RELATED APPLICATIONS

[0001] This application claims the benefit of the following four U.S. Provisional Patent Applications, all of which are incorporated by reference:

[0002] 1. Serial No. 62/096,959, filed on December 26, 2014;

[0003] 2. Serial No. 62/147,831 , filed on April 15, 2015;

[0004] 3. Serial No. 62/154, 181 , filed on April 29, 2015; and

[0005] 4. Serial No. 62/166,165, filed on May 26, 2015.

FIELD OF THE DISCLOSURE

[0006] The present disclosure relates generally to improved medical blankets designed for use by patients in a hospital. In this application, "blanket" includes any type of textile that provides protection against the elements and "hospital" includes any type of medical facility. The improved blankets may be branded as the Eco Blanket Solution™.

BACKGROUND

[0007] Hospital blankets for patient use must meet a number of requirements to satisfy the needs of the patient, the hospital and the laundry facility that cleans the blankets. For the patient, the blanket must be sanitary and comfortable, keeping the patient warm in a colder climate and cool in a warmer climate. For the hospital, the blanket must have minimal bulk, be easily portable, be easily distributable to patients for use and be easily collectable from patients for cleaning or disposal. For the laundry facility, the blanket must be easy to clean with minimal water/soap usage and minimal drying times.

[0008] Traditional cotton and polyester/cotton thermal blankets often do not satisfy these needs because of their numerous drawbacks. Such drawbacks include: poor warmth due to low thermal insulation, low strength and abrasion resistance, high water usage in laundering and longer drying time. This results in a blanket with shorter useful life and a relatively higher cost per usage.

[0009] Further, optimization in laundry industry has traditionally focused on improved machines, improved chemistry and improved water usage. Yet the state of the art ignores another equally important method of optimization: to improve throughput and profit margins at a laundry by improving the features of the laundered materials.

[0010] Accordingly, there is a need in the art to provide an improved hospital blanket that has a longer useful life while providing superior features for the patient, hospital and laundering facility.

BRIEF DESCRIPTION OF THE FIGURES

[0011] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention, and explain various principles and advantages of those embodiments.

[0012] FIG. 1 is an orthographic view of a first embodiment of a blanket in accordance with the present invention.

[0013] FIG. 2 is a close-up view of Fig. 1 .

[0014] FIG. 3 is a close-up view of a second embodiment of a blanket in accordance with the present invention.

[0015] Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.

[0016] The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DESCRIPTION

[0017] Turning to Figure 1 , shown is an improved polypropylene blanket constructed entirely of man-made fiber with a cotton-like hand. Figure 2 is a close-up of a portion of the improved polypropylene blanket shown in Figure 1 , enlarged to show detail. Figure 3 is a close-up of a portion of another

embodiment, an improved polypropylene/polyester blanket, enlarged to show detail.

[0018] I. IMPROVED POLYPROPYLENE BLANKET

[0019] The improved polypropylene blanket provides longer life and low cost per usage due to its high thermal insulation, high strength and high abrasion resistance. This results in a blanket with a fast drying time that conserves energy and proves more durable than cotton-rich products. The blanket is soil resistant that attracts less dirt and dust, is resistant to fungi, molds and mildew and wicks away perspiration from the skin.

[0020] A. PHYSICAL PROPERTIES

[0021] The overall properties of the improved polypropylene blanket may include:

[0022] - Size: 74" x 100" and weight: 2.60 lbs. per blanket (but the size may be adjusted to be any useful length and width and the weight will change

accordingly). [0023] - Appearances: Choice of white or color; and

[0024] - Texture: "Chevron" weave pattern, as shown in detail in Figure 2.

[0025] Specific features of the improved polypropylene blanket may include:

[0026] - Fiber Identification: 100% Olefin.

[0027] - Fabric weight (ASTM D3776): 6.94 oz./sq. yd.

[0028] - Fabric count (ASTM D3775): 36.7 ends/inch x 30 pics/inch.

[0029] - Yarn size (ASTM D 1059): 775.3 denier warp x 747.1 denier filling.

