LIQUID OR GEL DELIVERY DEVICES

Abstract

A delivery device is for intermittently delivering materials such as liquids or gels over a sustained period of time to a surface in a controlled way. The surface mountable delivery device is capable of delivering, an antimicrobial agent to protect surfaces from microbial contamination and/or to disinfect surfaces, e.g. door handles, push plates, hand rails, etc. as an aid in preventing and/or hindering the spread of infectious agents. The device uses a vertically lapped nonwoven material as the storage medium for the liquid or gel like materials within the device. A non-wicking liquid mediating layer controls transfer of liquid from a reservoir to a contact surface of the device to minimize liquid losses. An elastomeric contact liquid delivery layer is optimized for printability. Use of physical features at the device contact surface prevents pore occlusion on user contact and aids flow of liquid to the contact user.

Claims

1. A device for storing and discharging liquid or gel like materials, which device comprises vertically lapped nonwoven material as the storage medium for the liquid or gel like materials within the device.

2. A device as claimed in claim 1, wherein the vertically lapped nonwoven material comprises fibres and the material base of the fibre comprises at least one synthetic polymer.

3. A device as claimed in claim 2, wherein the fibre comprises at least one synthetic thermoplastic polymer fibre.

4. A device as claimed in claim 2, wherein the web comprises a mixture of fibre types and/or fibre material compositions.

5. A device as claimed in any one of claims 2 to 4, wherein the fibre component comprises one or more of polypropylene (PP), polyethylene (PE), polyamide (PA), PLA, PBT, PET, coPET, copolyester elastomers, HDPE, LDPE, PPS, PEI, PETG, PCT, elastomeric fibres or mixtures thereof, bicomponent fibres and/or conjugate fibres.

6. A device as claimed in any one of the preceding claims wherein the vertically lapped nonwoven has a density within the range of 20 to 90 kg.Math.m.sup.3, preferably within the range of 30 to 80 kg.Math.m.sup.3, more preferably within the range of 40 to 70 kg.Math.m.sup.3, more preferably within the range of 45 to 65 kg.Math.m.sup.3 and most preferably within the range of 50 to 60 kg.Math.m.sup.3, in the non-compressed state.

7. A device as claimed in any one of the preceding claims wherein the vertically lapped nonwoven material is in a compressed state within the device.

8. A device as claimed in any one of the preceding claims wherein the vertically lapped nonwoven material has a weight within the range of 200 to 900 g.Math.m.sup.2, preferably within the range of 300 to 800 g.Math.m.sup.2, more preferably within the range of 400 to 700 g.Math.m.sup.2 and most preferably within the range of 475 to 575 g.Math.m.sup.2.

9. A device as claimed in any one of the preceding claims wherein a surface of the vertically lapped nonwoven storage material is closed and exhibits no open surface pore structure.

10. A device as claimed in claim 9, wherein a surface of the vertically lapped nonwoven storage material has open surface area to total surface area of 0 to 0.3.

11. A device for storing and discharging liquid or gel like materials, which device comprises a reservoir material within the device as the storage medium for the liquid or gel like materials, the reservoir material being in communication with a liquid mediating layer located between the reservoir material and liquid discharging surface of the device.

12. A device as claimed in claim 11, wherein the mediating layer material comprises a spunbond nonwoven material.

13. A device as claimed in claim 11, wherein the mediating layer material comprises hydrophilic polypropylene.

14. A device as claimed in any one of claims 11 to 13, wherein the mediating layer has a porosity of at least 80%, more preferably at least 85% and most preferably at least 88%.

15. A device as claimed in any one of claims 11 to 14, wherein the weight of the mediating layer material is less than 60 g.Math.m.sup.2, preferably less than 50 g.Math.m.sup.2, more preferably less than 40 g.Math.m.sup.2 and most preferably between 10 and 30 g.Math.m.sup.2.

16. A device as claimed in any one of claims 11 to 15, wherein the mediating layer material has low absorbency such that no liquid in the reservoir layer is absorbed into the mediating layer during storage of the device.

