Note: Descriptions are shown in the official language in which they were submitted.
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ORTHOP~DIC SUPPORT PACKAGE AND METHOD
Background of the Invention
Storage is a major problem in connection with
supplyiny foam orthopedic supports for patients of
hospitals and other healthcare facilities due to the
hul~y nature of such supports~ It is difficult to carry
the foam supports, for example, upon the already crowded
carts which are utilized by nurses and other attendants
to supply patients with medication and other needs. It
has even been found that patients who would be best
treated with foam orthopedic supports are denied their
use becaùse of the difficulties in supplying them to
thP patients.
The most oommonly used method of packaging
the foam orthopedic s~pports which have been in use here-
tofore is through the use o heat shrinkable thermoplastic
material. While such material affords an attractive
sanitary package, there is little or no reduction in bulk.
~The prior art relating to the packaging of foam cushion~
includes United States Letters Patent No. 3,246D443, but
this patent contemplates the use of individual sheets
be~ween which the xegular shaped oam cushion is sandwiched.
The regular shape~ oam cushion with the thermoplastic
sheets above and below on either side is compressed between
press members acting a~ a bed ana a platen. The difficulty is
that a seal is required on all sides of the package, and
-~ while a uniformly aligned smoothly sealed package is
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~ illustrated in the patent, it has been found that fxom a
practical standpoi~t in commer~ial packaging involving sub-
stantial numbers, such a package is difficult to achieve~
Further efforts include those exemplified by ~nited States
Letters Patent No. 3,968,620 wherein an air suction apparatus
is used to evacuate the air from a package contai~ing regularly
shaped compressible material. This suction system is perhaps
the most apparent solution to the problem, but the degree of
compression or reduction in size of the foam article is not
sufficient to achieve the desired results when supplying
orthopedic foam supports.
Accordingly, the prese~t invention seeks
to supply an orthopedic support package
wherein the foam orthopedic support may be reduced in
volume to such an extent as to make its storage and presence
for use by a patient readily available.
Also the present invention seeks to provide
a sanitary means of packaging an orthopedic
support which will provide a longer storage shelf lie together
with convenience in dispensing for supplying in health-
care ~acil;ties to orthopedic patients.
Still further tlle in~ention seeks to
provide a method of forming a package for reduc;ng the size
of the orthopedic supports which may be relatively inexpensive
and practical from the standpoint of providing reduced
storage and space requirements to facilitate the supply;ng
of orthopedic supports of the foam type to orthopedic
patients.
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Summary of the Invention
It has been found that satisfactory orthopedic
packages of reduced size may be obtained by utilizing a multi-
layered thermoplastic bag which is sealed except for a single
opening to accommodate reception of the orthopedic support
within the bag. The orthopedic support is placed within the
bag which is then pressed within a suitable compression applying
means such as a press having members acting as a platen and
as a bed. After compression has been applied so as to
differentially compress the height dimensions of the irregularly
shaped orthopedic support, and evacuating air from the bag,
the sealing along the single open edge may be accomplished
conveniently, and the marginal portions in that area trimmed
away as by cutting. When the compressive action of the press
is removed, an evacuated flat marginal portion of the bag
extends outwardly entirely about the orthopedic support by
an amount resulting from the reduction in height of the support
due to the vacuum in the sealed bag and the tendency of the
foam article to expand.
The invention in one aspect pertains to the met~od
of packaging an orthopedic support comprising providing an
orthopedic support constructed essentially of resilient
synthetic open cell foam material with air entrained therein
having a substantial and irregular height profile and a highly
bulky configuration and providing a thermoplastic bag
constructed of heat sealable thermoplastic film having a
sufficient shelf life to prevent leaking and seeping of air
affording storage of the package in a healthcare facility for
extended periods of time, the bag having presealed edges but
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providing an open edge portion thereof for insertion of the
orthopedic support therethrough, compressing the orthopedic
support minimizing the bag size required, placing the orthopedic
support thus compresed within the bag, differentially
compressing the orthopedic support within the bag to such an
extent as to reduce the substantial profile and bulk
configuration by a major amount to a generally uniform flat
configuration with e~acuation of a corresponding amount of
air from the bag by urging a platen of a press into compressing
relation with a bed of the press by a predetermined amount,
placing a heat seal along the open edge portion after the
compression and evacuation, and releasing the compressing action
of the press after heat sealing the edge portionO
It is desirable but not necessary, that some
mechanical means be employed for precompressing the foam article
so that relatively small bags may be utilized thus conserving
on the thermoplastic bag material and pexmitting a less costly
process. This precompression may be obtained, for example,
by forcing the foam article between constricting members which
hold the bag on the outside thereof to facilitate reception
through the open end of the bag of the precompressed orthopedic
support.
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srief Description of the Drawings
The construction designed to carry out the invention
will be hereinafter described, together with other ~eatures
thereof.
