US3683921A - Absorbent sponges - Google Patents

Absorbent sponges Download PDF

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US3683921A
US3683921A US3683921DA US3683921A US 3683921 A US3683921 A US 3683921A US 3683921D A US3683921D A US 3683921DA US 3683921 A US3683921 A US 3683921A
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per square
square yard
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Berry A Brooks
Norman R Eisdorfer
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BERRY A BROOKS
NORMAN R EISDORFER
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BERRY A BROOKS
NORMAN R EISDORFER
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/01Non-adhesive bandages or dressings
    • A61F13/01021Non-adhesive bandages or dressings characterised by the structure of the dressing
    • A61F13/01029Non-adhesive bandages or dressings characterised by the structure of the dressing made of multiple layers
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15577Apparatus or processes for manufacturing
    • A61F13/15699Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/22Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing macromolecular materials
    • A61L15/24Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives thereof
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284Application of adhesive
    • B32B37/1292Application of adhesive selectively, e.g. in stripes, in patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • DTEXTILES; PAPER
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    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/488Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
    • DTEXTILES; PAPER
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    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D04H1/495Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet for formation of patterns, e.g. drilling or rearrangement
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/593Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/534Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F2013/00361Plasters
    • A61F2013/00727Plasters means for wound humidity control
    • A61F2013/00731Plasters means for wound humidity control with absorbing pads
    • A61F2013/00744Plasters means for wound humidity control with absorbing pads containing non-woven
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/534Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad
    • A61F2013/53445Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having an inhomogeneous composition through the thickness of the pad from several sheets
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61FFILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00Bandages or dressings; Absorbent pads
    • A61F13/15Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F13/539Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers
    • A61F2013/5395Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers with thermoplastic agent, i.e. softened by heat
    • A61F2013/53958Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers with thermoplastic agent, i.e. softened by heat with separate adhesive layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/38Meshes, lattices or nets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00Polyalkenes
    • B32B2323/10Polypropylene
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2535/00Medical equipment, e.g. bandage, prostheses or catheter
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659Including an additional nonwoven fabric
    • Y10T442/671Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material

Definitions

  • ABSORBENT SPONGES [72] Inventors: Berry A. Brooks, 284 English Court, Somerville, NJ. 08876; Norman R. Eisdorfer, 14 Colburn Rd., East Brunswick, NJ. 08816 [22] Filed: Aug. 17, 1970 [21] Appl. No: 64,455
  • ABSTRACT A bonded, self-sustaining, single-use, disposable absorbent product having excellent softness and excellent strength, bulk, resilience and resistance to surface abrasion and linting, particularly when wet, comprising a plurality of layers of reinforced nonwoven textile fabrics, each of said layers comprising a synthetic polymeric thermoplastic reinforcing reticulate grid netting covered on each side by at least one layer of overlapping, intersecting fibers mechanically intertwined around and bonded to the individual elements of said grid netting, said plurality of layers of reinforced nonwoven textile fabrics being secured together at their peripheral edges to form a bonded, self-sustaining, single-use, disposable absorbent product, having excellent softness and excellent strength, bulk, resilience and resistance to surface abrasion and linting particularly when wet.
  • Thepresent invention relates to absorbent products for absorbing and retaining body fluids, blood, and other body exudates. More particularly, the present invention relates to absorbent products, such as surgical are equally applicable to other absorbent products wherein the properties of softness, strength, bulk, resilience, and resistance to surface abrasion and linting, particularly when wet, are of interest.
  • absorbent products include, for example, general use sponges and pads, diapers, surgical dressings, postoperative dressings, underpads, combine pads, compresses, and the like.
  • a laparotomy is a medical or surgical procedure or operation involving an incision through any part of the abdominal wall into the abdominal cavity.
  • laparotomy sponges are used to absorb relatively large amounts of body fluids, blood, and other body exudates.
  • Such laparotomy sponges are also used to Wall off organs, cover the outer edges of the incision, handle organs, pack off areas in the inci sion opening so that itis easier to gain access to other organs in the cavityopening, etc.
  • Such cotton gauze sponges are customarily used to carry out such functions.
  • Such cotton gauze sponges are usually made from 4 plies of USP. 28 X 24 mesh cotton gauze and usually come in sizes of 12 inches X 12 inches square, 18 inches X 18 inches square, 18 inches X 4 inches oblong, 36 inches X 8 inches oblong, etc.