17. A device as claimed in any claim 16, wherein the mediating layer material has an absorbency of less than 0.1% by weight.

18. A device as claimed in any one of the preceding claims wherein the mediating layer has an air permeability within the range of 200 to 400, preferably 225 to 350 and most preferably 250-300 cm.sup.3/cm.sup.2s.sup.1.

19. A device comprising means for storing liquid or gel like materials and a contact liquid delivery layer with a contact surface through which the liquid or gel like materials may be discharged on contact of that surface with a human or object, characterized in that the contact surface of the contact liquid delivery layer comprises one or more physical features that prevent full contact by the human or object with the contact surface during their contact with the device.

20. A device as claimed in claim 19 wherein the physical features act as a liquid distribution aid or layer upon the contact surface.

21. A device as claimed in claim 19, wherein the features are small islands or ridges of material that have been deposited upon and over on the contact surface area in sufficient density to provide the desired effect.

22. A device as claimed in claim 19, wherein the features take the form of a web of material deposited upon and bonded to the contact surface.

23. A device as claimed in claim 19, wherein the features are provided by a layer of low density material bonded to the contact surface, which apparently occludes the surface but does no occlude the slits and/or pores and allows liquid discharge.

24. A device as claimed in claim 19, wherein the features are an integral part of the contact liquid delivery layer.

25. A device as claimed in claim 19, wherein the contact moderating physical feature is a filamentous material that is preferably heat sealed to the contact surface.

26. A device as claimed in claim 25, wherein the material is heat sealed at its edges to the contact surface whilst it is stretched, under tension and in intimate contact with the contact surface.

27. A device as claimed in claim 25, wherein the filamentous layer is a nonwoven structure such as spunbond, meltblown or a combination thereof, such as SMS or SMMS, needlepunched, hydroentangled, or a woven structure or a knitted structure.

28. A device as claimed in claim 25, wherein the filamentous layer comprises a hydrophobic polymer, selected from one or more of PE, PP, PET, PA, PLA, PBT, PET, coPET, copolyester elastomers, HDPE, LDPE, PPS, PEI, PETG, PCT, elastomeric fibres and mixtures thereof, preferably thermoplastic.

29. A device as claimed in claim 25, wherein a microperforated polymer film, preferably a thermoplastic polymer film, is attached to the surface of the filamentous layer.

30. A device as claimed in claim 25, wherein the filamentous layer has a weight from 5 to 100 g.Math.m.sup.2, preferably 5 to 60 g.Math.m.sup.2, more preferably 5 to 40 g.Math.m.sup.2 and most preferably 10 to 30 g.Math.m.sup.2.

31. A device for storing and discharging liquid or gel like materials, which device comprises a liquid or gel storage medium such as a reservoir and/or VLAP material and at least one internal structural support layer.

32. A device as claimed in claim 31, wherein the structural support layer is planar and the device is a planar device.

33. A device as claimed in claim 31, wherein the structural is tubiform and the device is a tubiform device.

34. A device as claimed in any one of claims 31 to 33, wherein the structural support material comprises a plurality of holes.

35. A device as claimed in any one of claims 31 to 34, wherein the structural support layer comprises a resiliently deformable material.

36. A device as claimed in any one of claims 31 to 35, wherein the structural support layer is resiliently biased against a rigid component of the device.

37. A device as claimed in any one of claims 31 to 36, wherein the structural support layer is located within the device between a) a reservoir and/or VLAP material and b) a contact liquid delivery layer within the device.

38. A device as claimed in any one of claims 31 to 37, wherein the structural support layer is located within the device between a) a reservoir and/or VLAP material and b) a mediating layer and/or wicking layer of the device.

39. A device as claimed in claim 31, wherein the device is a tubiform device and the reservoir and/or VLAP material is located within the bore of at least one internal tubiform structural support layer.

