap comprising a first layer and a second layer; a backing
layer; and a thermal pouch underlying the first layer and the
second layer, wherein the absorbent core comprises an area of
reduced thickness configured to receive the thermal pouch.
73. A device for applying thermal therapy to a patient, the device
comprising: a pad comprising an absorbent core; an overwrap
comprising at least a first layer; a backing layer; and a thermal
pouch underlying the first layer, wherein the absorbent core is
folded over at a first edge thereof and a second edge thereof to
form a single thickness underlying the thermal pouch and a double
thickness at the first and second edges.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/645,459, filed Jul. 19, 2017, which claims
the benefit of U.S. Provisional Patent Application No. 62/364,092,
filed Jul. 19, 2016 each of which is incorporated by reference
herein in its entirety.
BACKGROUND
[0002] The invention relates generally to thermal therapy devices
and relates more specifically to hot and cold pouches and pad
combination devices that provide thermal therapy and absorb fluid
from the perineal area of a patient.
[0003] Various forms of thermal therapy have been used in the past
to provide either heating or cooling to specific parts of a
patient's body. For example, heat has been used in the past to
increase blood flow and speed the healing process to an injured
area. Similarly, cooling has been used to prevent and reduce
swelling and pain. In the past, hot or cold packs have been used in
a variety of applications. One application of particular interest
is in providing thermal therapy to post-partum patients in the
perineal and rectal areas. This therapy has been provided in a
variety of ways.
[0004] One recent device includes an elongated pack to provide
either heat or cold therapy. The elongated pack also includes a
sealed inner space that is enclosed within the outer shell. The
sealed space has a first compartment containing a first chemical
and a second compartment containing a second chemical. In the
preferred embodiment, the first and second compartments are
adjacent to one another and are separated by a rupturable wall.
When the wall is ruptured, the contents of the two compartments are
allowed to mix to create a thermal reaction which produces a
temperature in a therapeutic range. In other embodiments, the
sealed inner space may be filled with a gel or other material which
may be mechanically heated or cooled to a therapeutic temperature
range. Although the heating/cooling of this pack may work,
absorption of the liquid or blood from the patient is not adequate.
Most of the lochia fluid runs off the side of the device and is not
absorbed.
[0005] Recently, a type of device which has been developed is a
combination perineal pad and cold pack in which the cold pack is
located on top of the perineal pad. In instances in which the cold
pack is fixedly attached to the top of the perineal pad, cooling is
readily available, but the cold pack may not be located in the most
useful location on the pad. The cold pack film is not appropriate
for direct skin contact, and the end seals of the cold pouch are
irritating, so there is a nonwoven layer that loosely wraps the
cold pouch, or the nonwoven layer loosely wraps the cold pouch and
the pad. Also, the pad may not be of the most appropriate size or
absorbency for the particular patient's needs.
[0006] The combination of a perineal cold pouch and a pad can be
used to absorb the lochia fluid flow that occurs following
childbirth. After delivery, the patient will undergo a postpartum
assessment and fundus examination where the healthcare professional
will massage the uterus. This causes gushing flow of lochia to
occur. Existing combinations of cold pouch and perineal pad do not
effectively contain all of the fluid flow.
[0007] It has been found in these previous designs that liquid will
flow to the edges of the pad and off the sides without absorbing
into the pad core.
[0008] A need exists to provide a device which will contain gushing
flow of liquid unlike the existing perineal thermal packs.
SUMMARY
[0009] Certain aspects of the present disclosure are directed
toward a perineal thermal pack with increased fluid containment.
The perineal thermal pack can have structural features adapted to
provide improved fluid containment, thereby reducing the volume of
fluid that is spilled or otherwise not collected into the perineal
thermal pack. The improved perineal thermal pack can include
modifications such as improved absorbent pad and/or core and
thermal pouch attachment, grooves or other similar structures in
the pack to aid in liquid collection, attached overwrap at multiple
positions on the pad and cold pack, an overwrap that may include
slits, additional absorbent material, and backing film edges that
fold up. All modifications show significant improvement in liquid
containment.
[0010] A device is provided for applying thermal therapy to a
patient. Specifically, in one embodiment, the thermal therapy is
provided to the perineal or rectal area of a patient. The perineal
thermal pack contains both a pad that includes an absorbent core
and at least a top sheet (and optionally a bottom sheet) and a
thermal pouch. The thermal pouch is attached to the pad. The pack
includes a backing layer or layers, which preferably comprises a
film layer. The pack also comprises optional adhesive means and
release tab on the backing film of the absorbent pad. In a
preferred embodiment, the thermal therapy is cold therapy.
[0011] In one embodiment of the perineal thermal pack, the pad is
compressed or thinned where the thermal pouch is attached. There is
also an overwrap layer. The overwrap comprises at least one layer,
a cover sheet. Additionally, the overwrap can comprise an
acquisition distribution layer. The overwrap is attached to the pad
beyond the perimeter of the thermal pouch. There are grooves
embossed into the overwrap and the pad. The grooves are continuous
or discontinuous and can follow the perimeter of the pad.
[0012] In another embodiment of the perineal thermal pack, the pad
is compressed where the thermal pouch is attached. There is also an
overwrap layer. The overwrap comprises at least one layer, a cover
sheet. Additionally, the overwrap can comprise an acquisition
distribution layer. The overwrap is attached to the pad beyond the
perimeter of the thermal pouch, inside the perimeter of the
grooves. There are grooves embossed into the pad. The grooves are
continuous or discontinuous and follow the perimeter of the
pad.
[0013] In another embodiment, the perineal thermal pack is
comprised of a thermal pouch and a pad, the absorbent material of
the pad surrounding the perimeter of the pouch. The absorbent
material surrounds the pouch on all four sides. There is also an
overwrap layer. The overwrap comprises at least one layer, a cover
sheet. Additionally, the overwrap can comprise an acquisition
distribution layer. The cover sheet is the top most layer, on the
patient facing side.
[0014] In another embodiment, the perineal thermal pack is
comprised of a thermal pouch with a pad, wherein the backing film
of the pack is folded up to act as a guard to contain fluid. The
pad is compressed or thinned where the thermal pouch is attached.
There is also an overwrap layer. The overwrap comprises at least
one layer, a cover sheet. Additionally, the overwrap can comprise
an acquisition distribution layer. The cover sheet is the top most
layer, on the patient facing side. On the longitudinal edges of the
pad, the film edges of the pad are folded up around pad edges and
adhered to nonwoven coversheet. The overwrap is attached to the pad
beyond the perimeter of the thermal pouch. There are grooves
embossed into the overwrap and the pad. The grooves are continuous
or discontinuous and follow the perimeter of the pad.
[0015] In another embodiment of the perineal thermal pack. The
overwrap consists of two layers, an absorbent nonwoven cover sheet
and an acquisition distribution layer. The cover sheet is the top
most layer, on the patient facing side. The overwrap has at least
one slit cut into the overwrap such that fluid can flow from the
center of the pack to the edges of the pad. In one embodiment, the
slits have a curved shape.
[0016] In another embodiment of the perineal thermal pack, a
thermal pouch is attached to a pad with a small bubble filled with
water attached to the top of the thermal pouch covered by an
overwrap that includes a nonwoven cover sheet and an acquisition
distribution layer. The small bubble filled with water consists of
a perforated or frangible film with water that when activated
spreads water over the patient contact area to promote evaporative
cooling.
[0017] In a preferred embodiment of the perineal thermal pack, a
thermal pouch is embedded in the pad. The pad comprises an
absorbent core and a surrounding sheet comprised of a top and
bottom sheet. In one embodiment, at least one sheet is a nonwoven.