The i~vention will ~e more readily understood
from a reading of the following specification ~nd by reference
to the accompanying drawings forming a part thereof, wherein
an example oÆ the invention is shown and wherein:
Figure 1 i~ a sectional side elevation illustrating
a suitable press and orthopedic support pac~age in process
of ~eing formed therein in accordance with the invention,
Figure 2 is an enlarged perspective view ~roadly
illustraæing the press and orthopedic support package of
Figure 1~
Figure 3 is a still further enlarged sec~ional
elevation through an edge por~ion of ~he press and
support package u~ili2ed in Figure 1,
Figure 4 is a perspective v;ew of an orthopedic
support package in the form o a cradle boot within a
thermoplastic bag prior to compression, .
Figure 5 is a plan view of a support package
~ormed from the article illustrated in Figure 4,
Figure 6 is a perspective view o~ an orthopedic
support in the form of a cast elevator and the like con-
tained withîn a thermoplastic bag prior to compression,
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Figure 7 is a pla~ view illustrating the support
packase formed after compression of the article illustrated
in Figure 6,
Figure 7A is an end view of the package illustrated
' in Figure.7,
Figure 8 is a perspective view illustrating a
- body aligner carried within a thermoplastic bay prior to
compression,
~igure 9 is an enlarge~l perspective view illustrating
the package comprising the body aligner illustrated in
Figure 8,
~ igure 10 is a~perspective view illustrating a
foot drop support and the like contained within a thermo-
plastic heat sealable bag prior to co~pression and
sealing~ and
Figure 11 is an enl~rged pla~ view illustrating
a package containing ~he article.
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Description of a Preerred Embodiment
The drawinys illustrate an orthopedic support
A constructed of resilient synthetic open cell foam material
having a substantlal, albeit irregular height dimension with
air entrained therein. A bag B is constructed of heat seal-
able thermoplastic multi~layered film sealed along its edges
except or a single open edge portion thereof for insertion of
said orthopedic support. The orthopedic support is
differentially compressed to such an extent as to reduce a
dimension thereof by a major amount with eYacuation of a
corresponaing amount of air from the bag. A heat seal C
is placed along the single open edge portion placed th rein
ater the compression and evacuationO An evacuated marginal
portio~ D of the bag extends outwar~ly about the orthopedic
support by an amount resulting fxom the reduction in height
of the orthopedic support. Thus 9 the package may be con-
veniently stored and the orthopedic support dispensed
therefrom by a healthcare acility by releasing same from
said bag permitting return of the orthopedic support sub-
2q stan~ially to its original full unrestrained size when neededfor use by an orthopedic patlentO The dif~erential com--
pression described above is obtained by uxging a cushioned
platen ~ of a press into compressing relationship with a
smooth bed of the press to an extent which may be determined
a ~y a suitable mechanical stop. The package is temporarily
stored to test for leaXs and is then shipped to the customex.
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Figure 1 illustrate~ a press which includes a
lower frame member broadly designated at 10 for carrying a
bed which includes a lower portion 11 which may carry built
up wooden member 12 for accommodating-a smo~th planer plastic
surface. .The platen is illustrated as including a rigi~
member 14 having compressible portions 15 which may be
constructed as from foam.
The press includes an upper fram~, broadly
designa~ed at 16 which supports a fluid operated cylinder 17
which~ thxough the rod 18 operates the platen E. Suitable
mechanical stop means are employed for limiting the down-
ward movement of ~he press platen member, but t~ese stops
are convèntional and are not shown except insofar as they
may include portions of the seali~g means which come
together and ~hich are d~scribe~ belo~.
A second hydraulic Qr air operate~ oylinder 19
has a piston rod 20 for owering a front gripping member
21 which bears against a first portion 22 ~f a U-~haped
member which defines an opening 23 therein. The U-shaped
member 22 at its back leg carries a wire or other suita~le
heating element 24 which e~gages a back member 25 opposite
the ~ember 21 for effecting a heat seal~C. The heat sealing
operation occurs immediately following compression ~y the
lowering of the platen E by actuation of the cylinder 17
by lowering of the memb~rs 21 and ~5 by operatio~ of the
cylinaer 19 which follows evaauationO Together with
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the sealing operation A, a transversely movable knife 26 is
provided for trimming of an edge 27 of the bag, primarily
for eslthe~ic reasorls, but also to provide a uniform pacXage
edge. Xnives of the type illustrated at 26 are common
expedients in various sealing operationsO
By reference to Figure 2, it will be noted that,
after the sealing operation forming the seal C, the
k~ife 26 moves transversely in the direction of the arrow
to trim off the edge 27. It will be fuxther noted that
auring and prior to compression, the edges of the bag are
expanded or substantially V-shaped, but by xeference to
Figur~ 3, it will be noted that after re val of the com-
pression by raising the platen E, that the edge portions
of the bag are sucked together because of the vacuum
obtained within the package and because of ~xpansion of
the foam member A after remov~l of ~he compres~ionO The
edges B thus form~d are significant in that ~hey may
be-punctured by an attendant which permits full expa~sion
. o~ ~he orthopedic suppoxt within ~he bag prior to tearing
awa~ the bag for u~e. Thu~, a limited sanitary storage
in.expanaed condition is possible and if ~his is not
desired, the bag may be easily removed at once without
damage to the orthopedic supportO
It has been ound that it is possible to reduce
the height dimension of the open cell type polyurethane
foam materials which ar~ often usea in orthopedic supports
by an amount ~n excess of about 80%~ or to approximately
a 6 to 1 reduction of the unxestricted he~ght of the
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orthopedic 'support~ Such foa~ material has a densi~y on the
order of about l.Ç3 pound~ per cubic foot, and an indentation
load defle~tion of about 34 to 38. It is important that the
material of the thermpolastic bag be capable of being heat
sealed and that it h~ve sufficient shelf life to prevent
leaking and seepaye of air or affording a suitable shelf life.