40. A delivery device according to the combination of claims 1 and 11.

41. A delivery device according to the combination of claims 1 and 19.

42. A delivery device according to the combination of claims 11 and 19.

43. A delivery device according to the combination of claims 1, 11 and 19.

44. A delivery device according to the combination of claims 1 and 31,

45. A delivery device according to the combination of claims 11 and 31.

46. A delivery device according to the combination of claims 19 and 31.

47. A delivery device according to the combination of claims 1, 11 and 31.

48. A

49. A delivery device according to the combination of claims 1, 11, 19 and 31.

50. A delivery device as claimed in any one of the preceding claims, further comprising a contact liquid delivery layer.

51. A delivery device as claimed in claim 50, wherein the contact liquid delivery layer comprises a hydrophobic polymer, such as polyurethane (PU), polyethylene (PE), polypropylene (PP) polyamide (PA) or polyethylene terephthalate (PET) and copolymers thereof.

52. A delivery device as claimed in claim 50, wherein the contact liquid delivery layer comprises one or more of polysiloxane, vinyl methyl silicone, chlorosulphonated polyethylene, TPE (thermoplastic elastomer), TPU (thermoplastic polyurethane), TPV (thermoplastic vulcanizates), TPO (thermoplastic polyolefin), TPE-E (thermoplastic polyester elastomers), TPC-ET (thermoplastic copolyester elastomers), TPE-A/TPA (thermoplastic polyamide elastomer), SBC (styrenic block co-polymers), SBR (Styrene butadiene rubber), Silicone, Polyisoprene, HNBR (Hydrogenated Nitrile Butadiene Rubber), EPDM (ethylene propylene diene monomer (M-class) rubber), NBR (Acrylonitrile Butadiene Rubber) XNBR (Carboxylated Nitrile Butadiene Rubber), Polybutadiene or copolymers thereof.

53. A delivery device as claimed in claim 50, wherein the contact liquid delivery layer comprises elastomeric material film manufactured using a blown film extrusion process.

54. A delivery device as claimed in claim 50, wherein the contact liquid delivery layer comprises a monolayer elastomeric material film.

55. A delivery device as claimed in claim 50, wherein the contact liquid delivery layer comprises a multi-layered elastomeric material film with two or more layers.

56. A delivery device as claimed in claim 54 or 55, wherein the monolayer or at least one layer of the multilayered material is a thermoplastic elastomeric material.

57. A delivery device as claimed in claim 40, wherein the multi-layered film comprises a top and/or bottom layers about a core layer and wherein the top and/or bottom layer comprise elastomeric thermoplastic materials and/or polymeric materials of other types and composition.

58. A device as claimed in claim 55, wherein the multilayered elastomeric materials are manufactured using blown film extrusion processes and/or are manufactured using a combination of blown film extrusion processes and other techniques such as coating and/or lamination or cast extrusion.

59. A device as claimed in claim 50, wherein the contact liquid delivery layer comprises at least two layers of material.

60. A device as claimed in claim 57, wherein the core layer comprising one or more thermoplastic elastomeric materials and the top and/or bottom layers comprising one or more polymeric materials and wherein the top and bottom layers are of identical or different composition but of different composition to the core material.

61. A device as claimed in claim 59, wherein there is at least one material common to two or more layers of the delivery layer and when the delivery layer comprises a core then at least one material common to the core and the top and bottom layers.

62. A device as claimed in any one of claims 50 to 61, wherein the contact liquid delivery layer comprises one or more additional layers upon one or more of its two surfaces provided using additional techniques such as extrusion, casting, coating and/or laminating of polymeric materials.

63. A device as claimed in any one of claims 50 to 61, comprising an additional printable layer bonded to the contact liquid delivery layer.

64. A device as claimed in any one of claims 50 to 61, wherein the contact liquid delivery layer material comprises one or more thermoplastic elastomeric materials as the core and top and/or bottom layers comprising one or more polymeric materials with optionally one or more other polymeric materials such as polyethylene terephthalate (PET).

65. A device as claimed in any one of claims 50 to 61, wherein the contact liquid delivery layer material comprises a binary or tertiary layered structure.

66. A device as claimed in claim 64, wherein the polymeric material comprises one or more polyolefin materials selected from one or more of polyethylene (PE), polypropylene (PP), low density polyethylene (LDPE), linear low density polyethylene (LLDPE) and olefin co-polymers.