The core has a void center portion and the top and bottom sheet are
attached together at the void. The opening is substantially similar
in dimensions to the size of the pouch. In one embodiment, the
dimensions of the void is the same size or smaller than the size of
the thermal pouch. The cold pouch is inserted underneath the top
and bottom sheets. The top and bottom sheets are fully secured to
the core with adhesive, except where the cold pouch is present. The
top and bottom sheets are secured to the cold pouch. The device
also has a backing layer. The backing layer can comprise multiple
layers and at least comprises a film layer. The backing layer is
below the cold pouch and pad.
[0018] This invention also includes a process for manufacturing the
perineal cold pack. In a preferred embodiment, an absorbent core is
made on an airlaid machine. The resulting rolls of core are cut to
the size and shape of the current invention. First, an outer
rectangle is cut, and then an inner rectangular window is removed
from the center of the rectangle. The windowed cores are then
wrapped in a nonwoven sheet. The sheet is secured to the fluff pulp
on both sides with adhesive. The two layers of nonwoven core wrap
are then adhered to each other in the window area where there is no
core. The top of a thermal cold pouch is then glued to the back of
the top and bottom sheet wrapped core in the window lacking
absorbent core, such that the end seals of the thermal pouch are
covered by the core when the product is viewed from the top. The
pouch was secured throughout the top/side areas so that fluid
containment areas form around the perimeter of the core void area.
A backing layer is adhered to the bottom of the cold pouch and the
bottom of the wrapped core using an adhesive.
[0019] In another embodiment, an absorbent core is made with a core
forming machine and includes a window. The windowed cores are then
wrapped in a sheet. The sheet is secured to the fluff pulp on both
sides with adhesive. The two layers of nonwoven core wrap are then
glued to each other in the window area where there was no core. The
top of a thermal cold pouch is then glued to the back of the top
and bottom sheet wrapped core in the window lacking absorbent core,
such that the end seals of the thermal pouch are covered by core
when the product is viewed from the top. The pouch was secured
throughout the top/side areas so that fluid containment areas form
around the perimeter of the core void area. A backing layer is
adhered to the bottom of the cold pouch and the bottom of the
wrapped core using an adhesive.
[0020] Any feature, structure, or step disclosed herein can be
replaced with or combined with any other feature, structure, or
step disclosed herein, or omitted. Furthermore, for purposes of
summarizing the disclosure, certain aspects, advantages, and
features of the devices have been described herein. It is to be
understood that not necessarily any or all such advantages are
achieved in accordance with any particular embodiments disclosed
herein. No individual aspects of this disclosure are essential or
indispensable.
BRIEF DESCRIPTION OF THE FIGURES
[0021] Embodiments of the present disclosure are described by way
of following drawings pointing out the various details of the
device and method of the present disclosure. The main features and
advantages of the present disclosure will be better understood with
the following descriptions, claims, and drawings, where:
[0022] FIG. 1 is a cross section view of an exemplary embodiment of
the current application.
[0023] FIG. 2 is a top view of the embodiment of FIG. 1.
[0024] FIG. 3 is a bottom view of the embodiment of FIG. 1.
[0025] FIG. 4 is a top view of another exemplary embodiment of the
current application.
[0026] FIG. 5 is a cross-section view of the embodiment of FIG.
4.
[0027] FIG. 6 is a top view of another exemplary embodiment of the
current application.
[0028] FIG. 7 is a cross section of the embodiment of FIG. 6.
[0029] FIG. 8 is a top view of another exemplary embodiment of the
current application.
[0030] FIG. 9 is a cross section of the embodiment of FIG. 8.
[0031] FIG. 10 is top view of an embodiment of the current
application.
[0032] FIG. 11 is a cross-section view of the embodiment of FIG.
10.
[0033] FIG. 12 is a top view of an embodiment of the current
application.
[0034] FIG. 13 is a cross-section view of the embodiment of FIG.
12.
[0035] FIG. 14 is a top view of an exemplary embodiment of the
current application.
[0036] FIG. 15 is a cross-section view of the embodiment of FIG.
14.
[0037] FIG. 16 is a top view of an embodiment of the current
application.
[0038] FIG. 17 is a cross-section view of the embodiment of FIG.
16.
DETAILED DESCRIPTION
[0039] The detailed description set forth below, in connection with
the appended drawings, is intended as a description of various
configurations and is not intended to represent the only
configurations in which the concepts described herein may be
practiced. The detailed description includes specific details for
the purpose of providing a thorough understanding of the various
concepts. However, it will be apparent to those skilled in the art
that these concepts may be practiced without these specific
details.
[0040] Various aspects of a perineal thermal pack may be
illustrated by describing components that are connected, coupled,
attached, bonded and/or joined together. As used herein, the terms
"connected", "coupled", "attached", "bonded" and/or "joined" are
used interchangeably to indicate either a direct connection between
two components or, where appropriate, an indirect connection to one
another through intervening or intermediate components.
[0041] Relative terms such as "lower" or "bottom", "upper" or
"top", and "vertical" or "horizontal" may be used herein to
describe one element's relationship to another element illustrated
in the drawings. It will be understood that relative terms are
intended to encompass different orientations of the perineal
thermal pack in addition to the orientation depicted in the
drawings.
[0042] Reference will be made to figures wherein like structures
are provided with like reference designations. It should be
understood that the figures are diagrammatic and schematic
representations of exemplary embodiments of perineal thermal pack
of the present disclosure, and are neither limiting nor necessarily
drawn to scale.
[0043] A device is provided for applying thermal therapy to a
patient. In a preferred embodiment, the thermal therapy is applied
to the perineal or rectal area of a patient. The perineal thermal
pack contains both a pad and a thermal pouch. The pad includes an
absorbent core and a surrounding sheet that comprises a top and a
bottom sheet. The thermal pouch is attached to the pad. The pack
also can include an overwrap, which comprises at least one layer.
The pack includes a backing layer. The pack also comprises optional
adhesive means and release tab on the backing layer.
Thermal Pouch
[0044] Any thermal insert can be utilized in the described
invention. In a preferred embodiment, the insert is a thermal
pouch.
[0045] Any thermal pouch known in the art can be utilized in the
current invention.
[0046] In the preferred embodiment, a sealed inner space is
provided, referred to as the thermal pocket. The sealed inner space
can be a polyolefin or combination of multiple polyolefins. The
sealed inner space can be formed of a pouch made of a laminated
roll stock, polyester/low-density polyethylene (LDPE). Other
materials which may be used to form the pocket include biaxially
oriented nylon laminated, linear low density polyethylene (LLDPE),
polyethylene, polypropylene, and co-polymers of polyolefins. The
thermal pouch can be an embossed or thermoformed film. Any material
known in the art can be used for the thermal pouch.
[0047] The inner space includes a first compartment which contains
a first chemical. The inner space also includes a second
compartment containing a second chemical. A rupturable wall is also
provided between the first and second compartments. When the
rupturable wall is ruptured, the first and second chemicals are
allowed to mix to cause either an endothermic or exothermic
reaction to occur. When heat therapy is desired, the first chemical
may be taken from the group consisting of sodium acetate and sodium
thiosulfate, and the second chemical may be taken from the group
consisting of borax and aluminum oxide so that when the first and
second chemicals are exposed, an exothermic crystallization of a
supersaturated solution occurs.
[0048] Similarly, when cold therapy is desired, the first chemical
may be taken from the group consisting of calcium ammonium nitrate,
ammonium nitrate, aluminum chloride, and urea, and the second
chemical may be taken from the group consisting of water and
additives so that when the first and second chemicals are mixed, an
endothermic dissolution reaction occurs.
[0049] In one embodiment, the first compartment is formed of a
rupturable sealed bubble. The bubble is located entirely within the
sealed pouch. The second compartment is formed from an area
remaining between the sealed bubble and the inner wall of the
pouch. Accordingly, the bubble contains the first chemical, and
area contains the second chemical. For example, bubble may contain
water, and area may contain ammonium nitrate. In another embodiment
the bubble may contain ammonium nitrate and the area may contain
water. When the bubble is ruptured, the ammonium nitrate and water
mix to produce an endothermic dissolution reaction, resulting in
cooling. In another embodiment of the invention, the outer shell of
the device is formed from first and second sheets of a fluid
impervious material. The first and second sheets are sealed to one
another around the edges to form a sealed inner space. A third
rupturable sheet is located between the first and second sheets.