  • Such cotton gauze sponges are subject to many disadvantages. For example, they have a relatively high initial cost and have relatively high subsequent I labor costs due to their re-usable nature requiring laundering and sterilization after each use, hand removal of pills or neps from the surface to prevent them from falling off during an operation, repairing, resewing, hand-folding, etc. Also, the danger of infection and cross-contamination is a very serious consideration.
  • the used sponges even though thoroughly washed and sterilized, are usually spotted with blood or other stains from previous medical or surgical procedures or operations and thereby present a very unsightly and somewhat repulsive appearance. The esthetic and psychological effect of such a stained or spotted sponge is not very pleasing.
  • such a single-use, disposable sponge or'pad may be made by forming a synthetic polymeric thermoplastic reinforcing grid netting defining a pattern of open areas, placing at least one layer of absorbent fibrous materials on each side of the grid netting, adhering the layer of fibrous materials to the grid netting, then forming a laminate of a plurality of layers of such grid netting and fibrous materials adhered thereto, and securing the plurality of layers together at their peripheral edges, and internally of such edges, if so desired.
  • FIG. 1 is a simplified, schematic, perspective, exploded view of a reinforced nonwoven textile fabric composed of a plurality of fibrous webs and a centrally located reinforcing reticulate grid netting, prior to assembling and processing in accordance with the principles of the present invention
  • FIG. 2 is a fragmentary, perspective view of a preferred embodiment of the reinforcing reticulate grid netting of FIG. I;
  • FIG. 3 is a simplified, schematic drawing of a preferred embodiment of apparatus and a method suitable for utilizing the principles of the present invention for making the reinforced nonwoven textile fabric such as shown in FIG. 1;
  • FIG. 4 is a simplified, schematic drawing of a preferred embodiment of apparatus and a method suitable for utilizing the principles of the present invention for assembling a plurality of reinforced nonwoven textile fabrics such as shown in FIG. 1;
  • FIG. Si is a simplified, schematic drawing of another preferred embodiment of apparatus and a method for utilizing the principles of the present invention for assembling a plurality of reinforced nonwoven textile fabrics such as shown in FIG. 1;
  • FIG. 6 is a simplified plan view of a laparotomy sponge as prepared by utilizing the principles of the present invention
  • FIG. 7 is a partially exploded, magnified cross-sectional view of the laparotomy sponge of FIG. 6, taken on the line 7 7 thereof, in the direction indicated by the arrows.
  • FIG. 8 is a simplified plan view of another laparotomy sponge as prepared by utilizing the principles of the present invention.
  • FIG. 9 is a partially exploded, magnified, cross-sectional view of the laparotomy sponge of FIG. 8, taken on the line 9-9 thereof, in the direction indicated by the arrows.
  • a reinforced nonwoven textile fabric 10 comprising an outer layer- 12 of fibrous material, a centrally or internally disposed reinforcing reticulate plastic grid netting l4, and another outer layer 18 of fibrous material.
  • Each outer layer 12 and 18 may comprise merely a single fibrous web or may comprise a number of laminated fibrous webs which are brought together, usually to create a heavier weight layer.
  • the fibers which are employed to make up the layers 12 and 18 are highly absorbent and are preferably of a cellulosic nature, such as cotton or rayon. However, other fibers, either synthetic, man-made, or natural, may be used in various proportions for special purposes or for special effects.
  • polyamides nylon 6/6, nylon 6, nylon 610, nylon l 1, etc.
  • acrylic fibers Acrilan, Creslan, Orlon, etc.
  • modacrylic fibers Dynel, Verel, etc.
  • polyester fibers Dacron, Kodel, etc.
  • polyolefinic fibers polyethylene, polypropylene, etc.
  • cellulose ester fibers cellulose acetate, cellulose triacetate, etc.
  • the fibrous layers 12, 18 placed on each side of the plastic grid netting 14 be composed of the same type of fiber or the same denier or even that one layer be made of only one type of fiber or that both layers have the same weight. Blends and mixtures of the above referred to fibers are, of course, possible in substantially any range of proportions or weights, as desired or required.
  • the fibers be of textile staple length or equivalent length, or at least be cardable, that is to say, they should be from about one-half inch in average length up to about 3 inches or more in average length.