67. A device as claimed in claim 57, wherein the elastomeric materials for the core comprise one or more of polyurethane (PD) based elastomers, elastomeric styrenic block copolymers (SBC), such as for example styrene-butadiene-styrene (SBS) and styrene-isoprene-styrene (SIS) block co-polymers, thermoplastic polyester elastomers or ethylene vinyl acetate (EVA) elastomers.

68. A device as claimed in any one of claims 50 to 67, wherein the multilayered contact liquid delivery layer is of overall thickness (DIN 53 370) of from 50 to 300 microns, more preferably from 75 to 250 microns, more preferably 100 to 250 microns and most preferably 100 to 225 microns; with an ideal thickness of about 200 microns.

69. A device as claimed in any one of claims 55 to 67, wherein each of the individual layers is from 1 to 290 microns (for overall thickness of 300 microns), preferably for a 100 micron multilayered material the top and bottom layers are from 1 to 10 micron with a core layer of from 80 to 98 micron with each thickness selected to provide and overall combined thickness of about 100 micron and for a 200 micron multilayered material the top and bottom layers are from 1 to 45 micron, preferably from 3 to 40 micron, more preferably 3 to 20, and most preferably 3 to 5 micron with a core layer of from 100 to 198 micron, preferably from 150 to 198 micron and more preferably 180 to 198 micron with each thickness selected to provide and overall combined thickness of about 200 micron.

70. A device as claimed in claim 55, wherein the multilayered film is 100 micron film with top and bottom layers of 3 to 5 micron and a core of 90 to 94 micron.

71. A device as claimed in claim 55, wherein the multilayered film is 200 micron film with top and bottom layers of 40 micron and a core of 120 micron.

72. A device as claimed in claim 55, wherein the multilayered film is about 200 micron film with top and/or bottom layers of 3 to 5 micron and a core of 190 to 194 micron

73. A device as claimed in any one of claims 57 to 72, wherein the elastomeric core material is a co-extruded mixture of SBC and EVA elastomers.

74. A device as claimed in any one of claims 57 to 72, wherein the top and/or bottom layers are co-extruded polyolefin mixtures of LDPE/PP.

75. A device as claimed in claim 50 wherein the contact liquid delivery layer comprises SBC and EVA elastomers.

76. A device as claimed in claim 50 wherein one surface of the contact liquid delivery layer comprises a coating of LDPE.

77. A device for storing and discharging liquid or gel like materials, which device comprises a tray unit and a holster for holding and securing the tray unit during use.

Description

[0109] The invention in all its aspects will now be referred to by the following Figures, which show/represent various forms/states and designs, the invention could take and in which:

[0110] FIG. 1 is a perspective view of a delivery device according to a preferred embodiment of the present invention;

[0111] FIG. 2 is a schematic cross-section across plane x, x of FIG. 1 of a preferred delivery device of the present invention incorporating the first and second aspects of the present invention;

[0112] FIG. 3 is a schematic cross-section across plane x, x of FIG. 1 of a preferred delivery device of the present invention incorporating the first and second aspects of the present invention and illustrating the third aspect of the present invention;

[0113] FIG. 4 is a perspective view of a tray unit for use in the device of the present invention;

[0114] FIG. 5 is a cross-section across the plane x, x of the tray unit of FIG. 4;

[0115] FIG. 6 is a side view of the tray unit of FIG. 4;

[0116] FIG. 7 is a cross-section across the plane Y, Y of the tray unit of FIG. 6;

[0117] FIG. 8 is a perspective view of a holster unit for use with the tray unit device of the present invention;

[0118] FIG. 9 is a plan view of a holster unit for use with the tray unit device of the present invention;

[0119] FIG. 10 is a sectional view along the axis z, z of the holster unit of FIG. 9;

[0120] FIG. 11 is a perspective view of a tubiform device of the present invention suitable for use on a handle;

[0121] FIG. 12 is a perspective view of a structural support layer for use in a tubiform device; and

[0122] FIG. 13 is a schematic sectional view along axis A of the tubiform device of FIG. 11.