[0030] - Filament count: 160 filaments warp and 160 filaments filling.

[0031] - Yarn twist (ASTM D 1423):

Singles, "S" twist with 4.08 TPI Avg. (warp); and

Singles "S" twist with 3.94 TPI Avg. (filling).

[0032] - Thermal transmittance of materials (ASTM F1868): resistance: Ret (CLO) of 0.681 average (Procedure Part A Thermal Resistance).

[0033] - Electrostatic Clinging of Fabrics, Fabric-to-Metal Test (AATC 1 15) at 23 degrees C, 42% relative humidity: Warp: 4 seconds for nylon rubbing fabric; 8 seconds for polyester rubbing fabric. Filling: 1 1 seconds for nylon rubbing fabric; 12 seconds for polyester rubbing fabric. (Average time required for specimen to lose electrostatic charge.)

[0034] - Fabric Dimensional Change and Appearance (Machine Wash @ 160 degrees F, Tumble Dry High, Unrestored):

First Cycle Dimensional Change: -1 .3% Length; -1 .2% Width. Appearance: Slightly to negligibly yellower and less bright shade change, No noticeable pilling or fuzzing, Hand is slightly to negligibly more soft. No other noticeable change or deterioration.

Third Cycle Dimensional Change: -2.1 % Length; -2.1% Width. Appearance: Slightly yellower and less bright shade change. No noticeable pilling or fuzzing. Hand is slightly to negligibly more soft. Slight to negligible short snags No other noticeable change or deterioration.

Fifth Cycle Dimensional Change: -2.3% Length; -2.6% Width. Appearance: Noticeably yellower and less bright shade change, No noticeable pilling or fuzzing., Hand is slightly more soft., Slight to noticeable short snags, No other noticeable change or deterioration.

[0035] The foregoing features may be adjusted so as to produce results similar to those described herein.

[0036] B. ADVANTAGES

[0037] The advantages of the improved polypropylene blanket are numerous. For the patient, the improved polypropylene blanket wicks away perspiration by promoting movement of moisture away from the skin because of its hollow fiber. This increases patient comfort because it allows the fabric to stays cooler in a warm climate. In a colder climate, the hollow fiber provides additional insulation, which keeps the patient warm.

[0038] The improved polypropylene blanket is also more sanitary due to its resistant to fungi, molds and mildew. This resistance inhibits growth of microscopic organisms on the surface and resists growth of odor producing bacteria. Polypropylene is also soil resistant attributable to chemical inertness and lower accumulation of static by friction during use. As a result, polypropylene fabric attracts less dirt and dust as compared to other materials.

[0039] For the hospital and laundry, the improved polypropylene blanket has minimal bulk and is easily portable. The improved polypropylene blanket also cleans easily with low water usage and quick drying when laundering. As such, it uses less energy, utilities and chemicals to process. This provides a cost savings both because it takes fewer resources to clean each blanket and because each blanket can endure more laundry cycles before needing disposal.

[0040] C. TEST RESULTS [0041] Various test results of the improved polypropylene blanket when compared with standard CVC thermal blankets show marked improved performance in the throughput of the blanket's washing and drying. (CVC stands for Chief Value Cotton, which is a blend of cotton and polyester where cotton is in the majority.)

[0042] EXAMPLE 1

[0043] Example 1 is based on a 5-cycle laundry tunnel wash and drying test comparing a 2.62-pound improved polypropylene blanket (a "new spread") and a 2.2-pound CVC thermal blanket (a "light-weight spread"). A cycle is a tunnel wash and dry. The therm is a unit of heat energy equal to 100,000 British thermal units (BTU). It is approximately the energy equivalent of burning 100 cubic feet (often referred to as 1 CCF) of natural gas. One therm can also be provided by about 96.7 cubic feet (2.74 m ³ ) of natural gas.

[0044] The following Table 1 shows information related to a 5-cycle wash for the new spread.