Such material has been found to be of a multi~layered
thermoplastic film material such as designated as B-620
bag supplied by Cryovac. This multi-layer sealing bag
is designed ~pecifically for vacuum packaging of fresh
meat, bu~ it has been found ~hat this bag may serve the
purpose of containing the orthopedic support as des~ribed
herei~. It is not believed at present that the heat
shrin~able material often employed in wrapping meat would
be suitable for the purposes d~scussed hexein.
By way of exampleO variou6-specific foam ortho-
pedi~ support articles and th~ir pacXages constructed in
accordance with the invention æ e illustrated. The
craale boo~ illustratea in Figures 4 and 5 is more fully
describea in United Sta~es Letters Patent No. 4,135,S04.
~t will be observed that the presealed e~ges as illustrated
at 30 are somewhat irregular after packagi~g ana sealing,
while ~he seal C is fairly regular in its alig~ment. The
article contai~ed wi~hin the marginal portions which extend
thereabout ana which contain collapsible portions of the
bag ~erYe to retain the orthopedic support in compressed
relation. The height aimension ~s reduced while the
general outline remains fairly unifoxm except that the thic~-
: ened portions of thè article extend outwardly as illustrated
at 31. ~he vert;cal opening is somewhat elongated as
illustrated at 32. The article i5 inserted as through an
~pen end of the bag illuskratea at 33. The height reduction
; of the cradle boot, for example, is approximatsly 83%. In
other words, the maximum nine inch dimension is reduced
to appxoximately 1 and 1/2 inches.
Figures 6 ana 7 illustrate the packaging of a cast
elevator which is of khe type more fully illustrated in
United States Letters Patent No. 3,946,451. The open end
of the bag is illustrated ait 33 and $he thickened portions
of the article may be observed as at 3-1 in Figures 7 and
7A.. These raised portions 34 w~ic:h are barely perseptible
after the height dimension has been dif~erentially reduced,
correspond to the rais~a side portions 34a in Figure 6.
~ igure~ 8 and 9 iilustrate the packaging o~E a body
aligner o~ the type more fully il~ustrated in United States
Letters Paterit No. 3,938,205. The l:~ody aligner has its
20 major height ~imension culmi~ating in the apex portion ~
illustrate~ at 35 . The apex pc>rtior~ is barely perceptibl e
being illustrated at 35a in Figure 9., The irregular edge
portions as illustr~ted at 36 ~ do not reveal themselves
~o any perceptible extent in 'che firlal package illustrated in
Figure 9. The packa~ing o~E a iEoot arop support is illustrated
in Figures 10 and 11 wherein the cuff portion 37- i~
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illu~trated in compressed form as at. 37a in Figure 11,
~arrying thereabout~ a ~ap 38 illustrated in compressed
foxm as at 33a ill Figure 11. ~he :~oot drop support i~
more fully illustrated in United States Letters Pate~t No.
3,903,873~ While specific or~hopedic supports are
illustratea for illus~rakive purposes, any open cell foam
orthopedic support may be thus packaged.
It is important that, af ter packaging, the foam
orthopedic supports be stored fox about a day or two .
10 to determine whether or not there is any leakage. If there
is arly sllbstantial expansion of the package during this
period, ~he supports are returned for repackaging prior
to shipme~t and use by the customer. It is also significant
that while the step of differentially compressing ~he
or~hopedic supports iq taking place, that a yieldable
substantially uni~orm ~orce is applied on one side of
.
the orthopedic support by the planer foam bed illustrated
upon ~he platen against the smooth surfa~e on the other
side o the orthopedic support which is furnished by the
sub~tantially rigid wooden planar surface bensath the
smooth plastic ~hee~. Such an application of force
a~roi~s lea~cage through partial or complete plmcturing oi~
the plas~ic bag~. The yieldable member may be carried by
the bed and the smooth ~heet by the platen if preferred.
While a pxeferred embodiment of the invention has
~een describe~ using specifi~ terms, such aescription i~
-~or illustr~tive purposes only and it is to b~ understood
that change~ and variations may be made without departing
from the spixit or scope of the following! claims.
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