The third sheet is sealed to at least one of the first and second
sheets around the edges of the third sheet so that a first
compartment is formed by an area between the first and third sheets
and a second compartment is formed in the area between the second
and third sheets.
[0050] Another embodiment of the thermal pouch is a device formed
from two sheets of material. A first sheet is used to form an outer
shell. A second sheet of material is a rupturable material. The
second sheet is sealed about its edges to the first sheet to form a
first compartment. The first sheet is then folded over the second
sheet and sealed about its edges to form a second compartment.
First and second chemicals are inserted in the first and second
compartments respectively.
[0051] In a particularly preferred embodiment, the first
compartment is formed from a bubble made of laminated film made of
polyester/LDPE and is filled with water. The second compartment is
formed from a second single sheet of mLLDPE (linear low density
polyethylene) polymer. The second sheet is folded to surround and
encase the bubble. The second sheet is sealed along its opposite
folded edges to form an envelope type pouch which forms the second
compartment. The second compartment is then filled with ammonium
nitrate. The remaining edges between the opposite folded edges are
then sealed to seal the second compartment. In the preferred
embodiment, the bubble has a perforated area which weakens the
bubble and allows it to rupture prior to any rupturing of the
second sheet. Thus, when pressure is applied to the device, the
perforated area will rupture first to allow the water and ammonium
nitrate to mix, thereby producing the desired endothermic reaction.
In other similar embodiments, other chemicals may be used as
described above to produce an exothermic reaction. The amount of
air present in both compartments is minimized.
[0052] The thermal pouch may be removable or permanent. In a
preferred embodiment, the thermal pouch is not removable and,
therefore, permanent.
[0053] The thermal pouch for the described invention can include
any of the preferred embodiments described above or any of those
known in the art. In a preferred embodiment, the thermal pouch is a
cold therapy pouch.
Absorbent Pad
[0054] In certain embodiments, a pad can be utilized. The pad is
comprised of an absorbent core and a surrounding sheet. The sheet
can be comprised of a top sheet and a bottom sheet. There can also
be only a top sheet or bottom sheet.
[0055] The absorbent core will normally have one or more layers of
absorbent material which may be contained within a wrapper.
Examples of suitable unmodified/modified naturally occurring fibers
that can be used in the absorbent core include cotton, Esparto
grass, bagasse, kemp, flax, silk, wool, wood pulp, chemically
modified wood pulp, jute, rayon, ethyl cellulose, and cellulose
acetate. Gauze, tissue or synthetic polymer foam may also be used.
Cellulosic fibers, in particular wood pulp fibers, are a preferred
element for use in the present invention. Optionally the core may
contain superabsorbent polymer (SAP) mixed in with the cellulosic
fibers.
[0056] Suitable wood pulp fibers can be obtained from well-known
chemical processes such as the Kraft and sulfite processes. It is
especially preferred to derive these wood pulp fibers from southern
soft woods due to their premium absorbency characteristics. These
wood pulp fibers can also be obtained from mechanical processes,
such as ground wood, refiner mechanical, thermomechanical,
chemomechanical, and chemothermomechanical pulp processes. Recycled
or secondary wood pulp fibers, as well as bleached and unbleached
wood pulp fibers, can be used.
[0057] The absorbent core can be formed in a variety of different
ways. For example, the core can be formed using a hammer mill and a
core forming drum, or the core can be formed using an airlaid
machine.
[0058] Airlaid cores are generally preferred, especially for the
embossed design. The airlaid cores are made with mixtures of
absorbent (typically cellulosic) natural fibers and thermoplastic
bonding fibers, or other core binders that make the core grooves
and recessed area where the thermal pack is placed easier to form
and hold in place thru the application of heat and/or pressure,
activating the binder during the embossing. An airlaid core with
bonding fibers or binders is a good method for making the core
because the thermal pouch overwrap layer(s) can pull up in the z
direction where they are bonded to the absorbent core. With a drum
formed fluff pulp core this z directional pulling can pull up on
the absorbent pad top sheet, and even pull apart the unbonded fluff
pulp, greatly reducing or eliminating the liquid containment
grooves, and reducing the core liquid absorption rate in the areas
where the thermal pouch overwraps pull up on the core. Airlaid
cores have a thermoplastic binder or bonding fibers, and this helps
to better set the embossed grooves, and the core is able to better
resist this overwrap z directional pulling force.
[0059] The liquid pervious sheet over the absorbent-core is
normally a soft fabric. A suitable sheet or sheets may be
manufactured from a wide range of materials, such as porous foams,
reticulated foams, apertured plastic films; or woven or nonwoven
webs of natural fibers, synthetic fibers, or a combination of
natural and synthetic fibers.
[0060] Generally, the top and/or bottom sheets are compliant, soft
feeling, and non-irritating to the wearer's skin. Further, the
sheet(s) are liquid pervious permitting liquids to readily
penetrate through their thickness. Provided it will satisfy the
requirements as laid out later, a suitable sheet(s) may be
manufactured from a wide range of materials, such as porous foams,
reticulated foams, apertured plastic films; or woven or nonwoven
webs of natural fibers, synthetic fibers, or a combination of
natural and synthetic fibers.
[0061] In a preferred embodiment, the top and bottom sheets are
nonwoven. The nonwoven top and bottom sheets can be pliant,
nonwoven, and fluid and liquid pervious.
[0062] The nonwoven webs may be wet laid, dry laid, spunlaced,
adhesive bonded, thermal bonded or spunmelt nonwoven including
spunbond or spunbonded-melt blown-spunbonded (SMS) web types. The
webs may be made of thermoplastic fibers, regenerated fibers,
natural fibers, and so-called bicomponent or sheath-core fibers,
and may comprise mixtures of any two or more of the foregoing fiber
types. Common synthetic fibers are polypropylene, polyethylene,
polyesters, nylons, and the most common natural fibers are composed
of cellulose. Other materials include carded nonwovens, carded
cellulose +synthetic fiber nonwovens that are bonded in a variety
of different ways. One specific example is 50 gsm Suominen
thermally bonded 20% viscose, 80% polypropylene carded nonwoven.
Top sheet nonwovens can also be perforated to help enable liquid to
pass thru the nonwoven. Embossed nonwovens can also be used as a
top or bottom sheet.
[0063] Preferably the top and/or bottom sheets according to the
current invention comprises a means to adjust hydrophilicity of the
material.
[0064] In case of nonwoven sheets, this can be done by adjusting
the surface energy of the fibers before the nonwoven is formed, or
by adjusting the surface energy of the nonwoven after it is formed.
The hydrophilicity adjustments can be made such that they do not
wash away easily upon wetting such as with urine, or, which is more
preferred, such that they remain effective even at repeated
wettings, though may be at a reduced level. In a preferred
embodiment, this is done by applying surfactant to the nonwoven top
sheet. The surfactant can be applied continually or non-continually
in any type of pattern or zone. The surfactant can be applied in
zones across web where absorbency is required.
[0065] The nonwoven material top and/or bottom sheets can be formed
from surfactant-treated spunbond polyolefin. In a preferred
embodiment, the nonwoven top layer is formed from
surfactant-treated spunbond polypropylene.
[0066] The top sheet and bottom sheet can also be comprised of a
film. The film can be fluid and liquid impervious.
[0067] There are various arrangements for the pad and thermal pouch
in the current pack. The pad and pouch can be attached to one
another by any means. In one embodiment, the pad and the pouch are
joined by adhesive. In one embodiment, the pad is compressed where
the thermal pouch is attached. In another embodiment, the backing
layer on the pad can be folded up and attached to the overwrap. In
another embodiment, part or all of the absorbent core can be
removed from the location where the thermal pouch is to be
attached. The thermal pouch can then be inserted in this area. In a
particular embodiment, the portion of the pad removed can be the
fluff pulp material. In another embodiment, the absorbent core can
be formed so that less or no absorbent material is located where
the thermal pouch is attached, creating a recessed area.
