HK1193338A - Thermal treatment device with variable heat distribution - Google Patents

Description

Thermal treatment device with variable heat distribution

Technical Field

The present invention relates to a thermal treatment device. More particularly, the present invention relates to thermal treatment devices having variable heat distribution along the device.

Background

For users with muscle aches and joint aches, heat application relaxes the stiff muscles, promotes blood flow in the affected area, facilitates tissue repair, and creates a sense of relaxation. Hot application to the skin has historically been used to relieve muscle and joint pain, and in the treatment of certain inflammatory conditions. The application of cold substances to the skin has been used for similar treatments, in particular for the treatment of inflammatory reactions such as arthritis.

Chemicals that oxidize when exposed to air, such as iron powder formulations, have been used to generate heat. Electrical heating elements attached to a power source have also been employed.

U.S. patent 6,074,413 to Proctor & Gamble discloses a disposable thermal back wrap containing one or more thermal packs.

U.S. patent No. 5,484,366 to Wilkinson discloses a waistband that includes at least one packet to hold a chemical gel pack. The gel pack may be heated or cooled to a desired temperature.

Us patent 5,605,144 discloses a garment having at least one pouch for holding an air-active heat-generating packet.

U.S. patent application 20080200971 to Mycoal Products Corporation discloses a heating element comprising three or more segmented heating sections comprising an exothermic composition capable of generating heat upon contact with air, the segmented heating sections consisting of a low temperature section, a medium temperature section, and a high temperature section.

U.S. patent application 20080140165 to Kimberly-Clark world wide, inc. discloses an article for delivering a heating sensation comprising a skin-facing surface, a plurality of warm portions disposed on the skin-facing surface, and a plurality of cold portions disposed on the skin-facing surface, wherein the warm and cold portions are disposed in an alternating pattern.

There is a need in the art for improved thermal treatment devices.

Disclosure of Invention

Currently available air-activated heat packs provide substantially uniform heat. Providing an uneven heat distribution may result in better therapeutic effect and reduced side effects. In particular, when the user's skin is exposed to a heat source of variable temperature, the sensitization of the user's skin to the sensation of heat may be reduced. In addition, the higher temperature generating zone may run for a shorter time but provide a very fast ramp up, thereby initiating treatment faster; while the lower temperature zone may run longer but provide a slower ramped temperature rise, thereby causing the treatment to start slower but providing a longer treatment. Thus, for therapeutic applications, uneven heat distribution in the thermal pack is beneficial. In addition, the hot-bake effect, such as that described in the aforementioned U.S. patent application 20080140165 to Kimberly-Clark Worldwide, provides a perceived sensation of heat without exposing the skin to potentially harmful high temperatures.

U.S. patent application 20080200971 to Mycoal Products Corporation (FIGS. 1,2,4,5 and 7) and U.S. patent application 20080140165 to Kimberly-Clark (FIGS. 1,2 and 3) show a hot-bake like structure having multiple narrow sections. Manufacturing such structures, and in particular filling them with different heated mixtures and subsequently sealing them, is complicated and requires highly specialized filling and sealing equipment. Furthermore, because there are so many sealed areas around each narrow heating element filled with heating mixture, the total amount of heating material in each thermal pack is limited, resulting in a smaller total amount of heating mixture.

It is an object of the present invention to provide a thermal treatment device comprising a variable heat distribution. The thermal treatment device is convenient in that different compositions may be placed in different portions of the thermal treatment device, such that the device provides a warmer portion for a short burst of time and a warmer portion for a longer period of time. Generally, air-active heating device compositions are limited in that the faster the composition oxidizes when exposed to air, the faster it is consumed. If the composition is exhausted too quickly, it does not provide long-term pain relief. In previous thermal treatment devices, manufacturers had to trade off the intensity of the heat with the duration of the heat delivery. It is advantageous for the user to have a device as follows: the strong heating part is provided at the beginning of use and then becomes a long-time warming device. This may be provided by using the device of the present invention.

Drawings

FIGS. 1A,1B and 1C-1 to 1C-6 illustrate embodiments of the thermal treatment device of the present invention wherein (a) the device has a hot center and a warm periphery (FIG. 1A); (b) the device has a warm center and a hot periphery (FIG. 1B); and (C) the device has a non-heated center and a heated periphery (fig. 1C-1 to 1C-6).

FIGS. 2A-1 through 2A-2 and 2B illustrate another embodiment of the thermal treatment device of the present invention, wherein (a) the device has a thermal center with holes and a warm periphery (FIGS. 2A-1 through 2A-2); and (B) the device has a warm center and a hot periphery with holes (fig. 2B).

FIGS. 3A,3B and 3C-1 to 3C-2 illustrate another embodiment of the thermal treatment device of the present invention, wherein (a) the device has a non-insulated thermal center and an insulated warm perimeter (FIG. 3A); (b) the apparatus has an insulated warm center and an uninsulated hot periphery (fig. 3B); and (C) the device has concentric insulation around the thermal center (fig. 3C-1 to 3C-2).