[0123] With reference to FIGS. 1 and 2 a deliver device (1) comprises a contact liquid delivery layer (2) adjacent to a liquid moderating layer (3), which is adjacent to a vertically lapped nonwoven material as the storage medium for the liquid or gel like materials within the device (4). The liquid moderating layer (3) and the vertically lapped nonwoven material (4) are located within a tray unit (5), which is bonded to the contact liquid delivery layer (2) at the periphery (6) of the tray unit (5) and the contact liquid delivery layer (2). The liquid moderating layer (3) is empty and the vertically lapped nonwoven material (4) is impregnated with an antimicrobial composition. The device may be attached to a vertical surface (not shown) by applying adhesive to the rear surface (7) of the device.

[0124] With reference to FIG. 3, there is shown the device of FIG. 2 with the addition of a physical feature (12) located upon the contact liquid delivery layer (2) and secured to the edges of the tray unit (5) at points (14). The physical feature (12) is shown in highly schematic form and in reality is in the form of a filamentous material that covers the contact liquid delivery layer (2). In this schematic form the physical feature (12) is illustrated with openings (15) over the slits (11) simply to illustrate that this physical feature (12) does not occlude the slit openings (11).

[0125] During use a person makes contact with the physical feature (12) and in doing so compresses the device (1). Before compression the slits (11) are closed and any antimicrobial composition is unable to exit through the surfaces (12) of the layer (2) which are impermeable. During compression the layer (2) is elastically deformed and under this deformation the slits (11) proximate to the deformation point and previously closed open and parallel sides separate to define a pore through which any antimicrobial composition may pass through the layer (2). It should be noted that slits that are remote from the point of compression are not opened by this mechanism as there are no local transverse forces across these slits to elastically deform the layer (2) proximate to these slits (11). When the compressive force is removed the layer (2) returns elastically to its original state and the parallel sides of the slits (11) close moving adjacent to each other and in doing so close the open pore. Under compression at contact the vertically lapped nonwoven material (4) is compressed and at the point of compression antimicrobial liquid passes from the vertically lapped nonwoven material (4) and through the liquid moderating layer (3), to pass through the elastically deformed slits at the point of compression and onto the contact surface (16) of the device (1). At the point of compression, the physical feature (12) prevents the compressing object e.g. human hand from occluding the slits (11) at the point of compression thus allowing the liquid to exit the device and onto the contact surface (16) and into contact with the compressing object. This arrangement ensures the optimum delivery of liquid material to the object contacting the device.

[0126] With reference to FIGS. 4 to 7 there is shown a preferred form of tray unit (40) for use in the device of the present invention. This tray unit is designed to hold and retain various components and ensure containment of the liquids or gels for dispensing when use in combination with the contact surface layer. In FIGS. 4 to 7 a tray unit (40) is shown which is rectangular in form and has a base (41) with longitudinal and lateral re-enforcing ribs (42) and four walls (43) generally upstanding from the base (41). At least two of the walls (43) comprise holster engaging means (44) and preferably as shown in FIG. 4 all of the walls (43) comprise holster engaging means. As illustrated in FIGS. 4 to 7 these engaging means make take the form of one or more slots (44) on the external surfaces of each wall, which generally protrude inwardly into the tray unit. When the tray unit (40) is engaged with the holster (80) these slots (44) engage with corresponding protrusions (81) in the holster (80). The tray unit (40) further comprises longitudinal channels (45) running along the longitudinal sides of the tray unit (40) and scalloped end regions (46), which will be described in more detail below. The longitudinal channels (45) provide additional rigidity. The top periphery of the walls (43) extend beyond the upstanding walls surface to form a peripheral flange (47), to which the contact surface layer of the device may be bonded during manufacture. This flange (47) is also of a form to preferably co-operate with tray flange contact surfaces (82) of the holster (80). As can be seen in FIGS. 5 to 7 the channel (45) and scalloped regions (46) have internal surfaces that are below the surface of the base (41). The scalloped regions (46) are therefore deeper than the majority of the base (41) area. When the vertical lapped nonwoven material is inserted into the tray unit (40) its top surface is at or below the flange (47) surfaces adjacent to these scalloped regions (46) compared to the flange (47) surfaces proximate to other regions of the base (41). This arrangement assists with assembly of the device by reducing the stretching of the contact surface layer at undesired angles over the vertical lapped nonwoven material of the tray unit (40) proximate to the flanges (47) at either end of the tray unit (40). They also assist in engaging the vertical lapped nonwoven material within the tray unit (40) during assembly of the device. The design of the tray unit (40) is such that the underneath surface of the base (41) is located above the bottom external surfaces of the longitudinal channels (45) and the scalloped regions (46).

