AU2020233610A1

AU2020233610A1 - An X-ray Detectable Gauze Sponge or Swab

Info

Publication number: AU2020233610A1
Application number: AU2020233610A
Authority: AU
Inventors: Ben Chen
Original assignee: Multigate Medical Products Pty Ltd
Current assignee: Multigate Medical Products Pty Ltd
Priority date: 2014-11-11
Filing date: 2020-09-14
Publication date: 2020-10-01
Also published as: AU2015255220A1

Abstract

The present invention relates to a medical sponge or swab which includes at least one layer of gauze and an X-ray detectable thread. The X-ray detectable thread is attached to the layer of gauze. The X-ray detectable thread is woven in 5 and heat bonded to the layer ofgauze. 8

Description

An X-ray Detectable Gauze Sponge or Swab

Technical Field

The present invention relates to a gauze sponge or swab. More particularly, the present invention relates to an X-ray detectable gauze sponge or swab.

Background of the Invention

Surgical dressings such as gauze swabs are used for handling open wounds and swabbing procedures during surgical operations. It is commonplace to fabricate a gauze swab out of a cut piece of absorbent gauze being folded into a square swab in such a manner that cut edges are invisible or stitched. The number of layers or plies of the gauze in the swab and its dimensions may vary according to surgical requirements.

An X-ray detectable thread is commonly used as a radiopaque component which is attached to products like gauze swabs, gauze sponges, laparotomy sponges etc. X-ray detectable threads are usually non-toxic and non-fluorescent 1s and useful for after-operational safety examination.

Conventionally, X-ray detectable threads are attached to surgical dressings by either thermal-heating or weaving methods. The two methods may be differentiated by utilising two different types of X-ray detectable thread for attachment to the gauze. The weaving method involves weaving the X-ray detectable thread into the cotton gauze during the weaving phase, as shown in Figure 1 (prior art 1). In contrast, the thermal-heating method involves bonding a different type of thread onto the weaved cotton threads by heat and pressure after the gauze swab is made, as shown in Figure 2 (prior art 2).

Both of the two methods referred to above however have a shortcoming in that the thread is prone to dislodgement during use.

It is an object of the present invention to provide an X-ray detectable gauze sponge or swab which may overcome or at least ameliorate the above shortcoming, or which will at least provide a useful alternative.

Summary of the Invention

According to the present invention, there is provided a medical sponge or swab including: at least one layer of gauze; an X-ray detectable thread attached to the layer of gauze; wherein the X-ray detectable thread is woven in and heat bonded to the layer of gauze.

In a preferred embodiment, the layer of gauze has a weave structure including weft and warp threads or yarns. Preferably, the weft threads or yarns are crossed before and after each warp thread or yarn thereby keeping the weft threads or yarns firmly in place.

Preferably, the X-ray detectable thread is woven in the weave structure going over-and-under the weft or warp threads or yarns.

Preferably, the X-ray detectable thread has a plurality of points or areas of contact with the weft or warp threads or yarns, the points or areas of contact being where the X-ray detectable thread goes over or under the weft or warp threads or yarns. More preferably, the X-ray detectable thread includes a binder adapted to facilitate thermal bonding. The binder is preferred to include a web having a thermoplastic element. The thermoplastic element may be in the form of one of the following: homofil fibre, powder, film, hot melt or as a part of bicomponent fibre. The thermoplastic element is preferred to be capable of becoming viscous under the application of thermal energy thereby functioning as an adhesive. As such, if and when heat is applied, the X-ray detectable thread woven in the gauze is bonded to the weft or warp threads or yarns at each of the points or areas of contact.

Brief Description of the Drawings

The invention may be better understood from the following non-limiting description of a preferred embodiment, in which:

Figure 1 is a perspective view of a layer of a prior art gauze swab having an X-ray detectable thread attached thereto by way of weaving;

Figure 2 is a perspective view of a prior art gauze swab having an X-ray detectable thread attached thereto by way of head bonding;

Figure 3 is a perspective view of a gauze swab in accordance with a preferred embodiment of the present invention;

Figure 4 is a perspective view of a layer of the gauze swab of Figure 3 with an X-ray detectable thread; and

Figure 5 is a cross sectional view of the layer of gauze swab of Figure 4 taken along line A-A.

Detailed Description of the Drawings

1s It should be noted that in the present specification, 'thread' and 'yarn' are meant to be interchangeable in referring to an elongate continuous length of fibres suitable for use in the production of a surgical dressing such as a gauze sponge or swab.