Fig. 4A and 4B illustrate another embodiment of the thermal treatment device of the present invention, wherein (a) the device has a hot center and a warm periphery made by placing a hot sub-pack on top of a warm sub-pack (fig. 4A); and (B) the device has a warm center and a hot periphery made by placing a warm sub-pack between two hot sub-packs (fig. 4B). In one embodiment, a sub-packet may be defined as at least a portion of the entire thermal treatment device, wherein such sub-packet encapsulates a separate portion of the heating composition. The size of the sub-pack is smaller than the size of the entire heating device, which may comprise one or more sub-packs.

Fig. 5A and 5B illustrate another embodiment of the thermal treatment device of the present invention, wherein (a) the device has a hot center and a warm periphery, wherein two or more compartments are filled with heated mixtures of different air activities; and (b) the device has a hot center and a warm perimeter, wherein three or more compartments are filled with a heated mixture of different air activities.

Fig. 6A is a top view of an example of a thermal treatment device of the present invention.

Fig. 6B is a side view of the thermal treatment device of fig. 6A.

Detailed Description

The following detailed description refers to the accompanying drawings, which illustrate example aspects of the disclosure. These example aspects are described in sufficient detail to enable those skilled in the art to practice the disclosure. It is to be understood that other aspects may be utilized or structural changes may be made such that the detailed description is not to be considered as limiting the scope of the claims.

As used herein, the term "heat" or "hot portion" and the plural thereof, and the term "warm" or "warm portion" and the plural thereof, refer to one or more portions of a device that are or may be exothermic. Exothermic, as used herein, means emitting heat, and the heat may be generated by a chemical reaction, by resistive heating, by a warming fluid, or by any other suitable method. The "hot portion" and/or "warm portion" may actually be perceived as hot and/or warm, respectively, as it is when activated, or the "hot portion" and/or "warm portion" may be potentially hot or capable of heating to a hot temperature, and/or warm or capable of warming just before activation, as it contains material that will emit heat when it is activated.

"Hot" means 5℃ and more hot than the skin temperature, i.e., about 5-20℃ hotter than the normal skin temperature of 36.6C. "warm" means skin temperature and up to 5 ℃ above skin temperature. In addition, a portion of the device may be completely unheated, in which case the temperature of that area may be at or slightly above skin temperature, i.e., "warm".

The thermal portion and the warm portion can be of various sizes, designs, configurations, shapes, temperatures, and orientations, so long as the thermal treatment device produces a sensation of heat without causing physiological damage to the individual when the individual uses the thermal treatment device. The relative sizes of the hot and warm portions forming the thermal treatment device will depend on the application, and where the thermal treatment device is used.

The thermal treatment device can be used, for example, as a heating pad, a thermal treatment device, a patch, a tape, or a pouch.

The present invention relates to a thermal treatment device for controlling muscle and joint pain, the thermal treatment device being worn in proximity to the skin of an individual. The thermal treatment device provides the beneficial effect of improved therapeutic relief in one embodiment by providing an interval in which higher intensity heating is performed for a shorter period of time followed by lower intensity heating for a longer period of time. In one embodiment, the hot portion may last for up to about 30 minutes, such as up to about 1 hour, such as up to about 2 hours; and the warm portion may last up to about 6 hours, such as up to about 8 hours, such as up to about 12 hours, such as up to about 24 hours. This allows the user to experience an initial period of pain relief with a higher intensity of heat application, followed by a longer warm period of heat. The initialization period also serves as an indicator to indicate to the user that the device is working as intended. In one embodiment, the hot portion or sensation may indicate to the user that the thermic device has been sufficiently exposed to air when opened, and may be placed under clothing where its exposure to air is more limited, thereby addressing the following issues with current thermal treatment devices: the user must wait for their heat to be applied. The apparatus of the present invention also provides the following means: the device can deliver both temperatures to pain and muscle receptors over time, as such receptors are typically adapted or accustomed to one temperature.

Based on analysis of the user perception and analysis of actual temperature measurements on the user's body, for example, when the hot zone is intermittent with the warm and/or non-heating zones, providing uneven heat causes the person to perceive the heat pack as becoming hotter, having reduced side effects, and having a better therapeutic effect. Advantageously, the variable heat applied to the user's body makes the skin less sensitive and enables the skin to breathe better. Advantageously, the presence of a warm zone and/or a non-heating cutout area near the heating zone will cause a person to perceive the thermal pack as becoming hotter at the same or lower effective temperature, thereby reducing the likelihood of overheating the skin. Advantageously, heat packs having lower temperatures may feel hotter for the user, thereby reducing the likelihood of undesirable side effects associated with very hot heat packs.