  • Shorter fibers, down to about three-sixteenths inch or less in average length may be added in various proportions to comprise up to about 50 percent by weight of the web, or may comprise the entire web, particularly where the original method of web formation involved a fluid deposition of fibers, such as in a conventional or modified aqueous papermaking process, or in air deposition techniques In such fluid deposition processes, average fiber lengths of about three-six teenths inch or one-eighth inch are preferred to the extremely short fiber lengths of down to about one-sixteenth or one thirty-second inch and even below, such as used in conventional papermaking processes for making paper.
  • Such very short fibers, such as these found in conventional papermaking processing are of use, however, particularly for economic reasons or in those uses and applications wherein the tendencies toward paper-like properties and characteristics of paper
  • the denier of the synthetic or man-made fibers used in forming the fibrous webs is preferably in the range of the approximate thickness of the natural fibers mentioned and consequently deniers in the range of from about 1 to about 3 are preferred. However, where greater opacity or greater covering power is desired, deniers of down to about three-fourths or even about onehalf may be employed. Where desired, deniers of up to l0, 15 or higher, may be used.
  • the minimum and maximum denier are, of course, dictated by the desires or requirements for producing a particular fibrous web or nonwoven fabric, and by the machines and methods for producing the same.
  • the weight of the individual fibrous layer which is placed on each side of the reinforcing reticulate grid netting may be varied within relatively wide limits, depending upon the requirements of the finished product.
  • the minimum weight of one individual fibrous layer contemplated by the present invention is, however, about grains per square yard, usually ob tained from one card or by plying two card webs.
  • the maximum weight for one individual fibrous layer may range upwards to about 600 or more grains per square yard depending upon the intended use of the final product.
  • individual fibrous layer weights of from about grains per square yard to about 300 grains per square yard are contemplated.
  • the number of fibrous layers in the reinforced nonwoven fabric should, of course, be at least two, that is, one layer on each side of the plastic grid netting, in order to obtain the desired or required effects. Three, four, five or more layers, in any desired arrangement may be used with the plastic grid netting in the center or closer to one surface, as desired, where special effects are desired.
  • a particular bonded reinforced nonwoven fabric may comprise more than one reinforcing reticulate plastic grid netting.
  • the reinforced nonwoven fabric may comprise three layers of fibrous webs as the two outermost layers and a central layer, with the two plastic grid nettings sandwiched in alternating fashion between the three layers of fibrous webs.
  • Other arrangements and other configurations involving a plurality of plastic grid nettings and a plurality of fibrous webs are also possible depending upon the needs and requirements of the particular situation.
  • carded or fiber oriented webs are used as the fibrous webs, it is not essential that the predominant direction of fiber orientation be the same for all the card webs. If desired, the card webs may be cross-laid with their predominant direction of fiber orientation at right angles or other angles to each other, whereby various strength relationships are available.
  • the reticulate grid netting 14 which is positioned between the fibrous layers 12 and 18 is a thermoplastic synthetic polymeric material, such'as polypropylene, polyethylene (low density 0.91-0.94, medium density 0.94, and high density 0.95-0.96 and above); polyamides especially nylon 66 (hexamethylene diamineadipic acid); nylon 610 (hexamethylene diaminesebacic acid) and nylon 6 (polycaprolactam); polyesters, especially polyethylene glycol terephtholate; polyacrylics or modacrylics; etc.
  • thermoplastic synthetic polymeric material such'as polypropylene, polyethylene (low density 0.91-0.94, medium density 0.94, and high density 0.95-0.96 and above); polyamides especially nylon 66 (hexamethylene diamineadipic acid); nylon 610 (hexamethylene diaminesebacic acid) and nylon 6 (polycaprolactam); polyesters, especially polyethylene glycol terephtholate; polyacrylics
  • High density polyethylene having a density generally greater than 0.94 grams per cubic centimeter, as well as predominantly isotactic polypropylene are of exceptional applicability to the principles of the present inventive concept.
  • the reticulate grid netting 14 comprises intersecting rods or monofilaments 15 running in one direction and rods or monofilaments 15a running cross-wise to the rods or monofilaments 15.
  • the intersecting rods or monofilaments l5 and 150 are preferably basically integral at their intersections l6 and define a regular pattern comprising a plurality of rectangular open areas 17 therebetween.
