IE86335B1 - A pants system with hip protection capsules - Google Patents

Abstract

The present invention relates to structure worn primarily by the elderly for protecting against Hip Fractures resulting from a fall. The protector is made of Pants with side pockets which hold a matching pair of hip protective air sealed capsules with open celled polyurethane foam cores and bonded polyurethane layers which are attached to the foam and which are strategically located over the user’s hips an secured in place by pockets which are sewn into the pants. The protector lightweight, easily put on and removed, does not interfere in daily living or indeed during bathing/showering activities, etc. proper infection control is maintained as the inner sealed air/foam capsules can be cleaned and machine washed as an integral part of the pants i.e. the air/foam capsules do not have to be removed during laundering. The structures of the present invention are used to provide infection control and energy impact absorption benefits but may have the advantage of providing greater levels of comfort for a user.

Description

A Pants System with Hip Protection Capsules The present invention relates to structures worn primarily by the elderly for protecting against Hip Fractures resulting from a fall. The protector is made of Pants with side pockets which hold a matching pair of hip protective air sealed capsules with open celled polyurethane foam cores and bonded polyurethane layers which are attached to the foam and which are strategically located over the user’s hips and secured in place by pockets or cavities which are sewn into the pants. The pants with protectors is light weight, easily put on & removed, does not interfere in daily living or indeed during bathing/showering activities, etc. Proper infection control is maintained as the inner sealed air/foam capsules can be cleaned and machine washed as an integral part of the pants i.e. the air/foam capsules do not have to be removed during laundering. The structures of the present invention are used to provide infection control and energy impact absorption benefits but may have the advantage of providing greater levels of comfort and protection against pressure sores for a user.

Background - Hip fractures are a major health problem for the elderly and have a significant cost both in economic terms and in pain and discomfort for the patient. Indeed, some hip fractures can result in deterioration of the patient’s health/condition and can sometimes accelerate or cause the death of a patient. The hip area is relatively poorly protected by muscle and other body tissue. Nearly 33% of women and more than 17% of men will experience a hip fracture if they live to age 90. The death rate for hip fracture patients is higher than for other people of the same age who do not sustain this type of injury. There are currently two main types of hip protectors on the market, one for use over clothing and one for use under clothing.

Hip protectors are now well known in the art. They are available primarily as integral parts of pants to cover the Greater Trochanter (Hip Bone). There are many variations of these Hip Protector pants available today. The most well known models have polyurethane foam inserts inside pouches(with our without welded plastic bags around the foam) on the sides of the pants. More have hard plastics shells with foam inner layers. More have air bags and some are strap-on devices which are strapped on around the leg and waist to provide air and foam layered areas over the hip to provide accessory protective devices in case of a fall. All of the Hip Protector devices on the market will perform with some degree of effectiveness. However, the shortcomings of most of the prior art are: a) Discomfort due to incorrect fit - there are many body sizes and many Pants sizes. Attempting to find a universally fitting shock-absorbing device/section over the hip has been all but impossible. The claimed invention allows a certain conformity/moulding to suit each user and is unique and novel in that regard. b) Inability to wash or launder the pants without first removing the side protective devices. At a minimum, this is inconvenient and can result in the loss or misplacement of the side protective layers/devices. c) In some cases an ill-fitting or excessively hard hip protector can and has been known to cause decubitus ulcers/pressure sores in patients.

Some of the prior art referenced to compare against the claimed invention is listed below: U.S. Pat. No 5,584,072, which discloses a hip protector using a belt with a hard buckle lock, a pair of holsters with hard shells and leg straps. This device can not be easily put on or adjusted to fit comfortably and removed by a person who is elderly, infirm or whose fingers, hands and grip have been weakened by arthritis and/or similar conditions. Additionally, this hip protector is not very comfortable to a wearer because it has hard shelis/shields (the same may be said of the devices of U.S. Pat Nos. 4,641,641; 4,926,883; 5,062,433; 5,497,511; 5,636,377; 5,722,093 & 6,334,443). The results of using hard shells include different problems, for example, the discomfort during sleeping, sitting or other daily activities, and problems for washing/drying, etc. If wearer can take out hard shells from pockets before, for example, sleeping, can arise other problems: during sleeping wearer can fall from bed or after sleeping old wearer can forget put in pockets these sheils-in both cases the wearer does not have a defence from hip fractures.