The thermal treatment device comprises an outer surface comprising a skin facing surface, wherein the skin facing surface comprises a variable heat distribution.

The thermic devices of the present invention will typically be worn in contact with the skin, either on or under a garment. In one embodiment, the thermal treatment device includes an adhesive that can be attached to a garment or skin.

The thermal treatment device may be constructed of a disposable, breathable, nonwoven fabric. In one embodiment, the device is configured with a breathable front material connected to an adhesive backing. In another embodiment, the breathable front material and adhesive backing encapsulate and contain an air-active exothermic reaction mixture.

In one embodiment, the thermal treatment device of the present invention comprises a thermally active component that delivers heat for therapeutic purposes.

In another embodiment, the thermal treatment device comprises a thermal reservoir containing a thermal composition.

The thermal composition can be any suitable material for generating or retaining heat. In one embodiment, the thermal composition emits heat at a temperature of about 1 to about 10 ℃ above the temperature of the skin surface of the subject.

In one embodiment, a temperature sensor, e.g. a thermocouple, placed directly on the skin of the user and subsequently covered by the thermal treatment device of the invention, i.e. positioned between the body of the user and the thermal treatment device, may be used to measure and adjust the temperature such that it is above the normal body temperature of about 36-37 ℃ but below a temperature that may cause injury after prolonged exposure, e.g. above 50-60 ℃. In one embodiment, the temperature measured as described above is from about 38 ℃ to about 50 ℃, e.g., from about 39 ℃ to about 45 ℃.

In a particular embodiment, the thermal reservoir contains a hot fill material that is a mixture of substances that react exothermically. For example, many commercially available hand warmers and therapeutic thermal products contain iron powder based mixtures that release heat when iron is exposed to air to oxidize. These types of systems are described in detail in, for example, U.S. Pat. No. 5,918,590 to Proctor & Gamble. These mixtures are formulated to maintain a temperature of at least about 40 ℃ for at least about 4 hours, and up to about 24 hours, as is known in the art. Depending on the application or desired product design, the temperature may be maintained for at least about 8 hours, at least about 10 hours, at least about 12 hours, at least about 16 hours, or at least about 24 hours, depending on the extent of the heating rate.

In certain embodiments, the temperature between the skin of the individual and the thermal treatment device is about 38 ℃, about 40 ℃, about 41 ℃, about 45 ℃, or about 50 ℃ when measured by a thermocouple placed between the skin and the thermal treatment device.

In one embodiment, the thermal reservoir may comprise an enclosure. The enclosure may be any material that encloses the heat reservoir or the thermal composition in the heat reservoir. In one embodiment, the enclosure is a pouch constructed from a breathable nonwoven fabric. In another embodiment, the enclosure is constructed from a woven fabric.

In certain embodiments, the thermal treatment device may be substantially flat with a rectangular or elliptical or oblong or other geometry; the thickness of the device is about 1mm to about 30mm and other dimensions of the device are suitable to fit into a profile frame having a rectangular shape and having dimensions of about 60 x 80mm to about 200 x 500 mm. In one embodiment, the thermal treatment device has a thickness of about 3 to about 8mm and is rectangular 80mm x 120 mm; in another embodiment, the thermal treatment device is a 100mm by 150mm rectangle; in another embodiment, the thermal treatment device is a 150mm x 250 rectangle. In another embodiment, the thermal treatment device is elliptical with an overall dimension of 100mm by 150 mm.

The thermal treatment device may be worn proximate to the individual's skin or may be applied directly to the skin. In one embodiment, the thermal treatment device may be applied to a garment through which heat is transferred to the skin. When direct application is employed, an adhesive may be used. Any suitable adhesive may be used that is safe and effective to attach the thermal treatment device to the skin. Suitable adhesives include, for example, hydrogels, silicone adhesives, hot melt adhesives, and the like. Ideally, the adhesive will allow the thermal treatment device to be applied to and conform to the skin contacting surface area. In some cases, the adhesive may facilitate the even distribution of heat or warmth across the area of skin covered by the thermal treatment device. The heat treatment device may have an adhesive layer on the skin-facing side, said layer preferably being a continuous layer covering substantially the entire device; in one embodiment, the adhesive is an intermittent layer exemplified by a plurality of adhesive stripes. In one embodiment, the adhesive is a hydrogel-based adhesive that provides "wet" heat. In another embodiment, the adhesive is a non-hydrogel adhesive.

The thermal treatment device can be inexpensive, lightweight, fully disposable, and easily portable, allowing for transportation and movement.

