Claims
- 1. A resin-coated sheet material comprising:
- (a) a knit fabric comprising a low modulus organic yarn having a modulus of about 5 to about 100 grams per denier;
- (b) a nonfiberglass stiffness-controlling yarn knit into the fabric as weft insertions, the stiffness-controlling yarn having a modulus of greater than about 5 grams per denier and comprising about 3 to 20 percent by weight of the total fabric weight; and
- (c) a curable resin coated on the fabric
- wherein the stiffness-controlling yarn reduces wrinkling in the fabric during application of the resin-coated sheet material to a body part.
- 2. The resin-coated sheet material of claim 1, wherein the stiffness-controlling yarn has less than 15% shrinkage.
- 3. The resin-coated sheet material of claim 1, wherein the fabric includes a stretch yarn.
- 4. The resin-coated sheet material of claim 3, wherein the stretch yarn is a heat shrinkable, thermoplastic yarn.
- 5. The resin-coated sheet material of claim 1, wherein the stiffness-controlling yarn is a monofilament yarn.
- 6. The resin-coated sheet material of claim 1, wherein the stiffness-controlling yarn has a denier between 80 and 350.
- 7. The resin-coated sheet material of claim 1, wherein the fabric comprises two or more of the weft insertion yarns and wherein the weft insertion yarns do not pass through the outermost wales of the fabric.
- 8. The resin-coated sheet material of claim 1, wherein the material is an orthopedic casting tape or a casting splint.
- 9. The resin-coated sheet material of claim 8, wherein the curable resin further comprises a filler.
- 10. The resin-coated sheet material of claim 9, wherein the filler comprises glass bubbles.
- 11. The resin-coated sheet material of claim 9, wherein the filler comprises microfibers.
- 12. The resin-coated sheet material of claim 9, wherein the filler is calcium metasilicate.
- 13. The resin-coated sheet material of claim 1, wherein the resin is water curable.
- 14. The resin-coated sheet material of claim 13, wherein the water-curable resin is an isocyanate functional prepolymer.
- 15. A resin-coated sheet material comprising:
- (a) a knit fabric comprising an organic-filament yarn, wherein the fabric has been calendered to not more than 30% of the fabric original thickness; and
- (b) a water curable resin coated on the calendered fabric.
- 16. The resin-coated sheet material of claim 15, wherein the fabric includes a stretch yarn.
- 17. The resin-coated sheet material of claim 15, wherein the fabric includes a fiberglass yarn.
- 18. A method of making a resin-coated sheet material, comprising the steps of:
- (a) knitting a stretch yarn and a nonfiberglass stiffness-controlling yarn with a warp knitting machine to provide a knit fabric, wherein the stiffness controlling yarn has a modulus of greater than about 5 grams per denier;
- (b) shrinking the fabric;
- (c) calendering the fabric to not more than 30% of the fabric original thickness; and
- (d) coating a curable resin on the fabric.
- 19. The method of claim 18, wherein the step of shrinking the fabric is carried out with hot air at a temperature of about 120-180.degree. C.
- 20. The method of claim 19, wherein the step of shrinking the fabric is carried out fully before the step of calendering the fabric.
- 21. The method of claim 19, wherein the step of shrinking the fabric is carried out simultaneously with the step of calendering the fabric.
- 22. The method of claim 19, further comprising a step of annealing the fabric to set the stiffness controlling yarn in its knitted orientation, wherein the annealing step occurs between the calendering step and the coating step.
- 23. A resin-coated sheet material comprising:
- (a) a knit fabric comprising a monofilament nonfiberglass stiffness-controlling yarn having an elastic modulus of greater than about 5 grams per denier; and
- (b) a curable resin coated on the fabric.
- 24. The resin-coated sheet material of claim 23, wherein the stiffness-controlling yarn has less than 15% shrinkage.
- 25. The resin-coated sheet material of claim 23, wherein the fabric includes a stretch yarn.
- 26. The resin-coated sheet material of claim 23, wherein the stiffness-controlling yarn is capable of being annealed in an as knit orientation.
Parent Case Info
This is a continuation of application Ser. No. 08/441,185 filed May 15, 1995 now U.S. Pat. No. 5,744,528 filed Jan. 19, 1994 and a continuation of application Ser. No. 08/183,160, now U.S. Pat. No. 5,540,982 which is a continuation-in-part of application Ser. No. 08/009,923, filed Jan. 25, 1993 now U.S. Pat. No. 5,512,354.
US Referenced Citations (30)
Foreign Referenced Citations (3)
Number |
Date |
Country |
0 407 056 |
Jan 1991 |
EPX |
2257440 |
Jan 1993 |
GBX |
WO 9002539 |
Mar 1990 |
WOX |
Non-Patent Literature Citations (3)
Entry |
Translation of "Microfasern--Modewelle Oder Standard von Morgen?", I. Heidenreich and H. Ninow, Melliand Textilberichte Dec. 1991, pp. 971 to 977. |
M. Isaacs III, Textile World, 48-50 (Mar. 1991). |
Heidenreich et al., Melliand English, Dec. 1991, E391-E394. |
Continuations (1)
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Number |
Date |
Country |
Parent |
441185 |
May 1995 |
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Continuation in Parts (1)
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Number |
Date |
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Parent |
009923 |
Jan 1993 |
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