  • Methods and apparatus for making such reticulate grid nettings are disclosed in greater detail in copending, commonly assigned patent applications Ser. No. 736,356, filed July 12, 1968; Ser. No. 799,438, filed Feb. 14, 1969; Ser. No. 857,989,filed Sept. 15, 1969.
  • the open areas 17 are preferably rectangular or square, as shown, but it is to be appreciated that other geometric shapes may be used. Such other shapes include diamonds, parallelograrns, rhomboids, polygons, etc., and are created by having the rods or monofilaments 15 and 15a intersect each other at acute or obtuse angles, other than the 90 angle shown.
  • the length of the sides of these geometric figures in the grid netting may vary relatively widely depending upon the needs and the requirements of the particular situation. Sides as small as about one-twelfth inch or about one-eighth inch are of use, although sides having a length of about one-fifth inch to about one-quarter inch are more commonly employed. Longer sides of up to about one-half inch or about three-quarter inch are utilizable, and even longer lengths are useful in special situations.
  • the grid netting is usually described in terms of its mesh size.
  • a 3 X 5 grid netting means that there are three monofilaments per inch in one direction and five monofilaments per inch in the other direction.
  • Many other mesh sizes are of use. Such include: 4 X 9; 4X4;7X9;etc.
  • Another important feature of the grid netting 14 is more grains per square yard are found satisfactory. Within the more commercial aspects of the present invention, however, a range of from about grains per' square yard to about 80 grains per square yard is deemed desirable.
  • the physical nature and the chemical composition of the grid netting 14, however, is such that it possesses a sufficient degree of potential residual shrinkage at the time it is inserted between the layers of fibrous materials.
  • Potential shrinkages of only about 3 percent are of use in the application of the present invention but larger potential shrinkages are preferred in the range of from about 5 percent to about 1.0 percent or l5 percent. Larger potential shrinkages up to 20 percent or 25 percent or even larger are useful in special applications.
  • the degree of residual or potential shrinkage which exists in the grid netting is controlled to a large extent by the particular processing and manufacturing techniques used in the original formation and pre-treatment of the grid netting itself. This is a very important factor. For example, the greater the degree of elongation, stretching, and drawing of the polymeric material during its original manufacture and the resulting greater degree of molecular orientation created in the polymeric material, then the greater is the tendency of the polymeric material to return or shrink in the the fact that the thicknesses of the intersections of the filaments l5 and 15a can be made the same as the thicknesses of the interstitial filaments between'the intersections whereby there are no high spots or low spots as is present in a conventionally woven gauze or scrim in which the intersections of the warp and filling are considerably thicker than the individual thicknesses of the interstitial warp and filling between the intersections.
  • This flatness feature is, of course, a great advantage in the manufacture of the laparotomy sponge in that there is more intimate and more complete contact of all parts of the grid netting with the adjacent fibrous webs. Additionally, there is a complete absence of high spots or bumbs in the laparotomy sponge which is advantageous during its subsequent use in a medical or surgical procedure or operation.
  • the weight of the plastic grid netting may vary relatively widely depending upon the needs and requirements of the particular situation. Weights as low as about 15 grains per square yard up to about 150 or material to shrink is recognized in the art and such recognition leads to the second factor affecting the shrinkage characteristics of the polymeric material.
  • the second factor exists in the extent and in the duration of the annealing and relaxing treatment which is used to stabilize or heat-set the grid netting subsequent to its original formation.
  • Use of extensive annealing or other heat-setting treatments such as normally used previously in theart with such products will generally tend to reduce'the tendency of the formed grid netting to shrink whereby its shrinkage capability substantially disappears.
  • the use of less extensive annealing or heat stabilizing treatments or the complete ommission thereof will serve to maintain the tendency of the grid netting to shrink after formation whereby it is rendered suitable for the purpose of the present invention.
  • a third factor in the development of the shrinkage properties lies in the subsequent treatment of the laminated fabric'containing the grid netting having the residual or potential shrinkage characteristics.
  • a heat treatment such as a drying or resin-curing treatment at elevated temperatures and the grid netting is maintained in a tensioned condition
  • the shrinkage characteristics are usually unable to assert themselves and substantially no shrinkage takes place.
  • the heat treatment takes place under controlled tension conditions, such as the passage of the laminated fabric over heated drying cans which rotate with controlled, predetermined progressively decreasing surface speeds, then the shrinkage'characteristics can be asserted and thegrid netting will shrink.