TABLE 1

DRY TIME 19 19 19 19 19

(minutes)

INLET TEMP (F) 445

OUTLET TEMP (F) 180

COOL DOWN 2.5

TIME (minutes)

WEIGHT AFTER 258

DRY CYCLE

(pounds)

THERMS USED 2.48 2.59 1.96 2.48 2.38

PER DRYER CYCLE

AVG. THERMS 2.38

FOR TEST

GAS METER READINGS

LOAD IN 121.1 130 132 137.2 139.6

LOAD OUT 123.5 132.5 133.9 139.6 141.9

TOTAL THERMS 2.48 2.59 1.96 2.48 2.38

USED

[0045] This results in a therm per blanket of 0.91 and a therm per pound of 0.34.

[0046] The following Table 2 shows information related to a 5-cycle wash for the light-weight spread.

TABLE 2 CYCLE # 1 2 3 4 5

PIECES PER 108 108 108 108 108 LOAD

TOTAL WEIGHT 237.6 237.6 236.7 236.7 236.7 PER LOAD

(pounds)

EXTRACTED 355.5 395 394 394 394 WEIGHT (pounds

at the end of the

tunnel wash)

DRY WEIGHT AT 243 31 .65%

THE END OF CYCLE 5 (pounds)

DRY TIME 28 28 28 28 28 (minutes)

INLET TEMP (F) 445

OUTLET TEMP (F) 185

COOL DOWN 2.5

TIME (minutes)

WEIGHT AFTER 218.7

DRY CYCLE

(pounds)

THERMS USED 3.35 2.79 3.07 2.79 2.98 PER DRYER CYCLE

AVG. THERMS 3.00 FOR TEST GAS METER

READINGS:

LOAD IN 1 17.5 124 133.9 141.9 144.9

LOAD OUT 121.1 127 137.2 144.9 148.1

TOTAL THERMS 3.72 3.10 3.41 3.10 3.31

USED

[0047] This results in a therm per blanket of 1.36 and a therm per pound of 0.61 .

[0048] EXAMPLE 2

[0049] Example 2 is based on a 5-cycle laundry tunnel wash and drying test comparing: a) a 2.62-pound improved polypropylene blanket (a "new spread"); b) a 2.2-pound CVC thermal blanket (a "light-weight spread"); and c) a 3.75-pound CVC thermal blanket (a "traditional spread") . The data in Example 2 was obtained in the following manner:

The data for the new spread of Example 2 is identical to the data for the new spread of Example 1.

The data for the light-weight spread of Example 2 is identical to the data for the light-weight spread of Example 1.

- The data for the traditional spread of Example is based on the data for the light-weight spread of Example 2 extrapolated to a 3.75 pound CVC thermal blanket.

[0050] The following Tables 3, 4 and 5 show further data comparing the new spread, the light-weight spread and the traditional spread.

TABLE 3 New Spread 1st 2nd 3rd 4th 5th Average (Based on 108 Cycle Cycle Cycle Cycle Cycle

pieces per

load)

TOTAL

WEIGHT 283 283 283 283 283

PER LOAD

(2.62

lb./piece)

(pounds)

EXTRACTED WEIGHT 361 361 361 361 361

(pressed)

(pounds)

DRY TIME

(minutes) 19 19 19 19 19 19

WEIGHT AFTER DRY 258 258 258 258 258

CYCLE

(pounds)

LOAD IN(therms) 121 130 132 137 140

LOAD OUT

(therms) 124 133 134 140 142

TOTAL

THERMS 2.48 2.59 1 .96 2.48 2.38 2.38

USED TABLE 4

Light Weight 1st 2nd 3rd 4th 5th Average Spread Cycle Cycle Cycle Cycle Cycle

(Based on 108

pieces per

load)

TOTAL

WEIGHT 238 238 238 238 238

PER LOAD

(2.20

lb./piece)

(pounds)

EXTRACTED WEIGHT 356 356 356 356 356

(pressed)

(pounds)

DRY TIME

(minutes) 28 28 28 28 28 28

WEIGHT AFTER DRY 243 243 243 243 243

CYCLE

(pounds)

LOAD IN

(therms) 1 18 124 134 142 145

LOAD OUT

(therms) 121 127 137 145 148 TOTAL

THERMS 3.72 3.10 3.41 3.10 3.31 3.33

USED

TABLE 5

(therms) 200 21 1 229 243 248

LOAD OUT

(therms) 206 216 234 247 252

TOTAL

THERMS 6.35 5.29 4.92 4.34 4.67 5.1 1

USED

[0051] The following Table 6 shows further data comparing the new spread and the light-weight spread.

