Rapid setting composite article

Patent metadata

Field	Value
Publication number	US-2016270945-A1
Application number	US-201415027984-A
Country	US
Kind code	A1
Filing date	Oct 6, 2014
Priority date	Oct 7, 2013
Publication date	Sep 22, 2016
Grant date	—

Abstract

A fiber-reinforced composite article useful in supporting or immobilizing an injured body part is disclosed. The composite is a multi-layer, flexible precursor including fiber reinforcement plies, which can be rapidly cured into a rigid body using a thermosetting resin. Methods of making and using the same are also disclosed, along with kits containing such composite articles.

First claim

1 . A fiber-reinforced composite article useful in supporting or immobilizing an injured body part comprising:
a multi-layer body having opposing first and second major surfaces and comprising:
a fiber reinforcement layer;
an encapsulating film adjacent said fiber reinforcement layer; and
an optional insulating barrier adjacent said encapsulating film; and
a thermosetting resin, wherein said fiber reinforcement layer is impregnated with said thermosetting resin.

2 . The fiber-reinforced composite article of claim 1 , wherein said fiber reinforcement layer is a first fiber reinforcement layer, said multi-layer body comprising a second fiber reinforcement layer.

3 . The fiber-reinforced composite article of claim 2 , wherein said multi-layer body further comprises a resin distribution system, said resin distribution system being between said first fiber reinforcement layer and said second fiber reinforcement layer.

4 . (canceled)

5 . The fiber-reinforced composite article of claim 2 , wherein said multi-layer body further comprises a second encapsulating film adjacent said second fiber reinforcement layer.

6 . The fiber-reinforced composite article of claim 5 , wherein said multi-layer body further comprises a second insulating barrier adjacent said second fiber reinforcement layer.

7 . The fiber-reinforced composite article of claim 1 , wherein said fiber reinforcement is selected from the group consisting of fiberglass, carbon fiber, polyaramid, natural fibers.

8 . (canceled)

9 . The fiber-reinforced composite article of claim 1 , wherein said thermosetting resin is selected from the group consisting of ethylenically unsaturated polymerizable compounds including monomers and oligomers.

10 . The fiber-reinforced composite article of claim 1 , wherein said thermosetting resin is selected from the group consisting of cyanoacrylates, acrylates, and methacrylates.

11 . The fiber-reinforced composite article of claim 1 , wherein said thermosetting resin is a photo-curable resin.

12 . The fiber-reinforced composite article of claim 11 , wherein said multi-layer body further comprises a light source adjacent said encapsulating film, optionally a spacer or light diffuser layer between said light source and encapsulating film, and optionally a reflector adjacent said light source and/or said encapsulating film.

13 .- 14 . (canceled)

15 . The fiber-reinforced composite article of claim 1 , wherein said thermosetting resin is cured, said a multi-layer body being a rigid lamellar body.

16 .- 20 . (canceled)

21 . A method of rapidly supporting or immobilizing an injured body part, said method comprising:
providing a flexible, multi-layer body having opposing first and second major surfaces and comprising:
a fiber reinforcement layer;
an encapsulating film adjacent said fiber reinforcement layer; and
an optional insulating barrier adjacent said encapsulating film;
arranging said flexible, multi-layer body around or next to and in conformance with said injured body part with said insulating barrier adjacent to said body part; and introducing a thermosetting resin into said body, said resin impregnating said fiber reinforcement layer, wherein said resin cures in less than about 10 minutes after said introducing, to yield a rigid lamellar body, thereby supporting or immobilizing said injured body part.

22 . The method of claim 21 , wherein said multi-layer body further comprises a resin distribution tube, said thermosetting resin being introduced into said body via said resin distribution tube.

23 . The method of claim 22 , wherein said multi-layer body further comprises a tackifier, said tackifier enhancing the wicking of said resin.

24 . (canceled)

25 . A method of rapidly supporting or immobilizing an injured body part, said method comprising:
providing a flexible, multi-layer body having opposing first and second major surfaces and comprising:
a fiber reinforcement layer pre-impregnated with a thermosetting resin or a photo-curable resin;
an encapsulating film adjacent said fiber reinforcement layer; and
an optional insulating barrier adjacent said encapsulating film;
arranging said flexible, multi-layer body around or next to and in conformance with said injured body part with said insulating barrier adjacent to said body part; and exposing said thermosetting resin to a catalyst or exposing said photo-curable resin to light, wherein said resin cures in less than about 10 minutes after said exposing, to yield a rigid lamellar body, thereby supporting or immobilizing said injured body part.

26 . The method of claim 25 , wherein said catalyst is selected from the group consisting of air, oxygen, sulfur dioxide, water, hydroperoxides, or peroxides.

27 .- 30 . (canceled)

31 . A kit for rapidly supporting or immobilizing an injured body part, said kit comprising:
a composite precursor comprising a flexible, multi-layer body having opposing first and second major surfaces and comprising:
a fiber reinforcement layer;
an encapsulating film adjacent said fiber reinforcement layer; and
an optional insulating barrier adjacent said encapsulating film;
a thermosetting resin; and instructions for use thereof.

32 . The kit of claim 31 , wherein said thermosetting resin is in a container separate from said composite precursor.

33 . The kit of claim 31 , wherein said fiber reinforcement layer is pre-impregnated with said thermosetting resin.

34 . The kit of claim 33 , wherein said resin is a photo-curable resin, said multi-layer body further comprising:
a source of light adjacent said encapsulating film; an optional light-diffusing layer or spacer between said source of light and said encapsulating film; and one or more optional reflector layers adjacent said source of light and/or adjacent said encapsulating film.

35 .- 36 . (canceled)

Assignees

• Univ Wichita State
• Commercial Chemistries Llc

Inventors

• Tomblin John S
• Aldag Thomas
• Mccarvill William T
• Reuter Kimberly M
• White Joel D
• Meyer Andrea C

Classifications

• A61L15/125

  Mixtures of macromolecular compounds · CPC title

• A61F5/0585

  for the legs (toe correcting devices A61F5/019) · CPC title

• A61F5/05825 Primary

  Strips of substantially planar form · CPC title

• A61F5/05841

  for the limbs (A61F5/05816, A61F5/05833 take precedence) · CPC title

• A61F5/01

  Orthopaedic devices, e.g. long-term immobilising or pressure directing devices for treating broken or deformed bones such as splints, casts or braces · CPC title