U.S. Pat. No. 4,807,301, discloses a protective garment for the hip area and uses a size-adjustable, wrap-around form, is adapted to fit under buttocks and includes pockets with shock-absorbent pads of foam. This garment can change its position on the user's body during sleeping or other daily activities and must be removed e. g. when bathing or going to the toilet.

U.S. Pat. No. 5,918,310, which discloses a body protective garment uses a soft, multi-layer polyurethane foam composite for hip protection. This garment must be removed e. g. when bathing or going to the toilet, and, due to the using of flaps, buttons and zippers, this device can not be easily put on, adjusted to fit comfortably and removed by a person who is elderly, infirm or whose fingers, hands and grip have been weakened by arthritis and/or similar conditions.

Some other patents which may be of background interest, are: ,867,842 February 5,918,310 July 1999 Pinsley et al. 1999 Farahany 20 6,334,443 January 4,573,216 March 2002 Olsen 1986 Wortberg 5,036,548 August 1991 Grilliot et al 5,557,804 September 5,717,997 February 1996 Ovortrup et al. 1998 Garcia. 25 5,790,981 August 1998 Bzoch 5,836,015 November 1998 Kristensen et al. 6,093,468 July 6,282,724 September 2001 2000 Toms Abraham et al. et al.

The present invention, providing an innovative and novel solution to the problems experienced with products currently known in the art. It is designed to ideally provide an innovative, much more effective, comfortable and protective system for protecting the user/patient’s hip(s) from damage. The particular method of manufacture provides huge advantage in terms of product performance, namely, the surface bonding of the inner foam to the outer layers of polyurethane ensure that air displacement is controlled if and when the inner pouch suffers an impact, such as, if the person wearing the pants of the claimed invention falls, the inner side pouch absorbs, controls and dissipates energy much more effectively than products which may have basic air bag pouches or air bags with loose foam cores inside the bags.

DISCUSSION OF THE INVENTON - The present invention relates to a hip protector system which solves the shortcomings of the prior art. The present invention, a hip protector worn by people, primarily but not exclusively by the elderly, is designed to prevent hip fractures, at least in most instances, resulting from a fall from different positions during normal activities. In a preferred embodiment of the protector preferably is a pants incorporating a removable matching pair of side, hip protective capsules preferably covering over each greater trochanter of the user, with each capsule being secured in place by strategically located pockets or cavities located in the pants. Each one of the capsules preferably includes an airsealed capsule with a core of polyurethane foam, with the foam core being fully face bonded to the outer polyurethane layers of the capsule.

When, for example, the user falls on his/her hip while wearing the hip protector device, the protective bonded air/foam capsule on the impact side primarily absorbs the impact force, thereby protecting the user's hip from the impact force. Each capsule should be of such a size to physically cover over the user's hip area, particularly for an adult.

According to a first aspect of the present invention there is provided a Pants system comprising: i) A pants with pockets or cavities at the sides to contain air-sealed, bonded foam capsules on the sides of the pants whereby the said capsules are made from foam cores with bonded outer polyurethane layers which as full face bonded to the foam to control air displacement and therefore energy absorption/dissipation in the case of a fall. Focusing on the protective shock-absorbing capsules, preferably the capsules comprise upper and lower material layers. The upper and lower material layers may be the same or different. Most preferably the upper and lower material layers comprise an air impermeable material whereby the said material layers together define an airtight capsule.

In a much preferred arrangement, the airtight capsule incorporates an energy dissipating foam which is bonded on both upper and lower faces to external envelope which consequently forms a sealed and bonded capsule including the polyurethane foam core.

In another preferred arrangement, one or more bores or channels may be defined in the polyurethane foam extending from side to side of the interior of the foam core. This facilitates the flow of air to strategic locations inside the capsule and can therefore have the effect of changing impact absorption or shock absorbing performance for various body sizes.

