Knit fabric for orthopedic support material
The invention relates to a knit fabric for orthopedic support material. The knit fabric comprises in the weft yarn in-lay/cross direction synthetic organic microdenier yarn of no greater than 1.5 denier per filament (dpf) and synthetic organic multi-filament yarn of greater than 2.5 denier per filament (dpf). It is impregnated with a curable resin which on activation with a curing agent forms a cast supporting the patient's limb. The knit fabric according to invention exhibits the high holding capacity of the resin over time, said capacity being sufficient to prevent resin leak from a resin-coated fabric.
1. A resin-coated sheet material comprising:
a knit fabric, said knit fabric comprising:
a weft yarn comprising:
a synthetic organic microdenier yarn of no greater than 1.5 denier per filament (dpf) and made of polyester, the synthetic organic microdenier yarn used in weft,
synthetic organic multi-filament yarn of greater than 2.5 denier per filament (dpf) and up to 6 dpf and made of polyester, the synthetic organic multi-filament yarn used in weft, wherein the synthetic organic microdenier yarn and the synthetic organic multi-filament yarn are air jet intermingled to form the weft yarn,
a synthetic organic non-microdenier stretchable yarn used in warp, and
a curable resin coated onto the knit fabric.
2. The resin-coated sheet material according to claim 1 , wherein the weight ratio of the synthetic organic microdenier yarn to yarn in total is 10-30%.
3. The resin-coated sheet material according to claim 1 , wherein the synthetic organic microdenier yarn is of 0.8-1.3 dpf.
4. The resin-coated sheet material according to claim 1 , wherein the synthetic organic multi-filament yarn is of 3.5-6 dpf.
5. The resin-coated sheet material according to claim 1 , wherein the threads of the synthetic organic multi-filament yarn are not twisted.
6. The resin-coated sheet material according to claim 1 , wherein the weight ratio of the synthetic organic microdenier yarn to the synthetic organic multi-filament yarn is between 1:1.3 to 1:6.
7. The resin-coated sheet material according to claim 1 , wherein the polyester is poly(ethylene terephthalate).
8. The resin-coated sheet material according to claim 1 , wherein a weight ratio of the synthetic organic non-microdenier stretchable yarn to yarn in total is 27-33%.
9. The resin-coated sheet material according to claim 1 , wherein the synthetic organic non-microdenier stretchable yarn is made of polyester.
10. The resin-coated sheet material according to claim 9 , wherein the polyester comprises poly(ethylene terephthalate), poly(trimethylene terephthalate) or their combinations.
11. The resin-coated sheet material according to claim 1 , wherein the curable resin is a water curable resin.
12. The resin-coated sheet material according to claim 11 , wherein the water curable resin is an isocyanate functional prepolymer.