Fig. 1A is a schematic diagram of an embodiment of the present invention, showing a top view (body facing) 50 and a side view 55 of a thermal pack 100 having a substantially planar rectangular shape. The thermal pack 100 has a hotter center 105 and a warm and/or cooler periphery 110, as further illustrated by the denser shading within the center 105 of the thermal pack 100 as compared to the periphery 110. The body-facing side 120 has a different configuration as compared to the air intake side 125, wherein the air intake side of the enclosure is microporous such that air, as indicated by arrows 150, enters the heat-generating mixture (not shown) contained within the enclosure of the thermal pack. The envelope pores are typically about 0.1 microns to about 25 microns.

Embodiments of the thermal treatment device of the present invention have a warmer center 105. In the embodiment shown in FIG. 1A, an additional permeability modifying member 200 is attached to the intake side 125 such that permeability is not compromised in the center 105 but is limited in the periphery 110. The breathability modifying member 200 is a fabric or polymer layer with variable permeability with high permeability or cut-outs in the center 105a and low permeability on the perimeter 110a, as shown by the shaded area on the perimeter 110a of the breathability modifying member 200. Restricting air flow to the perimeter 110 of the thermal pack 100 creates a warm and/or cooler perimeter 110 and a hotter center 105. In one embodiment (not shown), the breathability modifying member 200 is a microporous decal having the same dimensions as the thermal pack 100, the decal is placed onto the air intake side 125, and the decal has a cut-out in its center.

In one embodiment, the breathability modification member 200 is a breathable fabric with adhesive attached to the air intake side 125 that selectively blocks some of the micro-apertures so that breathability is not compromised within the center 105 but is limited on the perimeter 110. In this embodiment, more adhesive or adhesive strips are positioned on the periphery 110 and less adhesive or no adhesive is positioned within the center 105.

Referring now to fig. 1B, a schematic view of an embodiment of the present invention is shown in which the thermal pack 100 has a warm and/or cooler center 105 and a hotter periphery 110, as further illustrated by the denser shading within the periphery 110 of the thermal pack 100 as compared to the center 105. The permeability modifying member 200 is attached to the intake side 125 such that permeability is not compromised within the perimeter 110 but is limited within the center 105. In one embodiment (not shown), the breathability modifying member 200 is a microporous decal placed onto the center 105 on the air intake side 125, the decal having a size smaller than the size of the thermal pack 100.

In one embodiment, the breathability modifying member 200 is a breathable fabric with adhesive attached to the air intake side 125 that selectively blocks some of the micro-apertures so that breathability is not compromised on the perimeter 110 but is limited within the center 105. In this embodiment, more adhesive or adhesive stripes are positioned within the center 105 and less adhesive or no adhesive is positioned on the periphery 110.

Referring now to fig. 1C-1, heat pack 100 has at least one cutout 130. In the illustrated embodiment, the cutout is substantially within the center 105 and has a size of at least 10% of the area of the thermal pack 100 as seen in a top view (body facing) 50, more preferably 20% -50% of the area of the thermal pack 100. The cutouts may be rectangular, oblong, polygonal, oval, triangular, or any suitable shape. In one embodiment, the inner edge of the slit is sealed. In one embodiment, the cutouts are not contained within the perimeter of the thermal pack, as shown in FIGS. 1C-2. The presence of the incision 130 advantageously provides a warm and/or cooler zone within the treatment area, and also provides the following: in this area, the user's skin may evaporate water more easily.

Referring now to FIGS. 1C-3 through 1C-6, a number of additional embodiments having cutouts are shown, wherein the elements listed are the same as those used in FIG. 1C-1. As described above, providing uneven heat based on user perception, such as when the hot zone is intermittent with the warm and/or non-heated zones, results in better treatment, perception of the heat pack becoming hotter, and reduced side effects. Advantageously, the variable heat applied to the user's body makes the skin less sensitive and enables the skin to breathe better. Advantageously, the presence of the warm zone and/or non-heated cutout region near the heating zone will cause a person to perceive the adhesive thermal pack as becoming hotter at the same or lower effective temperature, thereby reducing the likelihood of overheating the skin. Advantageously, the cutout region allows evaporative cooling of the skin by perspiration, and also increases the temperature difference between the heated and warm and/or non-heated cutout regions. Advantageously, heat packs having lower temperatures may feel hotter for the user, thereby reducing the likelihood of undesirable side effects associated with very hot heat packs.

The packs and cutouts may be rectangular, circular, polygonal, or any geometric shape suitable for placement on or around the body. The pack may be worn on the body by attachment to the skin via the side coated with adhesive. Each incision having about 0.5cm²To about 5cm²The area of (a). The number of cuts in each thermal pack ranges from 1 cut to about 10 cuts.

Referring now to fig. 2A-1, which represents an embodiment of the present invention, there is shown a top view (body facing) 50 and a side view 55 of a thermal pack 100 having a substantially planar rectangular shape. The thermal pack 100 has a hotter center 105 and a warm and/or cooler periphery 110, as further illustrated by the denser shading within the center 105 of the thermal pack 100 as compared to the periphery 110. The body-facing side 120 has a generally different configuration as compared to the air intake side 125, wherein the air intake side is microporous such that air, as indicated by arrows 150, enters the heat-generating mixture (not shown) contained within the envelope of the thermal pack.