Preferably the external envelope of the capsule which is covering the foam core comprises a liquid impermeable material. In this way, in the unlikely event of any fluid spillage onto the pants, the fluid will not penetrate the external envelope and the entire pants can be cleaned easily and instantly by normal laundering without having to remove the protective inner capsules from the pants. The structure of the liquid impermeable material is also critically important in order to achieve; r a) a reliable and durable bond to the inner polyurethane foam b) A multiple membrane layer to provide 100% air-holding under load and over time (Standard single layer Polyurethane is structurally and inherently unable to provide 100% air-holding performance under load and over time.) c) a high stretch factor in the material in contact with the user/occupant of the capsule, at least, to allow conformity which in turn reduces shear, friction and pressure forces on the users skin tissues and therefore minimises the possible occurrence of a pressure sore over time. d) A resilient outer layer to prevent damage and fluid/infection ingress The design, construction and function of the outer polyurethane multilaminate used in making the inner protective capsules is a key component in the claimed invention.

Preferably in accordance with this first aspect of the invention, the lower face in use of the body of polyurethane foam material is attached to the inner surface of the lower material layer. Most preferably the said lower face is bonded to the said lower material layer. Preferably also at least a portion of the upper face in use of the body of polyurethane foam material is similarly attached to the inner surface of the upper material layer. This is, however, not essential in ail constructions. Movement between the upper material layer and the upper surface of the foam core may have therapeutic benefits by minimising shear forces between the patient’s skin and the upper material layer with which the skin is in contact (directly or indirectly).The polyurethane foam material in the Capsules of this aspect of the invention may preferably have a thickness in the range of from about 1cm to about 4cm. The body of foam material may advantageously include a plurality of generally horizontal (in use) bores, such as transverse or longitudinal bores. The upper surface of the foam material is most preferably planar but may be non-planar, for example a series of regularly arranged depressions and projections so that, in One form, the upper surface is provided with a waffle-like effect.

Alternatively, or additionally, the polyurethane foam may be provided with a series of generally vertical through bores or channels which also may achieve a waffle-like effect. The provision of the non-planar polyurethane foam surface and/or generally vertical through bores may contribute to an improvement in ventilation for the patient, preventing excessive moisture build up.

One or both of the upper and lower material layers is preferably a polymeric Multi-layer material to allow easy and immediate decontamination or cleaning. Preferred materials include thermoplastic polyurethane materials. The choice of material for the upper and lower material layers depends on the intended therapeutic use. For patients whose risk of developing pressure sores is lower, a relatively heavier grade polymeric material for the upper material layer is likely to be more appropriate. For patients at greater risk of pressure sores, the upper material layer should be made as light and compliant as possible and the polymeric skin material is likely to be more appropriate.

The upper and/or lower material layers may comprise a laminate structure having more than one layer of polymeric material, for example for example materials of different grades or properties, the layers optionally being bonded together. The polymeric material is typically a polyurethane. Such a laminate may preferably comprise at least an inner layer of a thermoplastic material having a relatively lower melting point and an outer layer of a thermoplastic material having a relatively higher melting point, or of a thermosetting material. Bonding materials may be incorporated between the respective layers to join them together, if desired. The lower melting point layer of the laminate allows the material layer to be heat bonded to the polyurethane foam. Generally, sufficient heat is applied to soften of melt said lower melting point layer so that it at least partially penetrates the polyurethane foam to form a bond. The lower material may also include an internal fabric layer between the Thermoplastic layers to provide extra puncture resistance and durability but at the same time retain an outer thermoplastic polyurethane layer for easy washing/disinfection and therefore assured infection control· Preferably in accordance with the first aspect of the invention the polyurethane foam core is substantially co-extensive with the external envelope. In other words, the foam core preferably essentially fills the void defined by the external envelope, subject to the possible presence of vertical through channels or horizontal channels either through the foam core or as an external single channel at the periphery of the Capsule and around the side face of the foam.

The polyurethane foam core may be joined to the external envelope over a major part of the area of its major (i.e. upper and lower) surfaces. This construction avoids movement of the external envelope with respect to the foam core and as a result provides much improved energy dissipation and impact absorption. In this case the inner foam core is preferably bonded to the external envelope.

