Medical bandage substrate, medical bandage, and medical bandaging product with low abrasion side edges and method

1. A substrate for a medical bandage, comprising:

(a) an elongate fabric having two opposed major faces connected by yarns extending between the faces, the yarns having a predetermined, relatively high modulus sufficient to provide rigidity to the fabric when conformed to an injury site and hardened by activation of a reactive system applied to the fabric;

(b) two opposed, relatively narrow and longitudinally-extending side marginal areas formed on the fabric and defining two opposed side edges, the marginal areas being formed to provide a sufficient degree of softness and flexibility when conformed to an injury site and hardened by activation of a reactive system applied to the marginal areas of the fabric to thereby reduce abrasion between the marginal areas of the substrate and the injury site; and

(c) a plurality of ingress channels formed by wales omitted at intervals along the length of the substrate;

wherein the fabric comprises a warp knitted fabric.

2. A substrate according to claim 1 , wherein the marginal areas are formed at least partially of yarns having a predetermined, relatively low modulus.

3. A substrate according to claim 2 , wherein the marginal areas are formed of low modulus yarns selected from the group consisting of polyester, polyethylene and polypropylene, and have a transverse extent of between about 1 to 15 wales.

4. A substrate according to claim 3 , wherein the marginal areas have a transverse extent of between about 4 to 7 wales.

5. A substrate according to claim 1 , wherein the fabric and the marginal areas comprises a warp knitted double fabric, and the marginal areas are formed at least partially of low modulus yarns are selected from the group consisting of polyester, polyethylene and polypropylene.

6. A substrate according to claim 5 , wherein the yarn count range is between about 20 Tex and about 136 Tex.

7. A substrate according to claim 5 , wherein the yarn count range is between about 44 Tex and about 136 Tex.

8. A substrate according to claim 5 , wherein the fabric that forms the substrate comprises about 450-580 courses per meter and about 15-25 wales per 10 centimeters.

9. A substrate according to claim 1 , wherein the marginal areas are knitted and comprise a more open knitted structure in relation to the knitted structure of the fabric.

10. A substrate according to claim 1 , wherein the fabric comprises a warp knitted double fabric constructed from yarns selected from the group consisting of glass, high tenacity polyester, polypropylene, aramid, and ultra high molecular weight polyethylene.

11. A substrate according to claim 1 , wherein the fabric thickness ranges from 1 mm to 10 mm.

12. A substrate according to claim 1 , wherein the fabric has a weight of about 500 to about 3000 grams per square meter.

13. A substrate for a medical bandage, comprising:

(a) an elongate fabric having two opposed major faces connected by yarns extending between the faces, the yarns having a predetermined, relatively high modulus sufficient to provide rigidity to the fabric when conformed to an injury site and hardened by activation of a reactive system applied to the fabric;

(b) two opposed, relatively narrow and longitudinally-extending side marginal areas formed on the fabric and defining two opposed side edges, the marginal areas being formed to provide a sufficient degree of softness and flexibility when conformed to an injury site and hardened by activation of a reactive system applied to the marginal areas of the fabric to thereby reduce abrasion between the marginal areas of the substrate and the injury site; and

(c) the marginal areas comprising a knitted construction having an open knitted structure in relation to the knitted structure of the fabric, wherein the marginal areas are formed at least partially of yarns having a predetermined, relatively low modulus.

14. A medical bandage, comprising:

(a) an elongate fabric having two opposed major faces connected by yarns extending between the faces, the yarns having a predetermined, relatively high modulus sufficient to provide rigidity to the fabric when conformed to an injury site and hardened by activation of a reactive system applied to the fabric;

(b) two opposed, relatively narrow and longitudinally-extending side marginal areas formed on the fabric and defining two opposed side edges, the marginal areas being formed to provide a sufficient degree of softness and flexibility when conformed to an injury site and hardened by activation of a reactive system applied to the marginal areas of the fabric to thereby reduce abrasion between the marginal areas of the fabric and the injury site; and

(c) a reactive system applied to and into the thickness of the fabric, the reactive system having a first state wherein the fabric remains in a flexible, conformable condition and a second state wherein the reactive system hardens, simultaneously hardening the substrate fabric into a desired conformation; and

wherein the reactive system comprises a moisture-curable resin, and wherein liquid ingress channels in the fabric are adapted to facilitate uniform distribution of water onto and through the thickness of the fabric.

15. A medical bandage according to claim 14 , wherein the fabric comprises a warp knitted double fabric constructed from yarns selected from the group consisting of glass, high tenacity polyester, polypropylene, aramid, and ultra high molecular weight polyethylene.

16. A medical bandage according to claim 14 , and including a soft, flexible protective material covering at least one of the major faces of the fabric and adapted to pass water therethrough and onto the fabric.

17. A medical bandage according to claim 14 , wherein the bandage is in a precut length suitable for a particular medical use.

18. A medical bandage according to claim 14 , wherein the bandage is in the form of a roll from which desired lengths may be cut as needed.

19. A medical bandaging product, comprising:

(a) a sleeve formed of moisture-impervious material and sealable to prevent entry of moisture;

(b) a medical material positioned in the sleeve and sealed therein against entry of moisture until use, the medical material comprising:

(i) an elongate fabric having two opposed major faces connected by yarns extending between the faces, the yarns having a predetermined, relatively high modulus sufficient to provide rigidity to the fabric when conformed to an injury site and hardened by activation of a reactive system applied to the fabric;

(ii) two opposed, relatively narrow and longitudinally-extending side marginal areas formed on the fabric and defining two opposed side edges, the marginal areas being formed to provide a sufficient degree of softness and flexibility when conformed to an injury site and hardened by activation of a reactive system applied to the marginal areas of the fabric to thereby reduce abrasion between the marginal areas of the fabric and the injury site;

(c) a reactive system impregnated into or coated onto the fabric, the system remaining stable when maintained in substantially moisture-free conditions and hardening upon exposure to sufficient moisture to form a rigid, self supporting structure; and

(d) a soft, flexible protective material covering both major faces of the fabric along its length to provide a cushioning barrier between the fabric and the skin of a patient when the material is in use; and

wherein the fabric comprises a warp knitted fabric, and further wherein ingress channels are formed by wales omitted at intervals along the length of the fabric in one or more of a chain, inlay and center stitch of the fabric.

20. A medical bandaging product according to claim 19 , and including a soft, flexible protective material wrapped around and enclosing both major faces and the longitudinally extending side edges of the fabric.

21. A medical bandaging product according to claim 19 , wherein the fabric comprises a warp knitted double fabric.

22. A substrate according to claim 19 , wherein the marginal areas are formed at least partially of yarns having a predetermined, relatively low modulus.

23. A substrate according to claim 19 , wherein the marginal areas are knitted and comprise a more open knitted structure in relation to the knitted structure of the fabric.