[0068] The pad can be any size or shape. In a preferred embodiment,
the pad is larger in length and width than the pouch. The pouch can
also be any size or shape. In some embodiments, the pad and pouch
are rectangular in shape. In other embodiments, the pouch and pad
have an hourglass or contoured shape. In another embodiment, the
pouch is rectangular and the pad has an hourglass or contoured
shape.
[0069] In the embodiments where a portion of the absorbent core of
the pad is removed, the pouch may be at least as large as the void
(removed portion). In some embodiments the pouch is larger than the
void.
Backing Layer
[0070] The backing layer of the current invention comprises at
least one layer. In one embodiment the backing layer comprises two
layers.
[0071] The backing layer preferably comprises a film layer. The
film layer is normally a thin flexible plastic film. Polymer films
which may be used herein include olefinic polymers and copolymers,
polyester polymers and copolymers and polyamide polymers and
copolymers. Olefinic polymers and copolymers may include
polyethylenes; polypropylene; ethylene-propylene copolymers;
copolymers of ethylene with other ethylenically unsaturated
monomers such as vinyl halides, vinyl acetate, vinylidene halides,
vinyl alcohol, styrene, (meth)acrylic acid, esters of (meth)acrylic
acid and acrylonitrile; and rubbery copolymers such as
ethylene-propylene rubber (EPR), ethylene propylene diene rubber
(EPDM), styrene-acrylonitrile rubber (SAR), styrene-butadiene
rubber (SBR), and acrylonitrile-butadiene elastomeric copolymers
(BAN). The films may be cast films, extruded films or blown films.
Vapor deposited or metallized polymer or metal films may also be
used as the film layer. In one embodiment of the current invention,
the film layer is pliant and fluid impervious. In a preferred
embodiment of the current invention, the film layer is
polypropylene.
[0072] The backing layer may further comprise a nonwoven sheet
layer. The nonwoven sheet layer can be pliant.
[0073] The nonwoven webs may be wet laid, dry laid, spunlaced,
adhesive bonded, thermal bonded or spunmelt nonwoven including
spunbond or spunbonded-melt blown-spunbonded (SMS) web types. The
webs may be made of thermoplastic fibers, regenerated fibers,
natural fibers, and so-called bicomponent or sheath-core fibers,
and may comprise mixtures of any two or more of the foregoing fiber
types. Common synthetic fibers are polypropylene, polyethylene,
polyesters, nylons, and the most common natural fibers are composed
of cellulose. Other materials include carded nonwovens, carded
cellulose and synthetic fiber nonwovens that are bonded in a
variety of different ways. One specific example is 50 gsm Suominen
thermally bonded 20% viscose, 80% polypropylene carded
nonwoven.
[0074] The film layer of the backing layer can be joined to the
pad. The film layer of the backing layer can also be joined to the
absorbent core. The backing layer can also be joined to the cover
sheet. Any suitable attachment means can be used for joining the
backing layer to the pad, the absorbent core, the cover sheet or
all. The pad can also be attached to the cover sheet and the
backing layer or both. Any suitable attachment means can be used
for joining the pad to the coversheet or the backing layer or
both.
Additional Absorbent Material
[0075] Additional absorbent material can be added on top of the
pad, surrounding the thermal pouch. The absorbent material can be
any known absorbent material. In one embodiment, the absorbent
material can be multiple layers of absorbent material. In another
embodiment, the absorbent material can be rolled up absorbent
material. In a preferred embodiment, the absorbent material is a
hydrophilic nonwoven. In a further embodiment, the absorbent
material can be foam material.
[0076] The absorbent material can be on any side of the thermal
pouch. In one embodiment, the absorbent material is on the two
longitudinal sides of the pouch. In another embodiment, the
absorbent material is on all four sides of the pouch.
[0077] The additional absorbent material can be at any level in
comparison to the thermal pouch. In a preferred embodiment, the
absorbent material is at the same height level as the activated
thermal pouch. In another preferred embodiment, the absorbent
material is at a height higher than the activated thermal
pouch.
Overwrap
[0078] In some embodiments, an overwrap is above the pad and
thermal pouch, facing the patient. In other embodiments, an
overwrap is surrounding the pad and thermal pouch.
[0079] The overwrap comprises at least one layer. In one
embodiment, the overwrap comprises at least two layers.
[0080] The overwrap can include a cover sheet. The overwrap can
also include an acquisition distribution layer. In an embodiment,
the cover sheet is above the acquisition distribution layer, facing
the patient.
[0081] Overwrap layer(s) can be joined to the pad and backing layer
with an adhesive. Overwrap layer(s) are attached the pad at
multiple points, including right outside the perimeter of the cold
pouch. The overwrap can also be fully attached to the pad in all
areas but that of the cold pouch.
Cover Sheet
[0082] The cover sheet can be the top layer, facing the
patient.
[0083] The cover sheet can be absorbent material.
[0084] Generally, the cover sheet is compliant, soft feeling, and
non-irritating to the wearer's skin. Further, the cover sheet is
liquid pervious permitting liquids to readily penetrate through its
thickness. Provided it will satisfy the requirements as laid out
later, a suitable cover sheet may be manufactured from a wide range
of materials, such as porous foams, reticulated foams, apertured
plastic films; or woven or nonwoven webs of natural fibers,
synthetic fibers, or a combination of natural and synthetic
fibers.
[0085] In a preferred embodiment, the cover sheet is a nonwoven.
The nonwoven cover sheet can be pliant and fluid pervious.
[0086] The nonwoven webs may be wet laid, dry laid, spunlaced,
adhesive bonded, thermal bonded or spunmelt nonwoven including
spunbond or spunbonded-melt blown-spunbonded (SMS) web types. The
webs may be made of thermoplastic fibers, regenerated fibers,
natural fibers, and so-called bicomponent or sheath-core fibers,
and may comprise mixtures of any two or more of the foregoing fiber
types. Common synthetic fibers are polypropylene, polyethylene,
polyesters, nylons, and the most common natural fibers are composed
of cellulose. Other materials include carded nonwovens, carded
cellulose and synthetic fiber nonwovens that are bonded in a
variety of different ways. One specific example is 50 gsm Suominen
thermally bonded 20% viscose, 80% polypropylene carded nonwoven.
Cover sheet nonwovens can also be perforated to help enable liquid
to pass thru the nonwoven. Embossed nonwovens can also be used as a
cover sheet.
[0087] Preferably the cover sheet according to the current
invention comprises a means to adjust hydrophilicity of the
material.
[0088] In case of nonwoven cover sheets, this can be done by
adjusting the surface energy of the fibers before the nonwoven is
formed, or by adjusting the surface energy of the nonwoven after it
is formed. The hydrophilicity adjustments can be made such that
they do not wash away easily upon wetting such as with urine, or,
which is more preferred, such that they remain effective even at
repeated wettings, though may be at a reduced level. In a preferred
embodiment, this is done by applying surfactant to the nonwoven
cover sheet. The surfactant can be applied continually or
non-continually in any type of pattern or zone. The surfactant can
be applied in zones across web where absorbency is required.
[0089] The nonwoven material cover sheet can be formed from
surfactant-treated spunbond polyolefin. In a preferred embodiment,
the nonwoven cover sheet is formed from surfactant-treated spunbond
polypropylene.