The holes 400 in the air intake side 125 have a higher density or larger diameter or both in the center of the thermal pack 100, making the center more air permeable. Thus, the center 105 is hotter than the periphery 110. In one version of this embodiment, the holes are present on one side of the thermal pack and do not represent cuts.

Referring now to fig. 2A-2, a view from the intake side 125 is shown schematically illustrating a higher density of holes in the center 105 as compared to the perimeter 110, such that the center 105 is hotter. In an alternative embodiment (not shown), the holes 400 in the center do not have a higher density, but have a larger diameter.

Referring now to fig. 2B, which represents an embodiment of the present invention, a top view (body facing) 50 and a side view 55 of a thermal pack 100 having a substantially planar rectangular shape are shown. The thermal pack 100 has a cooler center 105 and a hotter perimeter 110, as further illustrated by the more dense shading within the perimeter 110 of the thermal pack 100 compared to the center 105. The holes 400 in the air intake side of the envelope 125 have a higher density or larger diameter or both on the periphery of the thermal pack 100, thereby making the periphery more air permeable. Thus, the center 105 is cooler than the periphery 110.

Referring now to fig. 3A, a top view (body facing) 50 and a side view 55 of a thermal pack 100 having a substantially planar rectangular shape is shown, representing an embodiment of the present invention. The user perceives the thermal pack 100 as having a hotter center 105 and a warm and/or cooler periphery 110, as further illustrated by the denser shading within the center 105 of the thermal pack 100 as compared to the periphery 110. The body facing side 120 has an insulating layer 500 disposed on the periphery 110 of the thermal pack 100 to make the periphery 110 perceived as cooler.

Referring now to fig. 3B, which represents an embodiment of the present invention, a top (body facing) view 50 and a side view 55 of a thermal pack 100 having a substantially planar rectangular shape are shown. The user perceives the thermal pack 100 as having a cooler center 105 and a hotter perimeter 110, as further illustrated by the denser shading within the perimeter 110 of the thermal pack 100 in the top view 50. The body facing side 120 has an insulation layer 500 disposed only within the center 105 of the thermal pack 100, which causes the person to perceive the periphery 110 as being hotter.

Referring now to fig. 3C-1, which represents an embodiment of the present invention, a top (body facing) view 50 and a side view 55 of a thermal pack 100 having a substantially planar rectangular shape are shown. The thermal pack 100 has multiple concentric layers of insulation 500 on the body facing side 120, giving the user the perception that the thermal pack has a hotter center 105 (where there is no insulation) and a progressively cooler periphery 110.

In the embodiment shown in fig. 3C-2, a plurality of insulating materials 500 are intermittently applied to the body-facing side 120 such that the user perceives the thermal pack as having warmer zones and intermittent regions of warmer and/or cooler zones.

Referring now to fig. 4A, the thermal treatment device has a hotter center 105 and a cooler periphery 110, as further illustrated by the denser shading within the center 105 as compared to the periphery 110. In the embodiment shown in fig. 4A, a hotter thermal pack or sub-pack 600 is positioned within the center of the thermal pack 100 on the air intake side 125, the hotter thermal pack or sub-pack 600 having a generally smaller size than the main thermal pack or sub-pack 100. The heat emitted from the hotter thermal pack 600 is then conducted through the main thermal pack 100 toward the body-facing side 120, such that the thermal treatment device has a hotter center 105. Referring now to fig. 4B, the thermal treatment device has a warm and/or cooler center 105 and a hotter periphery 110, as further illustrated by the denser shading of the periphery 110 on the top view (body-facing side) 50. In the illustrated embodiment, two hotter thermal packs or sub-packs 600 are positioned on both sides of the primary thermal pack 100 on the air intake side 125. The heat emitted from the hotter thermal pack 600 is then conducted through the main thermal pack 100 toward the body-facing side 120 so that the thermal treatment device has a hotter perimeter 110.

Referring now to fig. 5A and 5B, the thermal treatment device has a hotter central region, as further illustrated by the denser shading of the center on the (body-facing side) view 50. In the illustrated embodiment, the warmer heating mix is filled into the central compartment of the thermal treatment device, while the warm and/or cooler heating mix is filled into the peripheral compartment.

Referring to fig. 6A, a thermal treatment device 10 in the form of a patch is shown for providing therapy to a subject. The thermal treatment device 10 may or may not be disposable and includes a body 12; when the thermal treatment device is placed on an individual, the subject applies therapy to the individual. The body 12 includes an outer surface 13 and is enclosed by the outer surface 13. As used herein, a patch refers to any type of patch, bag, pouch, or sachet that can be used to apply therapy to the body. Further, the thermal treatment device 10 can be directly or indirectly attached to the individual.