  • Such shrinkage properties and characteristics are of great advantage in controlling the thickness and bulk of the final product as well as the degree of rippling or puckering which can be imparted thereto.
  • Such controlled rippling and puckering may be brought about at any desired time but preferably takes place during the heat sterilization of the absorbent product prior to use.
  • the bulk or thickness is increased, and the softness and surface interest are enhanced.
  • the extent of the increase in bulk or thickness, softness and surface interest, etc. depends, of course, to a large extent upon the differential in shrinkage properties between the thermoplastic grid netting and the fibrous webs which are adhered thereto.
  • the peripheral edges of the thermoplastic grid netting and the fibrous webs are autogenously bonded together, and inasmuch as the thermoplastic grid netting shrinks to a far greater degree than the fibrous webs adhered thereto, the puckering and rippling in the central area bounded by the peripheral edges will be greater when the difference in shrinkage properties and characteristics is greater.
  • FIG. 3 there is shown apreferred embodiment of a method and apparatus suitable for assembling an outer fibrous layer 22, a reinforcing reticulate plastic grid netting 24, and another outer fibrous layer 28 to form a reinforced nonwoven fabric
  • Pressure-applying rotatable rolls 29, 30 and 31, 32 operate to press the various layers together into a laminated structure 33.
  • This laminated structure 33 is then passed through a conventional fluid-rearranging apparatus 36 so as to rearrange the individual fibers thereof into a KEYBAK bundled non-woven textile fabric possessing a predetermined pattern of fabric openings and fiber bundles.
  • Such apparatus is described ingreater detail in U. Pat. No. 2,862,251 which issued to Frank Kalwaites on Dec. 2, 1958 and reference thereto, particularly to FIGS. 7-10 thereof, is incorporated herein.
  • the rearrangement of the fibers during such a KEYBAK bundling process is particularly advantageous in that the individual fibers of the fibrous layers are rearranged and moved about sufiiciently so that they become mechanically intertwined and wrapped around the individual rods or filaments of the plastic grid netting.
  • Such mechanical adherence of the fibrous layers to the grid netting is particularly advantageous in the case of those polymeric grid materials which are more difficult to adhesively bond to the fibrous layers.
  • the rearranged laminated structure 33' is then passed through conventional adhesive-applying or bonding apparatus 34 wherein a bonding agent is applied.
  • a bonding agent is applied.
  • the specific form of bonding method and apparatus is not critical and basically any well known form of rotatable print rolls which are suitably engraved or embossed as to pick up the proper amount of bonding agent from a trough or tank and deposit the same in the desired pattern on the laminated fabric is suitable.
  • the binder used in adhering the plurality of webs and the grid netting together may be selected from a large group of such binders known to industry. It is necessary, however, that a binder be used which can satisfactorily adhere to and bond the different types of fibers together or at least mechanically interlock the fibers together.
  • binders available for such a purpose are: regenerated cellulose; vinyl resins such as plasticized or unplasticized polyvinyl acetate, polyvinyl chloride, polyvinyl alcohol, etc., either as homopolymers or copolymers; acrylic resins such as ethyl acrylate, methyl methacrylate, butyl acrylate, butyl methacrylate, etc.; butadiene resins such as butadiene-acrylonitrile, butadiene-styrene, etc.; other synthetic rubbers; natural rubber; urea resins such as urea-formaldehyde, cyclic urea-formaldehyde, etc.; aldehyde resins such as melamine-formaldehyde, phenolformaldehyde, resorcinol-formaldehyde, etc.; epoxy resins; cellulose derivatives such as carboxymethyl cellulose; hydroxyethyl cellulose, etc.;
  • binders may be added, as desired, in the form of emulsions, solutions, dispersions, plastisols, powders, etc.
  • Autogenic bonding preferably by heat and/or pressure and/or solvents, may also be used when thermoplastic fibers are present.
  • the percent add-on of such binder materials may be varied within relatively wide limits, depending to a large extent upon the specific binder employed and upon the type, weight and thickness of the fibrous web. For some binders, as low as about 1 percent by weight up to about 12 percent by weight, based on the weight of the dry webs being bonded, has been found satisfactory. For other binders, as high as from about 15 to about 50 percent by weight has been found preferable. Within the more commercial aspects of the present invention, however, from about 2 to about 35 percent by weight based on the weight of the dry webs being bonded has been found desirable.