Acquistion Distribution Layer
[0090] The overwrap may also comprise an acquisition distribution
layer. Materials which may be used to form the acquisition
distribution layer are tissue, apertured film, perforated nonwoven,
or carded or wet laid cellulose and synthetic fiber nonwovens. The
nonwoven webs may be wet laid, dry laid, spunlaced, adhesive
bonded, thermal bonded or spunmelt nonwoven including spunbond or
spunbonded-melt blown-spunbonded (SMS) web types. The webs may be
made of thermoplastic fibers, regenerated fibers, natural fibers,
and so-called bicomponent or sheath-core fibers, and may comprise
mixtures of any two or more of the foregoing fiber types.
[0091] In one embodiment, the acquisition distribution layer can be
pliant and fluid pervious.
[0092] In a preferred embodiment, the acquisition distribution
layer is formed from thermally bonded cellulose and polypropylene
(Suominen thermal bond grade BE149909). In another embodiment, the
acquisition distribution layer can be formed from spunbond
polypropylene.
[0093] The nonwoven top cover sheet and the acquisition
distribution layer can be applied to the pad/pouch separately or as
a single overwrap adhered thermally or with adhesive. In a
preferred embodiment, the nonwoven top cover sheet and the
acquisition distribution layer are adhered together as a single
overwrap.
[0094] The overwrap layer or layers can include slits in any
pattern or shape. The slits can be such that fluid can from the
center of the perineal thermal pack to the pad edges. In one
preferred embodiment, the slits have a curved shape.
Adhesive Layers
[0095] One of more adhesive layers can be utilized in the
embodiments of the current invention.
[0096] The adhesive layers can be the same adhesive, or
different.
[0097] The adhesive layer used in any embodiment can be any of
those known in the art.
[0098] The adhesives used in any of the embodiments can also
comprise thermoplastic adhesives, thermosetting adhesives and/or
crosslinked adhesives. Illustrative thermoplastic adhesives include
olefinic polymer and copolymer adhesives, such as ethylene vinyl
acetate, styrene, maleic anhydride modified polyethylene or
polypropylene; polyamide adhesives, polyester and polyurethane
adhesives. Illustrative thermosetting adhesives may include
(meth)acrylic adhesives or styrene adhesives. Other adhesives
conventionally employed in the field of nonwovens may also be
used.
[0099] Thermoplastic hot melt adhesives are generally preferred.
The hot melt adhesives may comprise ethylene vinyl acetate,
styrene, polyolefins, modified polyolefins, polyamides and/or
polyesters. Any suitable adhesive may be used, especially those
known in the art for hygiene product manufacturing.
[0100] The adhesive can also be a pressure sensitive adhesive. A
pressure sensitive adhesive can be any suitable adhesive including
pressure-sensitive adhesives (PSAs) and heat activated adhesives.
Useful PSAs include rubber based adhesives, acrylic adhesives,
vinyl ether adhesives, silicone adhesives, and mixtures of two or
more thereof.
[0101] In a preferred embodiment, one adhesive is a petroleum-based
adhesive.
[0102] The packs of the current invention can include an adhesive
layer on the bottom layer of the back layer and optional release
liner.
Grooves or Channels
[0103] The assembled thermal pack can include grooves, channels,
embossed pattern, embossment, depression or the like in the area
between the outermost edge of the pad and the thermal pouch. In one
embodiment, the assembled thermal pack has grooves. The grooves can
be embossed into the pad and overwrap or just into the pad.
Preferably, the grooves are embossed into the pad and overwrap. The
thermal pack overwrap layers are bonded together and then pushed
into the embossed grooves and adhered in the groove using some sort
of bonding method: a hot melt glue or tape, pressure, thermal
bonding, ultrasonic bonding or a combination of these. In another
embodiment, the groove is cut into the pad core and extends
completely through the thickness of the pad. The grooves can be
continuous or discontinuous. In a preferred embodiment, the grooves
are continuous. The grooves can also be formed in any shape or
pattern. In a preferred embodiment, the grooves are in the shape of
the perimeter of the pad. The groove cross-section can be any
shaped including `V` or `U` shaped. In a preferred embodiment, the
groove cross-section is `U` shaped. The depth of the groove can
extend 25% or more into the thickness of the pad. In a preferred
embodiment, the depth of the groove extends 50% or more into the
thickness of the pad.
[0104] It is preferred that in the current invention the device is
arranged such that there are not any loose portions of the overwrap
or top or bottom sheets that would create a tent-like or unattached
sheet. This improves the flow of the liquid in to the absorbent
core of the pad through capillary action.
[0105] In one embodiment of the perineal thermal pack, a thermal
pouch is attached to a pad with a small bubble filled with water
attached to the top of the thermal pouch covered by one or more
absorbent nonwoven layers. The small bubble filled with water
consists of a perforated or frangible film with water that when
activated spreads water over the patient contact area to promote
evaporative cooling. In another embodiment the small bubble can be
attached to the inside off the dustcover outerwrap. It can also
contain a therapeutic agent to help aide comfort and healing.
[0106] In a preferred embodiment, an absorbent core is made on an
airlaid machine. The core can be Georgia Pacific series 4881 fluff
pulp. The resulting rolls of core were cut to the size and shape of
the current invention using a die press machine and die cutter.
First, an outer rectangle is cut, and then an inner rectangular
window is removed from the center of the rectangle. Cores can range
from 0.41 to 0.79 inches in thickness, and 611to 1125 gsm in basis
weight. The windowed cores are then wrapped in a sheet. The sheet
is secured to the fluff pulp on both sides with adhesive. In a
preferred embodiment this is applied using a spiral spray hot melt
glue gun. The two layers of nonwoven core wrap are then glued to
each other in the window area where there was no core.
[0107] The top of a thermal cold pouch is then glued to the back of
the top sheet wrapped core in the window lacking absorbent core,
such that the end seals of the thermal pouch are covered by core
when the product is viewed from the top. An adhesive is applied to
glue the wrapped pad nonwoven to the thermal pouch. The pouch was
secured throughout the top/side areas so that fluid containment
areas form around the perimeter of the core void area. A backing
film layer is glued to the bottom of the cold pouch and the bottom
of the wrapped core using an adhesive, preferably a hot melt. The
fluid containment areas along the length of the cold pouch can
optionally be enhanced by heat sealing the nonwoven in the window
area adjacent to the long edges of the cold pouch to the backing
film, forming deeper fluid containment channels. This heat sealing
can be done electronically.
[0108] In another preferred embodiment, an absorbent core is made
on an airlaid machine. The core can be Georgia Pacific series 4881
fluff pulp. The resulting rolls of core are cut to the size and
shape of the current invention using a die press machine and die
cutter. The core is formed as a window. Cores can range from 0.41
to 0.79 inches in thickness, and 611to 1125 gsm in basis weight.
The windowed cores are then wrapped in a sheet. The sheet is
secured to the fluff pulp on both sides with adhesive. In a
preferred embodiment this is applied using a spiral spray hot melt
glue gun. The two layers of nonwoven core wrap are then glued to
each other in the window area where there was no core.
[0109] The top of a thermal cold pouch is then glued to the back of
the top sheet wrapped core in the window lacking absorbent core,
such that the end seals of the thermal pouch are covered by core
when the product is viewed from the top. An adhesive is applied to
glue the wrapped pad nonwoven to the thermal pouch. The pouch was
secured throughout the top/side areas so that low fluid containment
areas form around the perimeter of the core void area. A backing
film layer is glued to the bottom of the cold pouch and the bottom
of the wrapped core using an adhesive, preferably a hot melt.
Fluid Containment Testing
[0110] A test method was developed to evaluate gushing flow fluid
containment by using a separatory funnel filled with 50 mL of
synthetic blood. The synthetic blood mimics the fluid properties
and coloring of actual blood, and is purchased from Johnson, Moen,
& Co. Inc. The sample cold pouches were activated by folding
them in half, inward toward the pouch until the water bubble broke.