The polyurethane foam employed in the Capsule system according to the invention preferably has a more open-celled construction than is conventional in the art. Polyurethane foams used in other prior art typically have a very tight closed cell structure. A consequence is that air does not easily pass through the foam. The inventor has appreciated that more open25 celled foam is desirable in promoting a greater air flow through the foam to achieve an improved cushioning effect to provide greater protection if the patient falls.

Other preferred features of the outer membranes are as specified above in relation to the first aspect of the invention.

According to a second aspect of the invention there is provided a matching pair of Cushioning Capsules within a pants system comprising: i) a core comprising a body of polyurethane foam material; ii) an external envelope covering the core and comprising upper and lower material layers together defining an airtight and fully washable capsule substantially filled by the core; and Embodiments and preferred features and constructions of the polyurethane foam core and the external envelope covering the core are as described in relation to the first aspect of the invention.

Other embodiments and preferred features and constructions of the foam core and the external envelope are as described in relation to the first aspect of the invention.

For a better understanding of the invention and to show how the same may be carried into effect, reference will be made to the following drawings in which: Figure 1 is a representation of a Pair of Pants with integrated matching Capsules within the side pockets or cavities which are strategically placed over the vulnerable part of the hip (Greater Trochanter) which is a typical construction according to the invention; Figure 2 shows a side angled view of a Pair of Pants with integrated matching Capsules within the side pockets or cavities which are strategically placed over the vulnerable part of the hip(Greater Trochanter) which is a typical construction according to the invention; Figure 3 shows a front elevation of the typical construction of a Capsule according to the invention; Figure 4 shows the side cross section through a part of the Capsule of Figure 3.

Referring now to Figure 1 and the Capsules 7 are placed in the pants 3. The capsules 7 are inserted into the side pockets 8 on the Pants 3.

In preferred embodiments, the Capsule 7 according to the invention comprises upper and lower layers (10, 11) formed from an air impermeable material, the layers (10, 11) being joined at their marginal edges 12 to form an airtight capsule or external envelope, A polyurethane foam material 13 is disposed within the capsule and occupies substantially all of the volume of the capsule. The polyurethane foam material may be transversely or longitudinally cored (i.e. have transverse bores 15) which further reduces the bulk and weight of the Capsule 7 and may add to its ability to enhance impact resistance i.e. to enhance shock absorption and energy dissipation.

An important feature of the construction of the Capsule 7, is the use of polyurethane layered multi-laminates. In addition to providing added comfort - with characteristics similar to the air or gel based Capsules, the important advantage of being able, to some extent, to stretch and conform directly contribute to reducing shear and friction forces on the user’s skin tissues which in turn results in greater therapeutic benefit, as described above. The outer laminates allow the Capsule 7 to conform very closely to the shape of the patient so that the area of contact between the patient and the Capsule 7 is maximised. Maximising the area of contact with the patient also increases the shock absorption properties of the capsule 7. Typically the foam material 13 will have a thickness of from about 1 cm to about 4cm.

The choice of material for the respective upper and lower layers (10, 11) of the external envelope is important for therapeutic uses. Clearly the material must be air impermeable in order to retain air within the capsule defined by the layers (10, 11).

In preferred arrangements the foam material 13 is attached (e.g. bonded) to the inner surface of the layer of material 11 and to the inner surface of the layer of material 10. Bonding of upper and iower layers of material 10, 11 to the foam material 13 may be achieved as outlined above by providing said upper and lower layers of material 10 and 11 with an inner layer of relatively low melting thermoplastic material which is heat bonded to the foam material.

One preferred construction of the external envelope of the Capsule of the invention comprises the following material layers (starting from the outermost layer):a relatively high melting point polyurethane layer to provide air impermeability: at least one layer of relatively lower melting point polyurethane, which may be bonded to the foam core.

Typically, such a construction will have a combined thickness in the range of from about 0.05mm to about 0.5mm.

In some cases the multi-laminate material 11 at the base of the capsule 7 will have a reinforcing fabric between the High and Low melt layers of Thermoplastic Polyurethane to provide greater puncture resistance and durability while maintaining the ability to easily clean the layer of material 11, therefore assuring decontamination and infection control. In this embodiment the sealed seam 12 can be placed at the top edge of the capsule 7 to ensure the entire surface are of the side walls of the capsule 7 are made from the reinforced material.

