Apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them

a technology of polyurethane foam and apparatus, which is applied in the field of apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them, can solve the problems of difficult to find non-toxic, durable adhesives to bond materials, and achieve the effect of reducing costs and facilitating moisture vapor transmission

Inactive Publication Date: 2005-01-06
RYNEL
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The use of a polyurethane foam adhesive layer is also advantageous because regulatory approval requirements can arise when a new material (e.g., an adhesive) is introduced into an approved product (e.g., a medical foam). Hence, utilization as an adhesive of a foam that has already been approved for medical use would reduce costs associated with approval of the composite material for medical use.
Another aspect of the present invention relates to a composition comprising a substrate coated with a thin

Problems solved by technology

This advance is particularly important for hydrophilic or hydrophobic polyurethane foams because it can be difficult to find

Method used

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  • Apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them
  • Apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them
  • Apparatus and methods for the attachment of materials to polyurethane foam, and articles made using them

Examples

Experimental program
Comparison scheme
Effect test

example 1

Preparation of Composite Foam by the Casting Method

A method to bind a substrate to a foam using an adhesive is illustrated in FIGS. 1, 4, and 5. The material to be laminated to the foam is orientated such that the “side-to-be-adhered-to” is facing upright and said material resides on top of the carrier (e.g. casting paper) on the production line. The casting surface and laminate material are thus being pulled underneath the foam dispensing head of the foam line. Rynel medical prepolymer (Trepol®) is combined with an aqueous solution in the mixing head in a predetermined ratio (typically 1:1 or 1:1.2) and dispensed onto the “upside” of the laminate material. A top layer of casting surface is then continuously applied to make a sandwich consisting of: bottom casting surface, laminate material, dispensed Trepol® based foam and top layer of casting surface. All layers are being pulled at the same rate presenting a static interface of the layers. The sandwich is pulled underneath a ro...

example 2

Spraying Method

As depicted in FIG. 2, the material to be laminated to the foam is orientated such that the “side-to-be-adhered-to” is facing upright. The Rynel medical prepolymer (Trepol®) is combined with an aqueous solution in the spray head in a predetermined ratio (typically 1:1 or 1:1.2) and dispensed onto the “upside” of the laminate material via a spray gun. The dispensed foam reacts and begins to cure. Next, the previously made foam material is laid down on top of the polymeric adhesive mixture and pressure is applied using a roller. The composite material continues down the length of the production line while the adhesive continues to cure and cross link thereby binding the laminate material to the pre-made foam. The pre-made foam is rolled up ready for slitting, die cutting etc.

example 3

The moisture vapor transmission rate (MVTR) of a sample of 4005 Polyurethane foam coated with a layer of Trepol® based foam was determined using the following method. The layer of 4005 Polyurethane foam obtained from Scapa UK Limited was approximately 0.4 mm thick.

A sample cut from a dressing was applied to the upper flange of a Paddington Cup and fixed securely in place with the retaining ring. A 0.9% saline solution is added to the cup, which is then securely sealed and weighed. The cup is then inverted onto a screen support in a tray containing silica gel absorbent and placed in a 37° C. incubator for 24 hours after which the cup is removed from the incubator and allowed to equilibrate to room temperature and re-weighed. The loss in weight due to moisture vapor transmission is used to calculate the MVTR. The MVTR data is presented below.

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Abstract

One aspect of the present invention relates to a laminated foam product, wherein the adhesive binding the foam to the laminate comprises the mixture from which the foam is made. Another aspect of the present invention relates to methods for making a laminated foam product. A third aspect of the present invention relates to an apparatus for making a laminated foam product.

Description

BACKGROUND OF THE INVENTION Composite articles having a plurality of layers, especially those used to make wound dressings, garments, and industrial composites, could be vastly improved if there was a method for adhering the substrate to the foam layer while still maintaining the malleability and characteristics, e.g., biocompatability, of the original foam. For example, it has been difficult to construct safe, durable wound dressings. Moreover, industrial composite articles with increased durability, malleability and strength have been sought for many years. What is needed is a method of adhering the substrate to the polymer foam without adversely affecting the desired properties of the original untreated foam or substrate, e.g., biocompatibility or moisture vapor transfer rate. Methods for achieving adhesion between layers of a composite material typically involve a combination of surface modification techniques. Several types of surface modification exist. One type of surface m...

Claims

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Application Information

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IPC IPC(8): A44B19/00B05B7/04B32B3/26B32B37/12C08GC09J5/00
CPCB32B37/12B32B37/1284Y10T156/10C09J5/00B32B2305/022Y10T428/249986Y10T428/249981Y10T428/249984Y10T428/249982
Inventor DETERT, JAMES W.STORMONT, JONATHANLIBBY, FREDKENNEDY, T. SCOTTWINICOV, HERBERT
Owner RYNEL
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