Absorbent pads and methods of manufacturing
View Patent ↗The embodiments disclosed herein relate to absorbent pads. The absorbent pads can be used as cleansing wipes, and can be used to clean various objects, including gloves, medical appliances, and elongate medical devices. The absorbent pads can include a polymer matrix and a reinforcement member. Methods of manufacturing the absorbent pads can include physically cross-linking a polymer solution or foam to form a cross-linked polymer matrix. One or more freeze-thaw cycles can be used to cross-link the polymer solution or foam.
1. A method of manufacturing an absorbent pad, comprising:
obtaining a polymer solution;
mixing the polymer solution to form a foam;
dispensing the foam into a mold apparatus; and
curing the foam to form a cross-linked polymer matrix, wherein curing the foam comprises at least one freeze-thaw cycle, the freeze-thaw cycle comprising:
a freezing step; and
a thawing step.
2. The method of claim 1 , wherein the polymer solution comprises a polymer or copolymer of polyvinyl alcohol, polyhydroxyethylmethacrylate, polyacrylate, polyacrylic acid, polyamine, polyamide, or derivatives or mixtures thereof.
3. The method of claim 1 , wherein the polymer solution comprises between about 10% and about 20% by weight of a polymer material.
4. The method of claim 1 , wherein the polymer solution comprises at least one of a surfactant, an emulsifier, a wetting agent, a foaming agent, a thickening agent, or a stabilizing agent.
5. The method of claim 1 , wherein curing the foam comprises at least two freeze-thaw cycles.
6. The method of claim 1 , wherein the freezing step of the freeze-thaw cycle comprises subjecting the foam to temperatures below about −10° C.
7. The method of claim 6 , wherein the foam is subjected to temperatures below about −10° C. for greater than about 10 hours.
8. The method of claim 1 , wherein the thawing step of the freeze-thaw cycle comprises subjecting the foam to temperatures of between about 20° C. and about 30° C.
9. The method of claim 1 , further comprising disposing a reinforcement member into the mold apparatus, wherein the step of disposing the reinforcement member occurs prior to curing foam.
10. The method of claim 1 , wherein the reinforcement member comprises a mesh or scrim.
11. The method of claim 1 , wherein the mold apparatus is configured to impart a texture to a surface of the cross-linked polymer matrix.
12. The method of claim 1 , further comprising impregnating the cross-linked polymer matrix with at least one of an anticoagulant, an antimicrobial, or a cleansing solution.
13. The method of claim 1 , wherein the cross-linked polymer matrix is hydrophilic, absorbent, and elastic.
14. The method of claim 1 , wherein the cross-linked polymer matrix comprises a water-swellable hydrogel having a porous structure.
15. The method of claim 1 , wherein the polymer matrix is configured to be hydrated and dehydrated.
16. The method of claim 1 , wherein the thickness of the cross-linked polymer matrix is between about 1.0 mm and about 2.5 mm.
17. The method of claim 1 , wherein the cross-linked polymer matrix is lint free, non-fibrous, and non-particulate.