The product was shaken to mix the water with the ammonium nitrate
(AN). The activated perineal thermal pouch was laid flat on a
pre-weighed underpad and the stem of the separatory funnel was
placed over the center of the product, with a vertical distance of
5 to 10 mm between the bottom of the stem and the top of the
product. Fluid was introduced by fully opening the stopcock. The
flow rate was approximately 10 mls/second. The amount of blood that
leaked off the pad was evaluated by re-weighing the underpad. The
commercially available products contained very little blood, most
of it flowed right off the pad during testing. Most embodiments of
the current invention tested in this way contained all of the blood
within the pad. All embodiments contained greater than 70% of the
blood in the pad. Preferred embodiments contained at least 90% of
the blood in the pad. All embodiments did not have any fluid
present on the bottom outward facing side of the product.
Prototype Construction
Window Frame Design
[0111] Absorbent fluff pulp cores of varying densities and
thicknesses were made on an airlaid machine. The fluff pulp was
Georgia Pacific series 4881 fluff pulp. The resulting rolls of
fluff pulp were cut to the size and shape of the current invention
using a die press machine and die cutter. First, a rectangle of 12
by 4.5'' was cut, and then an inner rectangular window of 8.5 by
2.5'' was removed from the center of the rectangle. Cores ranged
from 0.41 to 0.79 inches in thickness, and 611to 1125 gsm in basis
weight. The samples were wrapped in 12 gsm durable surfactant
treated spunbond polypropylene (SBPP) nonwoven (top and bottom
nonwoven sheets), which was secured to the fluff pulp on both sides
with a hygiene construction grade adhesive (Henkel TECHNOMELT DM
898B) applied using a spiral spray hot melt glue gun. The two
layers of nonwoven sheets were glued to each other in the window
area where there was no fluff pulp.
[0112] Thermal pouches were fabricated from 3.5 mil monolayer white
mLLDPE non-treated film. The film was formed into a 9.5 by 2.75''
pouch using a heat sealer, and one end was left open. 57 grams
ammonium nitrate (AN) and a water bubble were added to the thermal
pouch before sealing it closed on the heat sealer. The water bubble
was formed using PPS perforated film consisting of 48 ga polyester,
6.0 ga saran, and 2.0 mil LDPE. When bent, the perforated film
breaks, releasing the water to mix with the AN, which causes a
decrease in temperature. The film was formed into a [8 by 1.625'']
bubble using a heat sealer. 85 grams of water was sealed into each
bubble with minimal air. After the AN and water bubble were added
to the thermal pouches, the pouches were sealed closed with minimal
air inside using the heat sealer.
[0113] The top of a thermal cold pouch was glued to the back of the
spunbond-wrapped fluff pulp core in the window lacking fluff pulp,
such that the end seals of the thermal pouch were covered by the
fluff pulp core when the product is viewed from the top. A spiral
spray construction grade hot melt was applied to glue the wrapped
pad nonwoven to the thermal pouch. The pouch was secured throughout
the top/side areas so that fluid containment areas form around the
perimeter of the fluff void area. A bilaminate back sheet was
fabricated by gluing a sheet of 25 gsm untreated hydrophobic
spunbond polypropylene nonwoven to a sheet of 12 gsm polypropylene
(PP) film. The bilaminate film side was glued to the bottom of the
cold pouch, which was the side of the pouch with the longitudinal
fin seal, and the bottom of the wrapped core using a spray gun and
construction grade hot melt, helping to secure the thermal pouch to
the fluff pulp core.
Embossed Channel/Groove Design
[0114] Absorbent fluff pulp cores of varying densities and
thicknesses were made on an airlaid machine. The resulting rolls of
fluff pulp were cut to a 12 by 4.5 inch rectangular shape using a
die press machine. The rectangular fluff pulp cores were wrapped in
12 gsm durable surfactant treated SBPP nonwoven, which was secured
to the fluff pulp on both sides with hygiene construction grade
adhesive applied using a spiral spray hot melt glue gun. Enough hot
melt was sprayed on the top of the core fluff pulp so that the top
sheet would stay attached to the fluff pulp when channels were
embossed into the core. The bottom of the cold pouch was glued to
the top nonwoven layer of the pad. A 17 gsm durable surfactant SBPP
cover sheet nonwoven was placed over the pouch and glued to the pad
top sheet everywhere except for the top of the pouch. A deep
channel was embossed around the perimeter of the cold pouch using a
hydraulic press and a stainless steel u-channel. The u-channel
embossing fixture edges were laser cut to make them flat. The width
of the edge used for embossing was 0.1875 inches wide. The
u-channel was placed over the coversheet and pouch and deep
channels were embossed around the perimeter of the pouch by
pressing the u-channel into the pad using 4100 psi for 30 seconds
using a hydraulic press. The embossing fixture width was 3 inches,
and it was centered over the middle of the pad. Placing the
channels approximately 3/4 of an inch from the edge of the core on
the sides of the pad. End channels were also embossed 3/4 of an
inch in from the end of the core. A 12 gsm PP hygiene film back
sheet was glued to the back side of the pad using the spray gun and
construction hot melt.
Airlaid Core Sample Design
[0115] Sample A1: a 7.times.13 inch sample of the same airlaid core
used in sample A3 (below) was slit down the center 9.5 inches of
the core. Two 3.0 inch wide cuts were made perpendicular on end of
the 9.5 inch long center slit, the center slit bisecting the 3 inch
cross slits. The slits look like the capital letter I. The airlaid
core was folded back on itself in the 9.5 in long slit area and
this folded over portion hot melted to itself to form double
thickness that was 1 inch wide on each side down the length of the
9.5 inches. This resulted in a void area (window) for the cold pack
insertion that was 2.50 inches wide by 9.50 inches in length. The
total pad core dimension was 7.5.times.13 inches. The core window
was placed over the cold pouch. A 17 gsm SBPP cover sheet was glued
to the top of the pouch and the entire top surface of the airlaid
core. Hot melt was applied to the cold pouch so that the cover
sheet followed the curvature of the cold pouch, creating fluid
collection areas at the edges where the cold pouch was contacting
the inside perimeter of the core void. The film side of 12 gsm PP
hygiene film plus 25 gsm untreated SBPP bilaminate back sheet was
glued the back of the airlaid core and the bottom of the cold
pouch.
[0116] Sample A2: This sample was prepared similar to sample Al
with following exceptions. The airlaid core was a 77/8
ths.times.117/8 inch piece of Glatfelter MH300.100 hybrid bonded
airlaid with SAP. The airlaid basis weight was 300 g/m2 and the
thickness was 3.2 mm (0.125 inches), with 17 g/g absorbency. The
core was slit and folded back onto itself as in sample A1, and then
1.25 inches from each outward edge were folded inward from the edge
along the entire length of the pad and glued to itself and glued to
the folded outward flap from the center hole. This resulted in a
9.5 inch area that was three layers of airlaid running along the
length of the opening for the cold pouch, with two layers of
thickness beyond the 9.5 inch length to the end of the pad
core.
[0117] Sample A3: Thermally bonded airlaid core was made with 10%
hydrophilic treated Trivera bicomponent PE/PET bonding fibers and
90% fluff pulp. The airlaid core was 210 gsm and 0.25 inches thick.
An 8.5.times.12 inch piece of airlaid core was rolled inward at the
outside edges and heat sealed together on a 1/4 inch wide bar
sealer forming channels the entire length of the core. The folded
overlapped width was 1.25 inches including the heat seal. The
resulting pad core measured 5.5 inches wide by 12 inches long, with
2 thickness of airlaid core 1.25 inches wide along both edges of
the pad, and a single thickness of airlaid core in the middle of
the pad. The width between the inside edges of the heat sealed
channels was 3 inches apart. A cold pouch was centered between the
channels and glued to the airlaid core. A 17 gsm hydrophilic
surfactant treated SBPP cover sheet was glued to the top of the
cold pouch, and to the pad core. A 12 gsm PP hygiene film was glued
to the back of the pad.