[0127] With reference to FIGS. 8 to 10 there is shown a preferred form of holster unit (80) for use in the device of the present invention. The holster unit (80) is generally permanently or semi-permanently secured to a surface where the device of the present invention is to be located during use. This is for example a vertical surface on a door. The function of the holster unit (80) is to provide such a location for holding and securing tray unit devices (40) of the present invention that may easily be attached to the holster unit (80) at this location and easily removed and replaced when the need arises. The use of the holster unit (80) aids in the easy deployment and use of the tray unit devices (40) of the present invention. The holster unit (80) generally comprises a tray like structure into which the tray unit (40) may be securely and reversibly inserted. The exterior wall surfaces of the tray unit (40) contact the internal wall surfaces of the holster unit (80) and the slots (44) of the tray unit (40) are reversibly engaged with the protrusions (81) of the holster unit (80). This engagement is robust enough to hold the tray unit (40) firmly within the holster unit (80) during use but is such that when appropriate force is applied to the tray unit (40) it may be disengaged and removed from the holster unit (80). The base (83) of the holster unit (80) further comprises a series of raised plinths (84) that make contact with and support the base (41) of the tray unit (40) when it is in locked engagement with the holster unit (80). In addition, the flanges (47) of the tray unit (40) are supported by and in contact with the tray flange contact surfaces (82) of the holster unit (80).

[0128] With reference to FIG. 11 there is shown a tubiform device (100) of the present invention suitable for use on relation to handles e.g. door handles. The device (100) has an external contact surface (101) of the contact liquid delivery layer (102). Central to the device is an inner conduit member (103), which acts effectively both as a backing layer for the device and also provides the means by which the tubiform device (100) can be secured over a door handle or similar as a sleeve or engineered into other door handle arrangements. Also show in part is a key internal component of the device (100), namely the VLAP material in a tubiform arrangement (104). The tubiform arrangement of the device enables a human hand to grab the device and through compressive forces on the contact liquid delivery layer (102) actuate the device to expel liquid or gel from the VLAP storage (104), through the contact liquid delivery layer (102) and onto its external contact surface (101) having passed through the other layers present but not shown in this Figure; these additional layers will be discussed below.

[0129] With reference to FIG. 12, there is shown a structural support layer (105) as used in the tubiform device (100) of FIG. 11. This tubiform structural support layer (105) sits at a location in the device (100) that is between the contact liquid delivery layer (102) and the tubiform VLAP material (104). It is made of resilient but flexible material so that it may be deformed under compression and then revert to the form indicated when these compressive forces are removed. In reverting back to its original pre-compressed form it forces any layers external to it including the contact liquid delivery layer (102) back to their pre-compressed form. In addition, it also redefines the internal space within its bore (106), which accommodates the tubiform VLAP material (104) and in doing so enables the tubiform VLAP material (104) to decompress and accommodate this internal space (105) substantially in its original form. This arrangement therefore ensures effective and extended use of the device (100). The structural support layer (105) in addition to being resiliently deformable also has a plurality of large holes or passages (108) that communicate between its bore (106) and its external surface (109). These holes or passages (108) effectively allow substantially unrestricted expulsion of liquid or gel in the VLAP or reservoir material (104) located within the bore (106) from the VLAP or reservoir material (104) and to the external surface (109) and eventually out of the device (100) in a controlled fashion through other layers external to the structural support layer (105) and as described herein.