  • binder pattern falls within the scope and range of binder areas previously used in the prior art. Examples of some of these binder patterns may be found in the abovementioned U. S. Pat. Nos. 2,705,687 and 2,705,688 or in U. S. Pat.'No. 2,880,111. Specific examples of binder areas, binder shapes and sizes, and interbinder spaces are noted in said patents.
  • the rearranged laminated structure 33" with the applied binder is then forwarded to a suitable heating device such as a heated oven 35 which is maintained at an elevated temperature in order to dry and, if necessary, cure the applied binder.
  • a suitable heating device such as a heated oven 35 which is maintained at an elevated temperature in order to dry and, if necessary, cure the applied binder.
  • Temperatures in the range of from about 212 to about 325 F. are normally used with exposure times of from about 20 seconds to about 30 minutes.
  • the combined mechanical and adhesive bonding between the fibrous webs and the plastic grid netting thus forms a superior bond to that obtained by mechanical bonding alone or by adhesive bonding alone.
  • the bonded nonwoven fabric 10' is then forwarded to suitable wind-up rolls 37 to be used as supply rolls for the next procedure.
  • the temperature, pressure, and duration of time of the heat-sealing are, of course, interdependent. Higher temperatures permit the use of shorter exposure times and lower pressures, and lower temperatures require the use of longer exposure times and higher pressures. Temperatures in the range of from about 225 to about 400 F. or 600 F., for periods of a part of a second, say 0.2 second, or a few seconds, say 1 or 2, up to or seconds, are possible.
  • the pressures employed are generally in the range of from about 30 pounds per square inch (gauge) to about 100 pounds per square inch (gauge) and preferably from about 40 pounds per square inch to about 80 pounds per square inch (gauge).
  • the heat sealing takes place along the peripheral edges of the laminate 39 as well as internally thereof, as desired or required.
  • Pressure is exerted by the heated platen 42 which presses the laminate 39 against a stationary base or anvil 44.
  • a conventional cutting device (not shown) is used to cut the endless length of laminate 39 into shorter lengths 46 which are forwarded by conveying means such as a conveyor belt 48 to an assembly zone 50 where tapes or loops 52 are applied, as desired or required.
  • FIG. 5 there is shown a variation of the method and apparatus illustrated in FIG. 4.
  • supply rolls 57 forward four reinforced nonwoven fabrics through the nips of rotatable pressure-applying rolls 58, 60 to form a laminate 59.
  • This laminate is then passed through the nip of heated rotatable sealing and cutting rolls 62 and 64 which serve to press together and heat the laminate at its peripheral edges and internally thereof, as desired or required.
  • Conventional cutting means (not shown) are used to sever the endless lengths of the laminate 59 into short lengths 66 which are forwarded by conveying means such as a conveyor belt 68 to an assembly zone 70 where tapes of loops 72 are attached, as desired or required.
  • FIGS. 6 and 7 illustrate one typical form of bonding used to bond the laminate 39 at its peripheral edges 51 and internally thereof.
  • FIG. 6 shows one manner of attaching the tapes or loops 52 to the main body of the laparotomy sponge.
  • FIGS. 8 and 9 illustrate another typical form of bond ing used to bond the laminate 59 at its peripheral edges 71 and internally thereof.
  • FIG. 8 shows another manner of attaching the tapes or loops 72 to the main body of the laparotomy sponge.
  • each ply comprising a polypropylene reinforcing re'ticulate grid 3
  • X 5 netting weighing 45 grains per square yard covered on each side by a fibrous web of rayon fibers 1%. denier and 1 9/ 16 inches staple length, each web weighing 185 grains per square yard to provide a weight of 414 grains per square yard per ply or a total weight (four plies) of 1,656 grains per square yard.
  • each ply comprising a 6 X 4 rayon leno'weave weighing 71 grains per square yard covered on each side by a fibrous web of rayon fibers 1% denier and 1 9/16 inches staple length, each web weighing 185 grains to provide a weight of 440 grains per square yard per ply or a total weight of 1,760 grains per square yard.
  • each ply comprising a 6 X 6 rayon leno weave weighing 106 grains per square yard covered on each side by a fibrous web of rayon fibers 1% denier and 1 9/16 inches staple length, each web weighing 185 grains per square yard to provide a weight of 476 grains per square yard per ply or a total weight of 1,904 grains per square yard.