The thermal treatment device includes a hot portion 14 and a warm portion 16. The hot and warm portions provide sufficient heat to warm the skin of the individual when applied thereto, respectively. In one aspect of the present disclosure, due to the positioning of the thermal treatment device 10 on the skin-facing surface 18 of the body 12, the thermal treatment device 10 maintains at least partial skin contact with a wearer of the thermal treatment device 10.

In one aspect of the present disclosure, the thermal portion 14 and the warm portion 16 of the thermal treatment device 10 are formed by applying a thermally and/or thermally insulating material to the skin-facing surface 18 of the thermal treatment device 10. The insulating material comprises any woven or non-woven fabric or material, for example in the form of a pad made of synthetic or natural polymer, or a foam-like pad made of polyurethane, for example. The thermally conductive material comprises a metal-based material and/or a composite material, such as aluminum foil or a fabric containing metal fibers or a metal-filled polymer. In various aspects of the present disclosure, the skin adhesive may be applied to the skin-facing surface 18. The skin adhesive may be comprised of a variety of materials and bond strengths, including, but not limited to, soft skin adhesives such as grades 7-9700 commercially available from Dow Corning, cosmetic glues, silicone-based adhesives, polyvinylpyrrolidone, and crosslinked polyvinylpyrrolidone-based adhesives; and pressure sensitive adhesives including, but not limited to, those made from: acrylic-based polymers and copolymers, polyvinyl ethers, and silicones. The adhesive may be applied to the entire face of the thermal treatment device, or may be applied to only a portion of the face of the thermal treatment device. In one embodiment, the adhesive has a paper or film backing that is removed prior to application of the adhesive to the skin. The heat source and warm source may be applied in a variety of configurations. The various hot portions 14 and/or warm portions 16 may be colored using ink, fuel, or any other suitable substance to inform the user of the desired effect.

Referring to fig. 6B, the body 12 of the thermal treatment device 10 may include an enclosure 30 and a heating composition 32 sealed within the enclosure 30. The heating composition 32 is a heat generator and is capable of generating heat when a gas, such as oxygen contained in ambient air, is received through the gas permeable portion 34 of the enclosure 30.

When the thermal treatment device 10 is a thermal patch, it can be stored in an air-tight environment (e.g., a sealed bag) such that the heating composition remains inactive until the thermal patch is removed from the air-tight environment. Once the thermal treatment device 10 is removed from the air-tight environment, the heating composition 32 within the enclosure 30 is exposed to air such that an exothermic reaction occurs within the body 12 of the thermal treatment device 10. The exothermic reaction generates heat within the thermal treatment device 10 to increase the temperature of the thermal treatment device 10. In one embodiment, the exothermic reaction occurs at a higher rate in the hot portion of the thermal treatment device than in the warm portion of the thermal treatment device.

Any conventional heating composition may be used to induce an exothermic reaction within the thermal treatment device 10. Some exemplary heating compositions include iron powder as a primary active ingredient. Alternatively, the thermal treatment device 10 may include any suitable electrical heating system as a heat generator. Still alternatively, the thermal treatment device 10 as a heat generator may include any suitable fluid, gel, or solid thermal storage system that can be heated in a microwave oven, in a conventional oven, in a water bath, or by any other suitable method.

In this regard, where at least one of the hot portion 14 and/or the warm portion 16 relies on a chemical reaction, that portion of the thermal treatment device may be activated in a variety of ways. The preferred manner of activation is to expose the thermal treatment device to air.

In this regard, where at least one of the hot portion 14 and/or the warm portion 16 relies on electrical or mechanical means, that portion of the thermal treatment device may be activated in a variety of ways. The user may operate the switch to close the circuit to supply current to that portion. The user may open a valve to the hot or warm fluid source.

In accordance with the present invention, a thermal gradient exists along the surface of the thermal pack at the interface with the user's body. In one embodiment, the center of the pack is heated more than the perimeter of the pack, thereby providing thermal treatment with a thermal gradient. In another embodiment, the center of the bag is heated less than (cooler than) the perimeter of the bag, thereby avoiding overheating the area of the body directly adjacent to the center of the bag.

Advantageously, the variable heat distribution (or thermal gradient) along the pack makes it possible to treat a small area of the body with a higher level of heat and a peripheral area of the body with a medium level of heat, thereby avoiding extensive overheating while providing substantial thermal treatment and pain relief. Furthermore, for the affected area on the body undergoing thermal treatment, it is possible to heat the surrounding area while avoiding direct heating of the affected area.

