Method for making elastic bandaging material

• US 4,737,400 A
• Filed: 06/25/1985
• Issued: 04/12/1988
• Est. Priority Date: 10/20/1983
• Status: Expired due to Term

• Current Assignee: Sherwood Services AG
• Original Assignee: Expandover Incorporated
• Inventors: Murphy, Thomas S. Jr., Willingham, Raymond H., Edison, Charles J.
• Primary Examiner(s): MCCAMISH, MARION E
• Application Number:
  US06/748,693
• Time in Patent Office: 1,022 Days
• Field of Search: 427/381, 427/389.9, 427/394
• US Class Current: 442/151
• CPC Class Codes: A61F 13/0273 Adhesive bandages for winding around limb, trunk or head, e.g. cohesive
• CPC Class Codes: A61F 13/58 Adhesive tab fastener elements A61F13/5611, A61F13/5616, A61F13/66 take precedence
• CPC Class Codes: A61F 2013/00102 oblong
• CPC Class Codes: A61F 2013/00119 elastic
• CPC Class Codes: A61F 2013/00238 characterised by way of knitting or weaving
• CPC Class Codes: A61F 2013/15821 characterized by the apparatus for manufacturing
• CPC Class Codes: A61F 2013/5666 connected to itself A61F13/58 and A61F13/62 take precedence
• CPC Class Codes: A61L 15/24 Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives thereof A61L15/225 takes precedence
• CPC Class Codes: A61L 15/58 Adhesives
• CPC Class Codes: C08L 33/00 Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
• CPC Class Codes: Y10S 428/906 Roll or coil
• CPC Class Codes: Y10S 602/90 Method of making bandage structure
• CPC Class Codes: Y10T 428/28 Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2839 with release or antistick coating
• CPC Class Codes: Y10T 428/2848 Three or more layers
• CPC Class Codes: Y10T 442/2754 Pressure-sensitive adhesive

Abstract

A method of producing breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material from a fabric which has been formed by interweaving essentially non-stretch filling yarns with stretch and non-stretch warp yarns, said method comprising conveying a continuous web of said fabric in a substantially relaxed condition, applying steam to the relaxed fabric, and applying an adhesive layer to the back side of the relaxed fabric.

A breatable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material comprising a fabric formed by essentially non-stretch filling yarns interwoven with stretch and non-stretch warp yarns, the fabric normally being in a relaxed condition, an adhesive applied in a level layer to the entire back side of the relaxed fabric such that, in its relaxed state, the bandaging material has an adhesive layer which has a smooth exposed surface and a substantially uniform depth throughout, and such that, in its stretched state, the adhesive bandaging material has an adhesive layer which has a non-uniform, discontinuous surface and a depth which varies from being relatively great where the non-stretch warp yarns extend to the back side of the fabric to being relatively slight or even zero where the non-stretch warp yarns extend away from the back side of the fabric.

Claims

1. A breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material comprising:

(a) a fabric having face and back sides and formed by essentially non-stretch filling yarns interwoven with warp yarns, said warp yarns consisting essentially of non-stretch textile warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on the back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said fabric normally being in a relaxed condition; and

(b) a pressure-sensitive, permanently tacky, adhesive applied in a level layer to the entire back side of said relaxed fabric to produce an adhesive bandaging material which in its relaxed state has an adhesive layer which has a smooth exposed surface and a substantially uniform depth throughout, and which in its stretched state has an adhesive layer which has a nonuniform, discontinuous surface and which has a depth which is relatively great where said non-stretch warp yarns extend to said back side of said fabric and which has a depth which is relatively slight or zero where said non-stretch warp yarns extend away from said back side of said fabric.

2. The bandaging material of claim 1 wherein each said stretch warp yarn has an elastomeric spandex core filament wrapped with essentially non-stretch fibers.

3. The bandaging material of claim 2 wherein said non-stretch yarns are cotton.

4. The bandaging material of claim 1 wherein said non-stretch yarns are cotton.

5. The bandaging material of claim 1 further including a coating applied to said face side of said fabric, said coating comprising a release agent to improve unwindability of a coiled roll of said bandaging material.