[0118] Sample A4: The core was constructed using Glatfelter airlaid
grade MH300.108 a 300 gsm 3.20 mm thick hybrid bonded airlaid with
SAP, and 17 g/g absorbent capacity. A 77/8th.times.117/8 inch sheet
of airlaid was used to construct the core. The construction was
similar to similar to sample A3, except that the total width of the
pad core was 5 inches and the folded in overlap was 13/8 ths inches
on each side including the 1/4 inch width of the thermal seal which
ran the entire length of the core.
TABLE-US-00001 TABLE 1 Prior Art Examples Fluid present on bottom
outward % Fluid facing side of Prior Art Product Catalog Number
Contained product? Cardinal Basic 115500-010 79 Yes 73 Yes 93.2 Yes
Cardinal Premium 11447-010 22.8 Yes 12 Yes 54 Yes Centurion CN14230
73 Yes 47.6 Yes 55 Yes Medi-Choice 69902 71.2 Yes 73.4 Yes 72.8 Yes
Medline Green MDS 138055 78.8 Yes 42.4 Yes 50.2 Yes Medline Premium
MDS 158055 61.6 Yes 36.2 Yes 47.8 Yes Medline Purple MDS 148055
58.2 Yes 55.8 Yes 60.6 Yes
[0119] Prior art examples, listed in Table 1, were purchased and
three replicates of each were evaluated with this method. All prior
art samples had blood on the back of the product after testing.
TABLE-US-00002 TABLE 2 Window Design Invention Examples Core
Wrapped Fluid present on Basis Core bottom outward Prototype Weight
Thickness % Fluid facing side Number (gsm) (inches) Contained of
product? 1 634 0.41 88 No 2 870 0.42 73.8 No 3 1068 0.79 100 No 4
611 0.51 100 No 5 896 0.52 100 No 6 1082 0.52 100 No 7 649 0.48 100
No 8 832 0.73 100 No 9 1062 0.57 100 No 10 637 0.59 100 No 11 827
0.69 100 No 12 1125 0.71 100 No
[0120] Table 2 shows the results for the testing of the window
design invention examples. Prototypes vary by core basis and
thickness (shown in table). In most of the prototypes there was
100% fluid containment. Two samples with a lower core thickness
contained most of the fluid, but not all. All of the fluid was
contained on samples with a core thickness of at least 0.48 inches.
None of the prototypes had fluid present on the bottom outward
facing side of the pack.
TABLE-US-00003 TABLE 3 Embossed channel design fluid containment
results. Core Fluid present on Basis bottom outward Prototype
Weight Thickness % Fluid facing side of Number (gsm) (inches)
Contained product? E1 975 gsm 0.57 97.6 No
[0121] Table 3 shows the results for the fluid containment testing
of the embossed channel design. Prototype E1 was tested and showed
97.6% fluid containment and no fluid present on the bottom outward
facing side of the pack.
TABLE-US-00004 TABLE 4 Fluid containment results for folded over
designs. Single layer of Fluid present on Core Single airlaid core
bottom outward Prototype Thickness Basis thickness % Fluid facing
side of Number Weight (gsm) (inches) Contained product? A1 210 0.25
100 No A2 300 0.13 85.6 No A3 210 0.25 100 No A4 300 0.13 90.4
No
[0122] Table 4 shows the fluid containment results for folded over
design prototypes. Prototypes A1-A4 differ in core single thickness
basis weight (gsm) and single layer of airlaid core thickness
(inches). The lower core single thickness basis weight and the
lower single layer of airlaid core thickness prototypes (A1 and A3)
performed better with 100% fluid containment. All of the prototypes
did not have any fluid present on the bottom outward facing side of
the pack.
[0123] Unlike the embodiments of the current invention, prior art
products do not maximize fluid containment. Prior art products are
designed with a thermal pack which sits on top of an absorbent
core, all of which is overlaid by a nonwoven layer. This design
creates a slanted surface down which lochia fluid flows, rather
than capturing the fluid in the pad. Since the top nonwoven layer
is not in contact with the absorbent core, the fluid is not wicked
through the nonwoven into the core. The combination of shape and
lack of absorbency results in a product which does not contain
fluid. Instead, the prior art is viewed solely as cold therapy, and
is often used in combination with a separate absorbent pad.
[0124] In a preferred embodiment (FIG. 1), a perineal thermal pack
[10] consists of a thermal pouch [23] attached to a pad [12]. The
pad [12] is formed of an absorbent core [27] with a top sheet [19]
and bottom sheet (20) to hold the absorbent core [27] in place. The
pad can also be comprised of an absorbent core and top sheet
without a bottom sheet. It is preferential to have a bottom sheet.
Having the bottom nonwoven sheet pulls down on the top nonwoven
sheet where they are glued together in the void, and this helps to
form deeper liquid pooling areas around the perimeter of the center
void. Also, having two layers of nonwoven helps with liquid
aqusition. The bottom sheet can act like an aqusition/distribution
layer. The absorbent core can be fluff pulp. The absorbent core can
have a center void area. Both the top sheet [19] and the back sheet
[20] can be nonwovens. The nonwoven sheets can be attached to each
other at the area of the voided core. The nonwoven sheets can be
attached to the pouch in this area. The perineal thermal pack has a
bottom film layer [30] and optionally a bottom nonwoven layer [21].
The perineal thermal pack [10] may have an adhesive strip [24]
running down the center of the pad the long way with a release
liner [25]. In a preferred embodiment, the thermal pouch is
embedded in the pad [12].
[0125] FIG. 2 shows the top view and FIG. 3 shows the bottom view
of the preferred embodiment of FIG. 1.
[0126] Another embodiment (FIGS. 4 and 5) of the perineal thermal
pack [10] consists of a thermal pouch [23] attached to a pad [12]
that can comprise an absorbent core and surrounding nonwoven sheets
(19 and 20 in FIG. 1). The pad [12] can optionally be an absorbent
core and a top sheet [19] without a bottom sheet. Top sheet [19] is
not shown in the drawing, but is present in the pad [12]. Above the
pad [12] and thermal pouch [23] there are one or more absorbent
nonwoven layers, referred to as the overwrap. In one embodiment,
there is an acquisition distribution layer [14] below an absorbent
nonwoven material cover sheet [15]. In other embodiments, the
overwrap is only the top cover sheet [15]. There are grooves or
channels [16] embossed into the nonwoven cover sheet [15],
acquisition distribution layer [14], and pad [12] between the edge
of the pad [12] and the thermal pouch [23] in any pattern. The
grooves [16] shown in the figure are continuous and can follow the
shape of the pad [12] or have a different shape. In the particular
embodiment of FIG. 4, the grooves do not match the overall shape of
the pad. Optionally cross grooves can be formed across the pad core
where the cold pouch is connecting with the longitudinal channels.
These cross channels help to direct the fluid into the core
underneath the cold pouch, increasing the fluid hold capacity of
the pad. The embodiment of FIG. 5 also includes a bottom backing
layer. Preferably this comprises a film layer [30]. The backing
layer can also include a nonwoven layer [21], as shown in FIG. 1,
underneath the film layer [30]. Attached to the backing layer can
also optionally be an adhesive layer [24] and release liner [25].
Additional adhesive layers are not shown, but can be present.
Layers [14] and [15] can be joined by an adhesive layer. The pouch
[23] can be attached to the pad [12] by an adhesive layer. Overwrap
layers [14] and [15] can be joined to the pad [12] and film [30]
with an adhesive. Overwrap layers [14] and [15] are attached the
pad at multiple points, including the edge and right outside the
perimeter of the cold pouch.
[0127] In one embodiment (FIGS. 6 and 7) of the perineal thermal
pack [10], a thermal pouch [23] is attached to a pad [12] that can
comprise an absorbent core and surrounding top and bottom sheets
(19 and 20 in FIG. 1). The pad can optionally be an absorbent core
and a top sheet [19] without a bottom sheet. Top sheet [19] is not
shown in the drawing, but is present in the pad [12]. The pad's
[12] absorbent core is thinner where the thermal pouch [23] is
attached. The thinner section under the thermal pouch can be
achieved by compressing the core, or alternatively the core can be
formed with less absorbent core material. There is an overwrap
above the pouch and pad. In this embodiment, there is an
acquisition distribution layer [14] below an absorbent nonwoven
material top sheet [15]. The overwrap may consist of both these
layers or just one. The top sheet [15] can extend to the backing
layer which comprises at least film layer [30]. Backing layer can
also comprise an additional nonwoven layer [21] below [30].