The thermal packs according to the invention have a suitable heating mix composition (typically iron, salt, water, carbon, fillers), particle size (finer particles with larger surface area and resulting higher temperature), and gas permeability of the pouch, which has high gas permeability resulting in higher temperature. The bag is a substantially flat bag having a thickness of from about 1mm to about 30mm, more preferably from about 3mm to about 10 mm. The bag has a common construction comprising a gas permeable pouch filled with an air-reactive heated mixture. The configuration of the bag and the air-activated heating mixture can be varied to result in higher or lower temperatures: for example, a package may contain (i) a specially formulated mixture (including different concentrations of components or additives, e.g., salts or more active metals such as aluminum, and/or finer particle size ingredients); (ii) higher gas permeability of the pouch; or (iii) both configurations (i) and (ii) to provide higher temperatures.

Many embodiments of thermal packs are described herein that provide a thermal pack with variable heat distribution. In the following figures, darker gray generally indicates regions of higher temperature, lighter gray generally indicates regions of lower temperature, and white indicates regions of even lower temperature and/or less heated or non-heated regions.

In one embodiment, the inlet of gas into the pack is variable along the heat pack. Breathability can vary in the following packages: the packet is tightly packed and flat, and the heated mixture within the bag or pouch does not move substantially (no clumping of heated mixture, also known as the "tea-in-bag" effect). For example, since the air permeability is higher at the periphery and lower in the middle, the temperature rise will be higher at the periphery and lower in the middle. The higher permeability in the middle will result in a hotter middle of the bag. In another embodiment, breathability can similarly vary in the following package: the packet is not tightly packed and some movement of the heated mixture within the bag or pouch is permitted ("tea-in-bag" effect). For example, since the air permeability is higher at the periphery and lower in the middle, the temperature rise will be higher at the periphery and lower in the middle. The higher permeability in the middle will result in a hotter middle of the bag.

Referring again to fig. 1A,1B and 1C-1 to 1C-6, there is shown a thermal treatment device of the present invention wherein (a) the device has a hot center and a warm periphery (fig. 1A); (b) the device has a warm center and a hot periphery (FIG. 1B); and (C) the device has a non-heated center and a heated periphery (fig. 1C-1 to 1C-6).

The breathability can be altered by using a specialized fabric, or by having more holes or additional holes or larger diameter holes in the areas where higher breathability is desired. In one embodiment, additional needle-shaped micro-holes are made in the pouch in areas where higher breathability is desired. Referring again to fig. 2A-1 to 2A-2 and 2B, a thermal treatment device of the present invention is shown wherein (a) the device has a thermal center with holes and a warm periphery (fig. 2A-1 to 2A-2); and (B) the device has a warm center and a hot periphery with holes (fig. 2B).

In one embodiment, the thermal gradient is achieved by variability of the thermal insulation of the thermal pack at the interface with the user's body. The insulation is a thicker fabric or pressure sensitive strip on the surface of the body facing bag. Referring again to fig. 3A,3B, and 3C-1 to 3C-2, there is shown a thermal treatment device of the present invention wherein (a) the device has a non-insulated thermal center and an insulated warm perimeter (fig. 3A); (b) the apparatus has an insulated warm center and an uninsulated hot periphery (fig. 3B); and (C) the device has concentric insulation around the thermal center (fig. 3C-1 to 3C-2).

In one embodiment, the thermal and warm portions, and thus the thermal and warm heat transfer, may be achieved by using different holes in each portion. In one embodiment, the hot portion may have more holes than the warm portion.

The housing of the thermal treatment device, or the sub-pack or heating composition, may be constructed of a variety of woven or non-woven fabric materials. In one embodiment, the shell of the hot portion has a higher porosity than the shell of the warm portion. The heat treatment device may be constructed in different shapes as described above, but the sub-packet portion of the heating device may also be constructed in different shapes, including shapes stitched or sealed into the entire heat treatment device. These stitched or sealed portions do not contain an internal heating composition. In one embodiment, the shape of the hot portion is the same as the shape of the warm portion. In one embodiment, the shape of the hot portion is different from the shape of the warm portion.

In another embodiment, the heating pack includes at least two sub-packs, wherein one sub-pack provides more heat than the other sub-pack. Referring again to fig. 4A and 4B, a thermal treatment device of the present invention is shown, wherein (a) the device has a hot center and a warm periphery made by placing a hot sub-pack over a warm sub-pack (fig. 4A); and (B) the device has a warm center and a hot periphery made by placing a warm sub-pack between two hot sub-packs (fig. 4B). The subpackets may be attached to each other in various ways. In one embodiment, the sub-pack is attached to another sub-pack by an adhesive. In another embodiment, the sub-packet is surrounded by a housing, the sub-packet being separated from its heating composition by quilting, sealing or stitch-bonding from the other sub-packets. In one embodiment, the hot sub-pack may be removed from the larger thermal treatment device after the user has determined that the sub-pack is exhausted. This removal may be facilitated by a pressure sensitive adhesive or by a detachable perforated section. In one embodiment, the thermal sub-pack portion has an indicator that allows the user to know that the sub-pack has been exhausted and removed, or to know that the position of the thermal treatment device can be changed. The indicator may be an electronic indicator, such as a light emitting diode or a colored indicator. The color indicator appears a single color when the heat is partially exhausted. In one embodiment, there may be more than one hot subpacket attached to one warm subpacket. In one embodiment, there may be more than one warm subpacket.