6. The bandaging material of claim 5 wherein said coating comprises a latex including a silicone release agent.

7. The bandaging material of claim 5 wherein said coating further comprises a non-fray agent to reduce fraying of the edges of said fabric during and after tearing.

8. The bandaging material of claim 7 wherein said coating comprises a latex including an acrylic polymer non-fray agent.

9. The bandaging material of claim 1 further including a coating applied to said face side of said fabric, said coating comprising a non-fray agent to reduce fraying of the edges of said fabric during and after tearing.

10. The bandaging material of claim 9 wherein said coating comprises a latex including an acrylic polymer non-fray agent.

11. The bandaging material of claim 1 wherein said adhesive is hypo-allergenic.

12. An assembly comprising a core onto which the bandaging material of Claim 1 is wound into a coiled roll.

13. A breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material comprising:

(a) a dry fabric having face and back sides and formed by essentially non-stretch filling yarns interwoven with warp yarns, said warp yarns consisting essentially of non-stretch textile warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on the back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said fabric normally being in a relaxed, fully contracted condition with said interwoven filling and warp yarns being exfoliated and spread and with said non-stretch yarns expanded and loosened;

(b) a dry coating on the entirety of said face side of said fabric, said coating comprising a release agent to improve unwindability of a coiled roll of said bandaging material; and

(c) a dry pressure-sensitive, permanently tacky, adhesive in a level layer on the entire back side of said relaxed fabric, said adhesive bandaging material in its relaxed state having an adhesive layer which has a smooth exposed surface and a substantially uniform depth throughout and in its stretched state having an adhesive layer which has a non-uniform, discontinuous surface and a depth which is relatively great where said non-stretch warp yarns extend to said back side of said fabric and a depth which is relatively slight or zero where said non-stretch warp yarns extend away from said back side of said fabric.

14. A breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material comprising:

(a) a dry fabric having face and back sides and formed by essentially non-stretched filling yarns interwoven with warp yarns, said warp yarns consisting essentially of non-stretch textile warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on the back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said fabric normally being in a relaxed, fully contracted condition with said interwoven filling and warp yarns being exfoliated and spread and with said non-stretch yarns expanded and loosened;

(b) a dry coating on the entirety of said face side of said fabric, said coating comprising a non-fray agent to reduce fraying of the edges of said fabric during and after tearing;

(c) a dry pressure-sensitive, permanently tacky, adhesive in a level layer on the entire back side of said relaxed fabric, said adhesive bandaging material in its relaxed state having an adhesive layer which has a smooth exposed surface and a substantially uniform depth throughout and in its stretched state having an adhesive layer which has a non-uniform, discontinuous surface and a depth which is relatively great where said non-stretch warp yarns extend to said back side of said fabric and a depth which is relatively slight or zero where said non-stretch warp yarns extend away from said back side of said fabric.

15. A breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material comprising:

(a) a dry fabric having face and back sides and formed by essentially non-stretch filling yarns interwoven with warp yarns, said warp yarns consisting essentially of non-stretch textile warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on the back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said fabric normally being in a relaxed, fully contracted condition with said interwoven filling and warp yarns being exfoliated and spread and with said non-stretch yarns expanded and loosened;

(b) a dry coating on the entirety of said face side of said fabric, said coating comprising a release agent, to improve unwindability of a coiled roll of said bandaging material, and a non-fray agent, to reduce fraying of the edges of said fabric during and after tearing; and

(c) a dry pressure-sensitive, permanently tacky, adhesive in a level layer on the entire back side of said relaxed fabric, said adhesive bandaging material in its relaxed state having an adhesive layer which has a smooth exposed surface and a substantially uniform depth throughout and in its stretched state having an adhesive layer which has a non-uniform, discontinuous surface and a depth which is relatively great where said non-stretch warp yarns extend to said back side of said fabric and a depth which is relatively slight or zero where said non-stretch warp yarns extend away from said back side of said fabric.