Table 6

[0052] The following Table 7 shows further data comparing the new spread and the traditional spread.

Table 7

[0053] EXAMPLE 3

[0054] In this Example 3, another set of lab trials for drying comparing the improved polypropylene blanket of 2.6 pounds (called ECO Thermal) with regular CVC thermal blankets of 3.75 pounds and 2.6 pounds was performed. Fabric samples from each product of the same size were taken and then dried them using tumble drying equipment and line drying.. After each interval the weight of the samples was recorded.

[0055] The following Table 8 shows tumble drying data comparing the ECO Thermal Blanket with the 2 CVC Thermal Blankets.

Table 8

[0056] The following Table 9 shows line drying data comparing the ECO Thermal Blanket with the 2 CVC Thermal Blankets.

Table 9 Thermal Thermal Thermal

Blanket Blanket Blanket

Weight per item 2.6 lbs 3.75 lbs 2.6 lbs

Initial Weight of sample 182 grams 308 grams 184 grams

Wet Weight after soaking in water 250 grams 735 grams 440 grams

Weight after spin cycle 232 grams 522 grams 312 grams

Weight after 30 minutes 210 grams 498 grams 300 grams

Weight after 60 minutes 200 grams 486 grams 291 grams

Weight after 90 minutes 190 grams 476 grams 284 grams

Weight after 120 minutes 182 grams 462 grams 275 grams

Weight after 720 minutes X 318 grams 1 84 grams

[0057] EXAMPLE 4

[0058] Shown in Table 10 are data comparing results after about 60 pieces of the improved polypropylene blanket (called ECO-Blanket) and a prior art standard blanket (called E49277-621 ) were washed 100 times.

Table 10

[0059] The data show that because of the lower absorbency level of the yarns, only about 1 /3 as much water ends up going into the dryer. There is a

corresponding 2/3 reduction in drying time.

[0060] D. CONCLUSIONS

[0061] The conclusions drawn from these Examples are:

[0062] - The improved polypropylene blanket inherently absorbs less water when compared to regular CVC thermal blankets. CVC thermal blankets absorb 1 50% water with respect to their own weights and the improved polypropylene blanket absorbs only 36% of its weight.

[0063] -Laundry machines operating at optimum workload are able to launder 50% more improved polypropylene blankets due to its less absorption. This means less water usage and waste, less chemicals, less wash detergents and higher efficiency per machine.

[0064] - The improved polypropylene blankets are quick to dry. In line drying, the improved polypropylene blanket dry 6 times faster than regular CVC thermal blankets. In tumble drying, the improved polypropylene blanket needs 75% less tumble drying time than regular CVC thermal blankets.

[0065] In addition to the foregoing specifications, a 1 .6 to 1 .75 pound plain weave blanket may be used with otherwise the same or similar physical properties, This plain-weave blanket may be a bath blanket with the same 100% Olefin.

[0066] II. IMPROVED POLYPROPYLENE/POLYESTER BLANKET

[0067] The improved polypropylene/polyester blanket is a second embodiment of a blanket that provides longer life and low cost per usage due to its high thermal insulation, high strength and high abrasion resistance. This results in a blanket with a fast drying time that conserves energy and proves more durable than cotton-rich products. The blanket is soil resistant that attracts less dirt and dust, is resistant to fungi, molds and mildew and wicks away perspiration from the skin.

