Medical pad and system for thermotherapy

1. A method for making a medical pad for contact and thermal exchange with a patient, comprising:

providing a fluid circulation layer for containing a thermal exchange fluid circulatable therethrough;

connecting a first port to the fluid circulation layer for circulating the thermal exchange fluid into the fluid circulation layer;

connecting a second port to the fluid circulation layer for circulating the thermal exchange fluid out of the fluid circulation layer; and

adding a hydrogel layer to the fluid circulation layer so that the hydrogel layer extends across one side of the fluid circulation layer to define an adhesive surface for adherence to a patient's skin, the hydrogel layer including an ultraviolet light-cured composition, wherein:

the ultraviolet light-cured composition comprises:

a cross-linking copolymer in an amount of between about 25% to 30% by weight of the ultraviolet light-cured composition;

water in an amount of between about 25% to 35% by weight of the ultraviolet light-cured composition; and

glycerol in an amount of between about 27.5% to 32.5% by weight of the ultraviolet light-cured composition; and

the hydrogel layer has a thermal conductivity of between about 1.9 cal/hr-cm-° C. and 2.37 cal/hr-cm-° C.

2. The method for making a medical pad according to claim 1 , wherein the adhesive surface has a tack strength of between about 20 g and 65 g, as determined according to ISO 9665:1998(E).

3. The method for making a medical pad according to claim 1 , wherein the hydrogel layer has a thickness of between about 0.018″ and 0.04″.

4. The method for making a medical pad according to claim 3 , wherein the hydrogel layer has a thickness of between about 0.022″ and 0.032″.

5. The method for making a medical pad according to claim 1 , wherein the fluid circulation layer is defined by:

a flexible film layer; and

a flexible base member interconnected to the flexible film layer for containing the thermal exchange fluid in an internal volume defined therebetween.

6. The method for making a medical pad according to claim 1 , wherein the fluid circulation layer defines an internal volume having a geometric height across the fluid circulation layer of at least about 0.06″.

7. The method for making a medical pad according to claim 6 , wherein the fluid circulation layer comprises:

a flexible film layer; and

a flexible base member interconnected to the flexible film layer for containing the thermal exchange fluid in an internal volume defined therebetween, wherein the flexible base member includes a plurality of rib members interconnected to the flexible film layer.

8. The method for making a medical pad according to claim 7 , wherein the plurality of rib members define a plurality of fluid flow channels through the fluid circulation layer.

9. The method for making a medical pad according to claim 8 , wherein the plurality of fluid flow channels direct flow of a circulatable fluid flow between the first port and the second port.

10. The method for making a medical pad according to claim 7 , wherein the plurality of rib members project from a base portion of the flexible base member by a projection distance that defines the geometric height of the fluid circulation layer.

11. The method for making a medical pad according to claim 10 , wherein the projection distance is between about 0.06″ and 0.1″.

12. The method for making a medical pad according to claim 11 , wherein the flexible base member further includes a plurality of offset projections that project from the base portion of the flexible base member by a distance substantially equal to the projection distance.

13. The method for making a medical pad according to claim 12 , wherein the adhesive surface has a tack strength of between about 20 g and 65 g, as determined according to ISO 9665:1998(E).

14. The method for making a medical pad according to claim 13 , wherein the hydrogel layer has a thickness of between about 0.022″ and 0.032″.

15. A method for making a medical pad for contact and thermal exchange with a patient, comprising:

providing a fluid circulation layer for containing a thermal exchange fluid circulatable therethrough;

connecting a first port to the fluid circulation layer for circulating the thermal exchange fluid into the fluid circulation layer;

connecting a second port to the fluid circulation layer for circulating the thermal exchange fluid out of the fluid circulation layer; and

adding a hydrogel layer to the fluid circulation layer so that the hydrogel layer extends across one side of the fluid circulation layer to define an adhesive surface for adherence to a patient's skin, the hydrogel layer including an ultraviolet light-cured composition, wherein:

the ultraviolet light-cured composition comprises:

a cross-linking copolymer in an amount of between about 15% to 30% by weight of the ultraviolet light-cured composition;

water in an amount of between about 15% to 40% by weight of the ultraviolet light-cured composition; and

glycerol in an amount of between about 25% to 35% by weight of the ultraviolet light-cured composition; and

the hydrogel layer has a thermal conductivity of between about 1.9 cal/hr-cm-° C. and 2.37 cal/hr-cm-° C.

16. The method for making a medical pad according to claim 15 , wherein the fluid circulation layer is defined by:

a flexible film layer; and

a flexible base member interconnected to the flexible film layer for containing the thermal exchange fluid in an internal volume defined therebetween.

17. The method for making a medical pad according to claim 15 , wherein a plurality of rib members define a plurality of fluid flow channels through the fluid circulation layer.

18. The method for making a medical pad according to claim 17 , wherein the plurality of fluid flow channels direct flow of a circulatable fluid flow between the first port and the second port.

19. The method for making a medical pad according to claim 15 , wherein the adhesive surface has a tack strength of between about 20 g and 65 g, as determined according to ISO 9665:1998(E).