16. The method of producing breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material from a fabric having face and back sides and which has been formed by interweaving essentially non-stretch filling yarns with warp yarns, said warp yarns consisting essentially of non-stretch warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on said back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said method comprising the following steps:

(a) conveying a continuous web of said fabric in a substantially relaxed condition and applying heat and moisture to said relaxed fabric to exfoliate and spread said interwoven filling and warp yarns and to expand and loosen said non-stretch yarns thereby facilitating a fuller contraction of said stretch yarns; and

(b) applying a layer of pressure-sensitive, permanently tacky adhesive to said back side of said conveyed fabric while said conveyed fabric is in a substantially relaxed condition.

17. The method of claim 16 wherein said application of heat and moisture is an application of steam.

18. The method of claim 16 wherein said layer of adhesive is applied in a uniform depth to said back side of said fabric while said fabric is in a substantially relaxed condition.

19. The method of claim 18 wherein said step of applying a layer of adhesive to said back side of said conveyed fabric while it is in a substantially relaxed condition comprises applying a layer of adhesive to a conveyor by means of a doctor blade, contacting the exposed surface of said adhesive layer with said back side of said relaxed fabric and transferring said adhesive layer from said surface of said conveyor to said back side of said relaxed fabric to form a continuously smooth and level layer of adhesive on said back side of said fabric.

20. The method of claim 16 further including the step of applying a coating to said face side of said conveyed fabric, said coating comprising a release agent to improve unwindability of a coiled roll of said bandaging material.

21. The method of claim 20 wherein the temperature of said fabric during said method is maintained below approximately 235°

F.

22. The method of claim 20 wherein said coating applied to said face side of said conveyed fabric comprises a latex including a silicone release agent.

23. The method of claim 20 wherein said coating applied to said face side of said conveyed fabric further comprises a nonfray agent to reduce fraying of the edges of said fabric during and after tearing.

24. The method of claim 26 wherein the temperature of said fabric during said method is maintained below approximately 235°

F.

25. The method of claim 26 wherein said coating applied to said face side of said conveyed fabric comprises a latex including an acrylic polymer non-fray agent.

26. The method of claim 16 further including the step of applying a coating to said face side of said conveyed fabric, said coating comprising a non-fray agent to reduce fraying of the edges of said fabric during and after tearing.

27. The method of claim 26 wherein the temperature of said fabric during said method is maintained below approximately 235°

F.

28. The method of claim 26 wherein said coating applied to said face side of said conveyed fabric comprises a latex including an acrylic polymer non-fray agent.

29. The method of claim 16 including the step of drying said conveyed fabric immediately after applying said heat and moisture.

30. The method of claim 29 including the steps, after drying said conveyed fabric immediately after applying said heat and moisture, of:

(a) applying a coating to said face side of said conveyed fabric, said coating comprising a release agent to improve unwindability of a coiled roll of said bandaging material; and

(b) drying said conveyed fabric immediately after applying said coating;

(c) the temperature of said fabric during said method being maintained below approximately 235°

F.

31. The method of claim 29 including the steps, after drying said conveyed fabric immediately after applying said heat and moisture, of:

(a) applying a coating to said face side of said conveyed fabric, said coating comprising a non-fray agent to reduce fraying of the edges of said fabric during and after tearing; and

(b) drying said conveyed fabric immediately after applying said coating;

(c) the temperature of said fabric during said method being maintained below approximately 235°

F.

32. The method of claim 29 including the steps, after drying said conveyed fabric immediately after applying said heat and moisture, of:

(a) applying a coating to said face side of said conveyed fabric, said coating comprising a release agent, to improve unwindability of a coiled roll of said bandaging material, and a non-fray agent, to reduce fraying of the edges of said fabric during and after tearing; and

(b) drying said conveyed fabric immediately after applying said coating;

(c) the temperature of said fabric during said method being maintained below approximately 235°

F.

33. The method of claim 16 further including the final steps of winding said conveyed fabric into a roll and slitting said roll into a plurality of rolls of predetermined roll width.

34. The method of claim 16 wherein said non-stretch yarns comprise cotton yarns.

35. The method of claim 16 wherein each said stretch yarn comprises a spandex filament core around which are wrapped fibers including cotton fibers.