  • the four samples are formed into laparotomy sponges in accordance with the method illustrated in FIG. 4. They are sterilized to shrink and ripple to varying degrees of surface interest, softness, bulk and rippled effect as a result of such sterilization.
  • Sample 2 containing the thermoplastic grid netting bonds autogenously at its peripheral edges and internally thereof as illustrated in FIGS. 6 and 7.
  • the thermoplastic grid netting softens and causes the bonding.
  • Samples 1, 3 and 4 not containing any thermoplastic grid netting do not bond autogenously and are stitched and sewn together at their peripheral edges and internally thereof.
  • Sample 1 (four plies of bonded nonwoven fabric without any reinforcement) is unsatisfactory. The cross tensile strengths are too low; and the wet and dry bulk and resilience are too low.
  • Sample 2 (4 plies of bonded nonwoven fabric with grid netting reinforcement) is satisfactory. Tensile strengths are excellent; wet and dry bulk and resilience are good; and softness is excellent. The puckered, rippled effect creates desirable softness, bulk, and surface interest.
  • Sample 3 (four plies of bonded nonwoven fabric with 6 X 4 leno weave reinforcement) is unsatisfactory. Softness is too low; wet and dry resilience are too low; and fabric is too harsh and has an unsatisfactory hand.
  • Sample 4 (four plies of bonded nonwoven fabric with 6 X 6 leno weave reinforcement) is unsatisfactory. Softness is too low; wet and dry resilience are too low; and fabric is too harsh and has an unsatisfactory hand.
  • Example II The procedures of Example 1 are followed substantially as set forth therein with the exception that the HA-8 ethyl acrylate polymer binder is replaced with a viscose regenerated cellulose binder. All other conditions remain the same.
  • Example II The test results are comparable to those obtained in Example I. Only the second sample (four plies of bonded nonwoven fabric with a grid netting reinforcement) is completely satisfactory.
  • Example 1 The procedures of Example 1 are followed substan tially as set forth therein with the exception that the PIA-8 ethyl acrylate polymer binder is replaced by a Goodrich 2600Xl20 self cross-linkable. acrylic copolymer binder. All other conditions remain the same.
  • test results are comparable to those obtained in Example 1. Only the second sample (four plies of bonded nonwoven fabric with a grid netting reinforcement) is completely satisfactory.
  • Example IV The procedures of Example I are followed substantially as set forth therein with the exception that there are (a) apertures, (b) 225 apertures, and (c) 144 apertures formed per square inch rather than apertures during the fluid-rearranging process.
  • the 144 and 225 apertured designs are square designs; that is, the apertures are aligned in rows in two directions in checkerboard fashion.
  • the 95 and 165 apertured designs have the apertures staggered or nesting into each other in adjacent rows.
  • Example II The test results are comparable to those obtained in Example I. Only the second sample (four plies of bonded nonwoven fabric with a grid netting reinforce ment) is completely satisfactory.
  • Example V The procedures of Example I are followed substantially as set forth therein with the exception that in Sample 2, the 3 X 5 polypropylene reinforcing reticulate grid netting weighs: (a) 39 grains per square yard; (b) 47 grains per square yard; and (c) 55 grains per square yard rather than 45 grains per square yard.
  • Example VI The procedures of Example I are followed substantially as set forth therein with the exception that in Sample 2 the reinforcing reticulate grid netting is (a) predominantly 'isotactic polypropylene and (b) high density polyethylene having a density between 0.95 and 0.96 grams per cubic centimeter.
  • each ply comprising a 6 X 4 rayon leno weave weighing 71 grains per square yard covered on each side by a fibrous web of rayon fibers 1% denier and 1 9/16 inches staple length, each web weighting 185 grains to provide a weight of 440 grains per square yard per ply or a total weight of 1,760 grains per square yard.
  • each ply comprising a 6 X 6 rayon leno weave weighing.
  • each ply comprises two fibrous webs each weighing about 172 grains per square yard to provide a total weight (four plies) of 1,376 grains per square yard.
  • the six samples are formed into laparotomy sponges in accordance with the method illustrated in FIG. 4. They are sterilized by heating. Only Sample 2 shrinks and puckers to a desirable surface interest and appearance, and possesses excellent bulk and a pleasing rippled effect as a result of such sterilization and the differential shrinking effect.