In another embodiment, the thermal pack has at least two compartments filled with a heating mixture of different air activities or having different air permeabilities, or both. Referring to fig. 5A and 5B, a thermal treatment device of the present invention is shown wherein (a) the device has a hot center and a warm periphery wherein two or more compartments are filled with a heating mixture of different air activities; and (b) the device has a hot center and a warm perimeter, wherein three or more compartments are filled with a heating mixture of different air activities. In one embodiment, there may be a portion stitched or sealed between the center of the hot portion and the periphery of the warm portion that does not include the heating composition. In one embodiment, a thermal sub-pack is placed over the warm sub-pack, wherein the warm heating composition comprises the entire surface area of the thermal treatment device and transfers heat through the thermal portion and is perceptible when the thermal portion is depleted.

The bag may be rectangular, circular, polygonal, or any geometric shape suitable for placement on or around the body. The adhesive may be used to wear the bag on the body by attachment to the skin or clothing, by inserting the bag into a belt, sleeve, or wrap, or by securing with a strap, Velcro attachment, adhesive, or otherwise attaching the bag to the body, clothing, or to another strap.

While the invention has been described above in connection with specific embodiments thereof, it will be evident that many changes, modifications and variations can be made without departing from the inventive concept disclosed herein and it is therefore intended to embrace all such changes, modifications and variations that fall within the spirit and broad scope of the appended claims. All patent applications, patents, and patent publications cited herein are incorporated by reference in their entirety.

Claims (22)

1. A thermal treatment device comprising:

an outer surface comprising a skin-facing surface, wherein the skin-facing surface comprises a variable heat distribution.

2. The thermal treatment device of claim 1, wherein the skin-facing surface has a hot center and a warm periphery.

3. The thermal treatment device of claim 1, wherein the skin-facing surface has a warm center and a hot periphery.

4. The thermal treatment device of claim 1, wherein the skin-facing surface has a non-heated center and a heated periphery.

5. The thermal treatment device of claim 1, wherein the skin facing surface has a thermal center and a warm periphery, the thermal center having air vents.

6. The thermal treatment device of claim 1, wherein the skin facing surface has a warm center and a hot periphery, the hot periphery having air permeable pores.

7. The thermal treatment device of claim 1, wherein the skin-facing surface has a non-insulated thermal center and an insulated warm perimeter.

8. The thermal treatment device of claim 1, wherein the skin-facing surface has an insulated warm center and a non-insulated hot periphery.

9. The thermal treatment device of claim 1, wherein the skin-facing surface has concentric insulation around a thermal center.

10. The thermal treatment device of claim 1, wherein the skin-facing surface has a thermal center and a warm perimeter made by placing a thermal sub-pack over a warm sub-pack.

11. The thermal treatment device of claim 1, wherein the skin-facing surface has a warm center and a hot periphery made by placing a warm sub-pack between two hot sub-packs.

12. The thermal treatment device of claim 1, wherein the skin-facing surface has a hot center and a warm periphery, wherein two or more compartments are filled with a heated mixture of different air activities.

13. The thermal treatment device, wherein the skin facing surface has a hot center and a warm periphery, wherein three or more compartments are filled with a heated mixture of different air activities.

14. The thermal treatment device of claim 1, further comprising a thermal composition.

15. The thermal treatment device of claim 14, wherein the thermal composition emits heat from about 1 to about 10 ℃ above the skin surface temperature of the individual when worn next to the individual.

16. The thermal treatment device of claim 14, wherein the thermal composition comprises iron powder.

17. The thermal treatment device of claim 14, wherein the thermal composition comprises a heat retentive material capable of being used for microwave heating.

18. A thermal treatment device comprising:

a skin-facing surface;

at least one thermal portion disposed on the skin-facing surface; and

at least one warm portion disposed on the skin-facing surface.

19. A method of treatment, comprising:

exposing the skin of an individual to a thermal treatment device, the thermal treatment device comprising:

a skin-facing surface;

at least one thermal portion disposed on the skin-facing surface; and

at least one warm portion disposed on the skin-facing surface.

20. The thermal treatment device of claim 1, further comprising a surface opposite the skin-facing surface, wherein the surface opposite the skin-facing surface has variable air permeability.

21. The thermal treatment device of claim 20, wherein the surface opposite the skin-facing surface has a vent having a size and/or density that is different in a center of the surface opposite the skin-facing surface than in a periphery of the surface opposite the skin-facing surface.

22. The thermal treatment device of claim 1, further comprising at least one cut-out in the skin-facing surface.