Water resistant undercast liner

Abstract

The present invention provides an undercast liner for being applied to an anatomical shape of a patient and overlaid with a cast material. The undercast liner includes an elongate fabric having two opposing faces and an intermediate spacer area that both separates and interconnects the opposed faces. The liner is constructed at least in part of hydrophobic, water resistant monofilament yarn for providing enhanced water resistance, light weight, breathability and resistance to collapse and degradation due to moisture and bacteria during extended use of the liner. The liner has sufficient stretch in both a length-wise and width-wise direction to facilitate conforming the undercast liner around the anatomical shape without wrinkling during application.

1 . An undercast liner for being applied to an anatomical shape of a patient and overlaid with a cast material, comprising: 
 an elongate fabric having two opposing faces;    an intermediate spacer area that both separates and interconnects the opposing faces; and    wherein the fabric is constructed at least in part of hydrophobic, water resistant monofilament yarn for providing enhanced water resistance and has sufficient stretch in both a length-wise and width-wise direction to facilitate conforming the undercast liner around the anatomical shape without wrinkling during application.    
   
   
       2 . The undercast liner according to  claim 1 , wherein the yarn is selected from the group consisting of polypropylene, polyester, polyethylene and nylon.  
   
   
       3 . The undercast liner according to  claim 1 , wherein the fabric is formed by one or more fabric-forming techniques selected from the group consisting of weaving, knitting non-woven, and stitching.  
   
   
       4 . The undercast liner according to  claim 1 , wherein the fabric is treated with a finish to provide at least one of: additional water resistance, anti-bacterial, anti-odor, aromatherapy characteristics or a combination thereof.  
   
   
       5 . The undercast liner according to  claim 1 , wherein an adhesive coating is positioned on at least one of the inner and outer faces to of the fabric to aid in application of the fabric to the patient.  
   
   
       6 . The undercast liner according to  claim 5 , wherein the adhesive is preferably a low tack, pressure sensitive adhesive selected from the group consisting of acrylic and silicone adhesive.  
   
   
       7 . The undercast liner according to  claim 1 , wherein the fabric has higher elongation in the width direction than in the length direction for allowing greater stretch during application.  
   
   
       8 . The undercast liner according to  claim 1 , wherein the monofilament yarn has a diameter of at least 0.03 mm.  
   
   
       9 . The undercast liner according to  claim 8 , wherein the monofilament yarn has a diameter of between approximately 0.05 and approximately 0.25 mm.  
   
   
       10 . An undercast liner comprising: 
 a fabric having an inner face and an outer face constructed using a pillar and inlay stitch wherein the inner face and the outer face are spaced apart to from a spacer area constructed using a needle V;    the fabric being constructed with yarn having a diameter from approximately 0.03 to approximately 0.25 mm; and    the fabric being formed such that it has at least 50 courses per meter and weighs between approximately 50 to approximately 400 grams per square meter.    
   
   
       11 . An undercast liner according to  claim 10 , wherein the fabric weighs between approximately 100 to approximately 250 grams per square meter and a has a nominal thickness when not compressed or under tension of approximately 1.5 to approximately 3.5 mm.  
   
   
       12 . An undercast liner according to  claim 10 , the fabric being treated with at least one of a fluorochemical, silicone, other water repellant finish, and a combination thereof for improving drainage and providing faster drying.  
   
   
       13 . An undercast liner for being applied to an anatomical shape of a patient and overlaid with a cast material, comprising: 
 a tubular fabric having two opposing faces and an intermediate spacer area that both separates and interconnects the opposing faces;    the fabric is constructed at least in part of hydrophobic, water resistant monofilament yarn for providing enhanced water resistance, light weight, breathability and resistance to collapse and degradation due to moisture and bacteria during extended use of the liner; and    the fabric has sufficient stretch in both a length-wise and width-wise direction to facilitate conforming the undercast liner around the anatomical shape during application.    
   
   
       14 . An undercast liner according to  claim 10  wherein the fabric includes a water repellant finish to improve drainage and provide faster drying.  
   
   
       15 . An undercast liner for being applied to an anatomical shape of a patient and overlaid with a cast material is provided, comprising: 
 an elongate fabric in roll form, the fabric having two opposing faces and an intermediate spacer area that both separates and interconnects the opposing faces;    the fabric is constructed at least in part of hydrophobic, water resistant monofilament yarn; and    the fabric has sufficient stretch in both a length-wise and width-wise direction to facilitate conforming the undercast liner around the anatomical shape during application.    
   
   
       16 . An undercast liner according to  claim 15 , wherein the monofilament yarn has a diameter of between approximately 0.05 and approximately 0.25 mm.  
   
   
       17 . An undercast liner according to  claim 15 , wherein the liner is constructed using a pillar and inlay stitch on the inner and outer faces and a needle V in the spacer area.  
   
   
       18 . An undercast liner according to  claim 16 , wherein the yarn has a diameter of approximately 0.03 to approximately 0.25 mm.  
   
   
       19 . An undercast liner according to  claim 16 , wherein the fabric is formed with at least 50 courses per meter and weighs between approximately 50 to approximately 400 grams per square meter.  
   
   
       20 . An undercast liner according to  claim 16 , wherein the liner weighs between approximately 100 to approximately 250 grams per square meter and has a nominal thickness when not compressed or under tension of approximately 1.5 to approximately 3.5 mm.