36. The method of claim 16 wherein the temperature of said fabric during said method is maintained below approximately 235°

F.

37. The method of claim 16 wherein said adhesive applied to said back side of said fabric is hypo-allergenic.

38. The method of producing breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material from a fabric having face and back sides and which has been formed by interweaving essentially non-stretch filling yarns with warp yarns, said warp yarns consisting essentially of non-stretch warp yarns interspersed with stretch warp yarns, said filling and stretch warp yarns woven in a pattern such that said stretch warp yarns have an average float length on said back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said method comprising the following steps:

(a) conveying a continuous web of said fabric in a substantially relaxed condition and applying heat and moisture to said relaxed fabric to exfoliate and spread said interwoven filling and warp yarns and to expand and loosen said non-stretch yarns thereby facilitating a fuller contraction of said stretch yarns;

(b) drying said conveyed fabric immediately after applying said heat and moisture;

(c) applying a coating to the entirety of said face side of said conveyed and dried fabric, said coating comprising a release agent to improve unwindability of a coiled roll of said bandaging material;

(d) drying said coating comprising said release agent on said conveyed fabric immediately after applying said coating;

(e) applying a layer of pressure-sensitive, permanently tacky adhesive to said back side of said conveyed fabric while it is in a substantially relaxed condition; and

(f) drying said adhesive layer on said conveyed fabric;

(g) the temperature of said fabric during said method being maintained below approximately 235°

F.

39. The method of producing breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material from a fabric having face and back sides and which has been formed by interweaving essentially non-stretch filling yarns with warp yarns, said warp yarns consisting essentially of non-stretch warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on said back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said method comprising the following steps:

(a) conveying a continuous web of said fabric in a substantially relaxed condition and applying heat and moisture to said relaxed fabric to exfoliate and spread said interwoven filling and warp yarns and to expand and loosen said non-stretch yarns thereby facilitating a fuller contraction of said stretch yarns;

(b) drying said conveyed fabric immediately after applying said heat and moisture;

(c) applying a coating to the entirety of said face side of said conveyed fabric, said coating comprising a non-fray agent to reduce fraying of the edges of said fabric during and after tearing;

(d) drying said coating comprising said non-fray agent on said conveyed fabric immediately after applying said coating;

(e) applying a layer of pressure-sensitive, permanently tacky adhesive to said back side of said conveyed fabric while it is in substantially relaxed condition; and

(f) drying said adhesive layer on said conveyed fabric;

(g) the temperature of said fabric during said method being maintained below approximately 235°

F.

40. The method of producing breathable, conformable, elastic, pressure-sensitive, permanently tacky, adhesive bandaging material from a fabric having face and back sides and which has been formed by interweaving essentially non-stretch filling yarns with warp yarns, said warp yarns consisting essentially of non-stretch warp yarns interspersed with stretch warp yarns, said filling and warp yarns woven in a pattern such that said stretch warp yarns have an average float length on said back side of said fabric which exceeds the average float length of said non-stretch warp yarns on said back side, said method comprising the following steps:

(a) conveying a continuous web of said fabric in a substantially relaxed condition and applying heat and moisture to said relaxed fabric to exfoliate and spread said interwoven filling and warp yarns and to expand and loosen said non-stretch yarns thereby facilitating a fuller contraction of said stretch yarns;

(b) drying said conveyed fabric immediately after applying said heat and moisture;

(c) applying a coating to the entirety of said face side of conveyed fabric, said coating comprising a release agent, to improve unwindability of a coiled roll of said bandaging material, and a non-fray agent, to reduce fraying of the edges of said fabric during and after tearing;

(d) drying said coating comprising said release and non-fray agents on said conveyed fabric immediately after applying said coating;

(e) applying a layer of pressure-sensitive, permanently tacky adhesive to said back side of said conveyed fabric while it is in a substantially relaxed condition; and

(f) drying said adhesive layer on said conveyed fabric;

(g) the temperature of said fabric during said method being maintained below approximately 235°

F.