Referring to Figure 3, a multi-ply gauze swab 10 is shown having an X-ray detectable thread 12 attached to one of the multiple layers 14 of gauze. The X ray detectable thread 12 takes the place of one of the cotton threads which form the gauze swab 10. Each layer of the gauze is a thin fabric with a loose open weave. The X-ray detectable thread 12 has a barium sulphate content of 60 %

or higher rendering it visible under medical x-ray machines.

As shown in Figure 4, the X-ray detectable thread 12 is woven in and heat bonded to a middle gauze layer 16. The middle layer 16 has a weave structure 18 which includes weft and warp threads 20 & 22, respectively. The weft threads 20 are crossed before and after each warp thread 22 thereby keeping the weft threads 20 firmly in place. The X-ray detectable thread 12 is woven in the weave structure 18 going over-and-under the weft threads 20.

Turning to Figures 4 and 5, the X-ray detectable thread 12 has multiple areas 24 of contact with the weft threads 20. The areas 24 of contact are crossover or overlapping regions where the X-ray detectable thread 12 goes over or under the weft threads 20.

The X-ray detectable thread 12 includes a binder (not shown) which is capable of facilitating thermal bonding. In this embodiment, the binder has a web having a thermoplastic element. The thermoplastic element may be in the form of one of the following: homofil fibre, powder, film, hot melt or as a part of bicomponent fibre. The thermoplastic element becomes viscous under the application of 1s thermal energy thereby functioning as an adhesive bonding the X-ray detectable thread 12, which is already woven in the gauze layer 16, to the weft threads 20 at the areas 24 of contact. The thermal energy may be generated by ironing for example. The areas 24 of contact, being the bonding regions, are fixed by subsequentcooling.

It should be noted that the X-ray detectable thread has good elasticity with breaking elongation and good colour fastness. Also, it is capable of adhering at around 130°C with a short pressing time and is not susceptible to de pigmentation.

Now that a preferred embodiment of the present invention has been described in some detail, it will be apparent to a skilled person in the art that the X-ray detectable gauze swab of the present invention may offer at least the following advantages:

1. it enhances the stability of the X-ray detectable thread thereby reducing the likelihood of dislodgement caused by for example the thread getting caught on a stainless steel instrument during a procedure;

2. it enhances the integrity and reliability of the gauze swab as a product in ensuring that it gets picked up by an X-ray machine if inadvertently left inside a body after a procedure or an operation; and

3. it is economical to manufacture.

Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. For example, the X-ray detectable thread may be woven into the gauze layer 16 in addition to the existing cotton threads instead of in place of one of the cotton threads. Also, the X-ray detectable thread may replace a weft thread instead of a warp thread or take the orientation of a weft thread. As such, it would go over-and-under the warp threads. All such variations and modifications are to be considered within the scope and spirit of the present invention the nature of which is to be determined from the foregoing description.

Claims

1. A medical sponge or swab including: atleastone layer ofgauze; an X-ray detectable thread attached to the layer of gauze; wherein the X-ray detectable thread is woven in and heat bonded to the layer of gauze.

2. The medical sponge or swab of claim 1, wherein the layer of gauze has a weave structure including weft and warp threads or yarns.

3. The medical sponge or swab of claim 2, wherein the weft threads or yarns are crossed before and after each warp thread or yarn thereby keeping the weft threads or yarns firmly in place.

4. The medical sponge or swab of either claim 2 or 3, wherein the X-ray detectable thread is woven in the weave structure going over-and-under the weft or warp threads or yarns.

5. The medical sponge or swab of any one of the claims 2 to 4, wherein the X-ray detectable thread has a plurality of points or areas of contact with the weft or warp threads or yarns, the points or areas of contact being where the X-ray detectable thread goes over or under the weft or warp threads or yarns.

6. The medical sponge or swab of any one of the preceding claims, wherein the X-ray detectable thread includes a binder adapted to facilitate thermal bonding.

7. The medical sponge or swab of claim 6, wherein the binder includes a web having a thermoplastic element.

8. The medical sponge or swab of claim 7, wherein the thermoplastic element is in the form of one of the following: homofil fibre, powder, film, hot melt or as a part of bicomponent fibre.

9. The medical sponge or swab of either claim 7 or 8, wherein the thermoplastic element is capable of becoming viscous under the application of thermal energy thereby functioning as an adhesive.

1O.The medical sponge or swab of claim 9, wherein if and when heat is applied, the X-ray detectable thread woven in the gauze is bonded to the weft or warp threads or yarns at each of the points or areas of contact.