Attached to the backing layer can also optionally be an adhesive
layer [24] and release liner [25]. Additional adhesive layers are
not shown, but can be present. Layers [14] and [15] can be joined
by an adhesive layer. The pouch [23] can be attached to the pad
[12] by an adhesive layer. Overwrap layers [14] and [15] can be
joined to the pad [12] and film [30] with an adhesive. Overwrap
layers [14] and [15] are attached the pad at multiple points,
including the edge and right outside the perimeter of the cold
pouch. The overwrap can also be fully attached to the pad in all
areas but that of the cold pouch.
[0128] Another embodiment (FIGS. 8 and 9) of the perineal thermal
pack [10] consists of a thermal pouch [23] attached to a pad [12]
that can comprise an absorbent core and surrounding nonwoven sheets
(19 and 20 in FIG. 1). The pad can optionally be an absorbent core
and a top sheet [19] without a bottom sheet. Top sheet [19] is not
shown in the drawing, but is present in the pad [12]. The long side
of the pad film border [30] is folded up to act as a guard to
contain fluid. The pad [12] can be thinner where the thermal pouch
[23] is attached. Above the pad [12] and attached thermal pouch
[23], there is an acquisition distribution layer [14] and above the
acquisition distribution layer [14], there is an absorbent nonwoven
material top sheet [15]. On the long edges of the pad [12], the
nonwoven material top sheet [15] is attached to the film edge
border [30] of the pad [12] such that the film edges of the pad
fold up. Attached to the backing layer can also optionally be an
adhesive layer [24] and release liner [25]. Additional adhesive
layers are not shown, but can be present. Layers [14] and [15] can
be joined by an adhesive layer. The pouch [23] can be attached to
the pad [12] by an adhesive layer. Overwrap layers [14] and [15]
can be joined to the pad [12] and film [30] with an adhesive.
Overwrap layers [14] and [15] are attached the pad at multiple
points, including right outside the perimeter of the cold pouch.
The overwrap can also be fully attached to the pad in all areas but
that of the cold pouch.
[0129] Yet another embodiment (FIGS. 10 and 11) of the perineal
thermal pack [10] consists of a thermal pouch [23] attached to a
pad [12] that can comprise an absorbent core and surrounding
nonwoven sheets (19 and 20 in FIG. 1). The pad can optionally be an
absorbent core and a top sheet [19] without a bottom sheet. The pad
core [27] can be thinner where the thermal pouch [23] is attached.
The one or more absorbent layers have a slit [19] cut into them
such that fluid can flow from the center of the perineal cold pack
[10] toward the edges and fall into the slit [19]. In a preferred
embodiment, there is an acquisition distribution layer [14] below
an absorbent nonwoven top sheet [15] and there are slits [19] in
the top layer on both sides of the cold pouch that have a curved
shape. Attached to the backing layer can also optionally be an
adhesive layer [24] and release liner [25]. Additional adhesive
layers are not shown, but can be present. Layers [14] and [15] can
be joined by an adhesive layer. The pouch [23] can be attached to
the pad [12] by an adhesive layer. Overwrap layers [14] and [15]
can be joined to the pad [12] and film [30] with an adhesive.
Overwrap layers [14] and [15] are attached the pad at multiple
points, including right outside the perimeter of the cold pouch.
The overwrap can also be fully attached to the pad in all areas but
that of the cold pouch.
[0130] In one embodiment (FIGS. 12 and 13) of the perineal thermal
pack [10], a thermal pouch [23] is attached to a pad [12] that can
comprise an absorbent core and surrounding nonwoven sheets (19 and
20 in FIG. 1). The pad can optionally be an absorbent core and a
top sheet [19] without a bottom sheet. The pad [12] is compressed
or thinner where the thermal pouch [23] is attached. The pad [12]
core is folded over at the edges to form a single thickness under
the thermal pouch and a double thickness at the edges of the core
where it is folded over. The overwrap comprises an acquisition
distribution layer [14] and nonwoven material top sheet [15]. The
absorbent core [27] or fluff pulp, is folded over. The nonwoven top
sheet [15] extends to the end of the film [30]. Attached to the
backing layer can also optionally be an adhesive layer [24] and
release liner [25]. Additional adhesive layers are not shown, but
can be present. Layers [14] and [15] can be joined by an adhesive
layer. The pouch [23] can be attached to the pad [12] by an
adhesive layer. Overwrap layers [14] and [15] can be joined to the
pad [12] and film [30] with an adhesive. Overwrap layers [14] and
[15] are attached the pad at multiple points, including right
outside the perimeter of the cold pouch. The overwrap can also be
fully attached to the pad in all areas but that of the cold
pouch.
[0131] In another embodiment (FIGS. 14 and 15) a perineal thermal
pack [10] is comprised of a thermal pouch [23] and pad [12] that
can comprise an absorbent core and surrounding nonwoven sheets (19
and 20 in FIG. 1). The pad can optionally be an absorbent core and
a top sheet [19] without a bottom sheet. The embodiment further
comprises elastic strips 31. The elastic strips pull down the
length of the pad on the edges of the pad from the leg cuffs, for
fluid containment. The overwrap comprises an acquisition
distribution layer [14] and nonwoven material top sheet [15]. The
nonwoven top sheet [15] extends to the end of the pad. The ADL [14]
only partially extends. Attached to the backing layer can also
optionally be an adhesive layer [24] and release liner [25].
Additional adhesive layers are not shown, but can be present.
Layers [14] and [15] can be joined by an adhesive layer. The pouch
[23] can be attached to the pad [12] by an adhesive layer. Overwrap
layers [14] and [15] can be joined to the pad [12] and film [30]
with an adhesive. Overwrap layers [14] and [15] are attached the
pad at multiple points, including right outside the perimeter of
the cold pouch. The overwrap can also be fully attached to the pad
in all areas but that of the cold pouch.
[0132] In another embodiment (FIGS. 16 and 17) a perineal thermal
pack [10] is comprised of a thermal pouch [23] and a pad [12] that
can comprise an absorbent core and surrounding nonwoven sheets (19
and 20 in FIG. 1). The pad can optionally be an absorbent core and
a top sheet [19] without a bottom sheet. The embodiment further
comprises elastic leg cuffs [32]. The overwrap comprises an
acquisition distribution layer [14] and nonwoven material top sheet
[15]. The nonwoven top sheet [15] extends to the end of the pad.
The optional ADL [14] only partially extends. The elastic leg cuff
[32] extends over the nonwoven top sheet [15]. Attached to the
backing layer can also optionally be an adhesive layer [24] and
release liner [25]. Additional adhesive layers are not shown, but
can be present. Layers [14] and [15] can be joined by an adhesive
layer. The pouch [23] can be attached to the pad [12] by an
adhesive layer. Overwrap layers [14] and [15] can be joined to the
pad [12] and film [30] with an adhesive. Overwrap layers [14] and
[15] are attached the pad at multiple points, including right
outside the perimeter of the cold pouch. The overwrap can also be
fully attached to the pad in all areas but that of the cold
pouch.
[0133] The foregoing description is provided to enable any person
skilled in the art to practice the various example implementations
described herein. Various modifications to these variations will be
readily apparent to those skilled in the art, and the generic
principles defined herein may be applied to other implementations.
All structural and functional equivalents to the elements of the
various illustrious examples described throughout this disclosure
that are known or later come to be known to those of ordinary skill
in the art are expressly incorporated herein by reference.
* * * * *