  • Sample 2 containing the thermoplastic grid netting bonds autogenously at its peripheral edges and internally thereof, as illustrated in FIGS. 6 and 7.
  • Samples 1 and 3-6 which do not contain a thermoplastic grid netting do not bond autogenously and are stitched and sewn together.
  • 36 inch X 36 inch squares are cut from each sample and are autoclaved at 250 F. for minutes. Each sample is then soaked in distilled water for thirty seconds and allowed to absorb 150ml. Excess water absorption is removed by squeezing. Each sample is then placed in a 1,000 ml. tall Pyrex beaker (4 inch internal diameter) in a randomlyballed manner. A plastic beaker (3% inch external diameter) is placed on top on the randomly balled sample and various weights are added, causing the sample to compress. The degree of compression is observed. All weights are then removed and the amount of spring-back or resilience is observed. The results are as follows:
  • Example Vllll The procedures of Example V11 are followed substantially as set forth therein with the exception that (0.9 percent) saline solution, containing sodium chloride in the proportion of nine to 1000, is substituted for the distilled water.
  • the linting properties and characteristics of these samples are determined as follows: 10 samples of each sponge are steam sterilized at 250 F. for 30 minutes and then conditioned at 65 percent Relative Humidity and 70 F. for at least 4 hours. The samples are then weighed. The samples are then immersed and dipped five times in 1,000 ml. saline solutions in a 1,500 m1. beaker. The samples are squeezed once to remove all free running water which is returned to the 1,500 ml. beaker. The wet samples are then placed on a black filter paper on a Buchner funnel and the remainder of the collected 1,000 ml. saline solution filtered through the sample on the black filter paper. The samples are then washed with distilled water. The lint is then collected and weighed and averages for the ten samples are calculated. The results are as follows:
  • a reinforced bonded rearranged KEYBAK nonwoven fabric is prepared by placing a fibrous web of rayon fibers 1% denier and 1 9/16 inches staple length weighing 750 grains per square yard on each side of a polypropylene reinforcing reticulate 4 X 9 grid netting weighing 100 grains per square yard. Rearrangement forms fabric openings and fiber bundles, whereby many individual fibers are intertwined and wrapped around the grid netting. Adhesive bonding with I-IA-8, a self cross-linkable ethyl acrylate copolymer, bonds the nonwoven fabric. Autogenic heat sealing at the peripheral edges and internally thereof is rendered more difficult due to the heavier weight of the fibrous webs.
  • the heavier weight of the polypropylene grid netting helps in the autogenic bonding.
  • the resulting product is relatively stiff and has poor drape and hand. It is not soft.
  • the reinforced nonwoven fabric shrinks as doall such fabrics but the instant fabric becomes stiff and boardy. It is not suitable for use as a surgical sponge or pad.
  • Samples 1, 3 and 4 do not shrink materially and remain relatively flat without any enhancement of the surface interest, softness or bulk. These products are not considered satisfactory for use as laparotomy sponges.
  • a laparotomy sponge is formed of six plies of reinforced, bonded, rearranged KEYBAK nonwoven fabric, each ply comprising a central layer of polypropylene reinforcing reticulate grid 3 X 5 netting weighing 40 grains per square yard, covered bn each side by a fibrous web of rayon fibers 1% denier and 1 9/16 inches staple length, weighing grains, for a total weight (six plies) of 1,920 grains per square yard.
  • the laparotomy sponge is found satisfactory in use.
  • An improved sterilized surgical sponge comprising a plurality of layers of reinforced, non-woven, textile fibers; said layers each comprising a synthetic, polymeric thermoplastic reinforcing grid covered on each side by at least one layer of a non-woven textile fabric of overlapping, intersecting fibers mechanically intertwined around the individual elements of said grid; said grid having, prior to sterilization, a shrinkage potential of about 3 to about 25 percent; said plurality of reinforcedlayers being secured together continuously at their peripheral edges and intermittently interfrom about three-sixteenths inch and to about 3 inches.
  • thermoplastic reinforced grid is made of polypropylene.

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NL7111337A (enrdf_load_stackoverflow) 1972-02-21
FR2102312B1 (enrdf_load_stackoverflow) 1977-01-21
ZA715487B (en) 1973-03-28
FR2102312A1 (enrdf_load_stackoverflow) 1972-04-07
GB1367959A (en) 1974-09-25

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