In accordance with a further aspect of the invention there is provided a Capsule for insertion into side pockets on a pants comprising: i) upper and lower material layers together defining an airtight and washable capsule; ii) a body of polyurethane foam materia! substantially filling the capsule; and wherein the Capsule is further defined by one or more features selected from features (a) to (d) below: (a) the upper material layer comprises a Multi-Layer thermoplastic polyurethane material; (b) the lower material layer comprises a Multi-Layer thermoplastic polyurethane material which may include a reinforcing fabric between the high and low melt Thermoplastic layers/la mi nates; (c) the upper and/or lower material layer is attached to the body of polyurethane foam material; (d) the upper and/or lower material layer comprises a liquid impermeable vapour and/or moisture impermeable material.

Claims (5)

1. Claims 5 1. A pants system comprising a pants with pockets or cavities incorporating a capsule or matching pair of capsules comprising a core of a polyurethane foam material and an external polyurethane multi-iaminate/multi-layer envelope covering the core where the external laminates of the capsule are bonded to the foam core within the air-sealed capsule. 10
2. 2. A pants system as claimed in claim 1 wherein the external envelope for the capsule comprises a material which is impermeable to air and easily cleaned by wiping or washing.
3. 3. A pants system as claimed in claim 1 to 2 wherein the external envelope forms a sealed capsule including the resilient foam core.
4. 4. A pants system as claimed in any preceding claim wherein the external envelope comprises an inner layer of a relatively low melting point polyurethane material and an outer layer of a relatively high melting point polyurethane material. 20 5. A pants system as claimed in claim 4 wherein the lower and side faces comprise an inner layer ofa relatively low melting point polyurethane material, a reinforcing fabric such as woven nylon or similar laminated to the outer side of that layer and an additional outer layer ofa relatively high melting point polyurethane material to provide an outer seal to the inner layers. 6. A pants system as claimed in any preceding claim wherein the entire arrangement comprises a construction that is easily laundered and fully machine washable without removing any parts of the claimed construction. 30 7. A pants system as claimed in any of claims 1 to 6 wherein the polyurethane foam material has a thickness in the range of from about 1cm to about 4cm. 8. A pants system as claimed in any of claims 1 to 7 wherein the polyurethane foam material includes a plurality of longitudinal and/or transverse bores. 9. A pants system as claimed in any of claims 1 to 8 wherein the resilient foam core is substantially co-extensive with the external envelope. 10. A pants system with integrated matching capsules substantially as hereinbefore described 40 with reference to any of Figures 1 to 4. 6. A Capsule or mattress system as claimed in any of claims 1 to 3 or a Capsule or mattress as claimed in claim 4 to 5 wherein the external 5 envelope comprises a polyurethane multi-laminate material. 7. A Capsule system as claimed in claim 6 wherein the external envelope comprises an inner layer of a relatively low melting point polyurethane material and an outer layer of a relatively high melting point polyurethane 10 material. 8. A Capsule system as claimed in claim 7 wherein the lower and side faces comprises an inner layer of a relatively low melting point polyurethane material, a reinforcing fabric such as woven nylon or similar laminated to 15 the outer side of that layer and an additional outer layer of a relatively high melting point polyurethane material to provide an outer seal to the inner layers. 9. A Pants System with internal air-sealed Capsules as claimed in any of 20 claims 1 to 8 wherein the entire arrangement comprises a construction that is easily laundered and fully machine washable without removing any parts of the claimed construction. 10. A Capsule as claimed in any of claims 1 to 9 wherein the polyurethane 25 foam material has a thickness in the range of from about 1cm to about 4 cm. 11. A Capsule system as claimed in any of claims 1 to 10 wherein the polyurethane foam material includes plurality of longitudinal and/or 30 transverse bores. 12.A Capsule system as claimed in any of claims 1 to 11 wherein the resilient foam core is substantially co-extensive with the external envelope.
5. 5. 13. A Pants System with integrated matching capsules substantially as hereinbefore described with reference to any of Figures 1 to 4.