Stabilized foam for medical PSA substrate

Abstract

The present invention provides a stabilized foam having a crosslinked closed cell polyolefin foam having a top and a bottom surface; a stabilizing layer disposed onto at least one of the top and the bottom surfaces of the crosslinked closed cell polyolefin foam; and an adhesive layer disposed onto at least one of the top or the bottom surfaces. Also provided is a method of preparing the stabilized foam, a method of treating a wound, scrape, abrasion or skin puncture, a method of maintaining cleanliness of an operation incision site, suture site, catheter insertion site, or an intentional skin breach site, a method of monitoring electrical impulses during EKG or delivering electrical impulses in a TENS or biofeedback therapy, and a method of softening the collagen deposits on a scar and reducing the raised or keloid portion of the scar over time.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a stabilized foam. More particularly, the present invention relates to a stabilized foam suitable for use in medical and skin contact applications, having a crosslinked closed cell polyolefin foam, at least one stabilizing layer and at least one adhesive layer. [0003] 2. Description of the Related Art [0004] For a variety of medical and skin contact products including first-aid bandages, tapes, absorbent dressings, wound covers and closures, scar reduction therapy pads, electrode grounding pads and drug delivery patches, foam is used as the exterior layer away from the skin. A skin contact adhesive is applied to this foam to provide adhesion to the skin. Many adhesives are in use and include acrylics in hot melt, solvent solution or aqueous suspension, synthetic block copolymer and other hot melts, silicone gels and silicone from solvent or hot melt systems. Often such foam films are...

AI Technical Summary

Benefits of technology

[0021] It is an object of the present invention to provide a stabilized foam that exhibits softness and conformability properties approaching or even exceeding those of PVC.

Problems solved by technology

An alternative unstabilized polyolefin foam material is presently in limited use.

There are several disadvantages to the use of PVC foams.

These plasticizers have been investigated for possible medical safety risk with a concern of migration from the foam into the skin.

Additionally, when bandages and tapes utilizing PVC foam are sterilized or simply aged, shrinkage of the foam is often observed.

This shrinkage can be minor and is generally considered to be only a visual problem.

But it can also be a more severe problem that can cause finished product rejections and / or can cause a visible exposed adhesive edge resulting from the PVC foam shrinking while the adhesive layer remains stable.

Shrinkage in the PVC foam can also cause curling or rolling of the finished product.

The plasticizer used in the PVC can also limit the selection of fillers and “actives” that could potentially be incorporated into or on the foam.

Additionally, via a process known as “plasticizer migration” the PVC plasticizer can flow to adjacent materials and effectively limits what materials and adhesives can be adjacent to it.

A typical problem is softening and expansion, even wrinkling, of an adjacent layer.

However, it also has several undesirable properties.

Polyolefin foams tend to be stiff and rigid when flexed and are easily torn or ripped.

It is believed that this cross-linking leads to the stiffness and tearing tendency.

In summary, if polyolefin foam is made to be thin and conformable, it is very weak and tears.

Conversely, if thickness or density is increased to decrease tearing, the foam is stiff and not conformable to the skin.

Stiffness is generally not a desired property for foam used in a skin contact application.

Thus, despite the presence of an adhesive layer, stiff foams do not remain attached during flexing and, as a result, tends to lift off the skin.

Although strong in the machine-direction, so is the tendency to tear.

For many potential end-use applications, this pronounced tear is a problem.

The physical apertures of the perforation imparted for breathability additionally weaken the foam and further promote tearing.

The low level of dimensional stability makes PO foams difficult to process through converting operations.

Tensions within the unwinding pull-roll and die cutting zones result in elongation often with delayed recovery or no recovery.

This tension and stretch imparted in the foam will often relax after processing and result in differential shrinkage of components and / or curling of the finished products.

As thinner grades of PO foam are converted, the stretch and curling problems become exaggerated.

However, there have been no suitable alternatives found to date that meet all the design criteria listed above.

The reasons for the absence of suitable alternatives include the following: (1) polyvinyl alcohol foams are difficult to manufacture and not readily commercially available; (2) polyurethane foams offer good physical properties but are very expensive; (3) silicone foams also offer good properties but are more costly than the polyurethanes; and (4) although polyolefin foams are relatively low cost, they have poor dimensional stability, exhibit stretching especially when thin and tend to rip or tear when stressed, particularly when a bandage is removed from a wound.

Thus, because of their stiffness, polyolefin foams generally have poor adhesion to the skin and are not conformable to the skin when flexed.