[0068] The improved polypropylene/polyester blanket may have one or more of the following physical properties:

[0069] - Blend: 85% Polypropylene / 15% Polyester.

[0070] - Finished Size: 70" width x 90" length and weight 1 .6 lb. (but the size may be adjusted to be any useful length and width and the weight will change accordingly).

[0071] - Warp Count: 150 Denier.

[0072] - Weft Count: 330 Denier.

[0073] - Warp Threads per inch: 34.

[0074] - Weft Threads per inch: 34.

[0075] - Packing Bale: 48 pes per bale.

[0076] - Fabric weight (AST D3776): 4.66 oz./sq. yd.

[0077] - Fabric count (ASTM D3775): 36.0 ends/inch x 40.0 pics/inch.

[0078] - Yarn size (ASTM Dl 059): 145.6/1 denier warp x 738.7/2 denier filling.

[0079] - Filament count: 48 filaments warp and 80 filaments filling per ply.

[0080] - Yarn twist (ASTM D1423):

<1 TPI (warp); and

2 Ply "S" twist with 199.6 TPI Avg. (filling).

[0081] - Fiber Identification (AATCC 20A - With Moisture): Olefin: 83.91 %

(confirmed by DSC analysis) and Polyester: 16.09%.

[0082] - Thermal transmittance of materials (ASTM F 1 868): resistance: Ret

(CLO) of 0.67 average (Procedure Part A Thermal Resistance).

[0083] - Electrostatic Clinging of Fabrics, Fabric-to-Metal Test (AATC 1 1 5) at 23 degrees C, 27% relative humidity: Wales: 0 seconds for nylon rubbing fabric; 0 seconds for polyester rubbing fabric. Courses: 0 seconds for nylon rubbing fabric; 0 seconds for polyester rubbing fabric. (Time required for specimen to lose electrostatic charge: fabric does not cling.)

[0084] - Fabric Dimensional Change and Appearance (Machine Wash @ 160 degrees F, Tumble Dry High, Unrestored):

First Cycle Dimensional Change: - 15.5% Length; -3.9% Width. Appearance: Slightly brighter shade change. No noticeable pilling. Slight to negligible fuzzing, Slightly puckered overall. Hand is slightly to negligibly less soft. Slight to negligible short snags. No other noticeable change or deterioration.

Third Cycle Dimensional Change: - 1 7.5% Length; -5.1 % Width. Appearance: Slightly brighter shade change. No noticeable pilling. Slight fuzzing, Slightly puckered overall. Hand is slightly less soft. Slight short snags. No other noticeable change or deterioration.

Fifth Cycle Dimensional Change: -1 7.9% Length; -5.5% Width. Appearance: Slightly brighter shade change. No noticeable pilling. Slight fuzzing, Noticeably puckered overall. Hand is slightly less soft. Slight short snags. No other noticeable change or deterioration.

[0085] In an additional test, after 3 washes, the length shrank by 20% and the width shrank by 5%. These washes produced a yellowed fabric with a rough hand, stretches and rough wavy edges.

[0086] The foregoing features may be adjusted so as to produce results similar to those described herein. Specifically, a second embodiment may have a fabric weight of 6.82 to 7.2 oz/sq. yd. and a fabric count within a range of 35-40/" ends x 30-34/" pics.

[0087] The improved polypropylene/polyester blanket may have the same advantages as the improved polypropylene blanket set forth in Section I.D, above.

[0088] In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.

[0089] The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims that claim benefit to this application. The invention is defined solely by such claims including any amendments thereto and all equivalents of those claims as issued.

[0090] In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such

modifications are intended to be included within the scope of present teachings.

[0091] The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

[0092] Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," "has", "having," "includes", "including," "contains", "containing" or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by "comprises ...a", "has ...a", "includes ...a", "contains ...a" does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms "a" and "an" are defined as one or more unless explicitly stated otherwise herein. The terms "substantially", "essentially", "approximately", "about" or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art. The term "coupled" as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is "configured" in a certain way is configured in at least that way, but may also be configured in ways that are not listed.

[0093] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.