[0130] With reference to FIG. 13, there is shown a cross-section along axis A of the tubiform device (100) illustrated in FIG. 11. Indicated are: an external contact surface (101) of the contact liquid delivery layer (102); the central inner conduit member (103); the VLAP material in a tubiform arrangement (104); and the structural support layer (105) as described in relation to FIGS. 11 and 12. In addition is indicated a liquid mediating layer (107). In this arrangement the structural support layer (105) is located between the VLAP material (104) and the liquid mediating layer (107) and the contact liquid delivery layer (102).

EXAMPLE

[0131] A device for storing and discharging liquid or gel like materials in accordance with the present invention was prepared as follows:

Vertically Lapped Nonwoven Material Storage Medium

[0132] A commercially available vertically lapped nonwoven material was used as the storage medium and manufactured and sold under the trade names VLAP and Struto. The material had a composition of 40% hydrophilic PET (4.4 dtex), 40% PET/CoPET BiCo (2.2 dtex) and 20% conjugate/spiral PET (10 dtex). This material had a density of 55 kg/m.sup.3, a thickness of 30 mm and was cut into 2 m length slabs. These slabs were converted into 310 mm thick slabs using band knife. These 9 mm slabs were then stamped into 27071 mm pieces using bladed press, with longitudinal edge being in machine direction, perpendicular to the strata.

Mediating Layer

[0133] A hydrophilic polypropylene spunbond material of weight 20 gsm was selected as the mediating layer material.

Contact Liquid Delivery Layer

[0134] The material selected for this layer was a multilayered 200 micron material comprising a core of SBC/EVA elastomer film that had been coextruded with 5 micron polyolefinic printable surface layer. Individual reels of this material were processed through a perforating drum machine. The main perforating drum possess a 3D pattern of narrow blades of the dimensions and frequency of the desired perforation pattern. Inlet tension setting is 30/25 N, perforation pressure 650 psi and post perforation speed is +2%.

Tray Unit

[0135] A PET/PE film (400/50 micron) was vacuum formed over specifically designed 3D mould to produce multiple trays per cycle (depending on machine and mould size used). The tray unit was as described in FIGS. 4 to 7 and was designed to have a 3 mm internal depth to the tray base so that the top of the inserted vertically lapped nonwoven storage medium reservoir protruded above top surface of the tray walls; there was a 7 mm external depth to allow secure fastening into the holster unit. The tray unit also has internally scalloped ends to reduce the stretching of the perforated film/opening of the perforations when film is pulled at an acute angle over the top and bottom edges of the nonwoven reservoir in the tray. These internally scalloped ends also assist in the insertion of the gel filled nonwoven reservoir into the tray by preventing the short edges of the vertically lapped structure springing out of the tray, which would occur if the depth at each end was only 3 mm. The tray unit also has longitudinal channels, as well as longitudinal and lateral ribs, in the base to improve rigidity of the tray for processing, and in use.

Holster Unit

[0136] The holster unit was vacuum formed from 900 micron APET film. The internal cavity of the unit was 7 mm with fastening protrusions around the internal perimeter to secure tray unit once inserted. The holster unit also has 34 mm high rectangular raised plinths projecting upward into the cavity from the base to support the base of the shallower tray unit when inserted to prevent bowing of the tray unit when pressure is applied to tray unit in use.

Active Liquid Medium

[0137] The active medium comprised a viscosity modified 57% ethanol gel.

Device Assembly

[0138] 160 g of active liquid medium gel was distributed uniformly throughout the stamped vertically lapped nonwoven pad (27071 mm). This could be by impregnation through a fixed distance nip, multiple internal injectors, forced in via a scraper/doctor blade, or a combination of the above. The 270 mm long gel filled VLAP was compressed longitudinally into the 250 mm long internal tray unit cavity and the upper sealing surface of the tray (the upper surface of the flanges) was cleaned of fugitive gel to prevent this from interfering with heat sealing. An oversized VLAP slab is used for a number of reasons. Lower density material is easier to fill with gel and compressing gives the desired finished density. Also, compressing longer lengths of VLAP removes the possibility of the VLAP shrinking/settling longitudinally excessively in situ, therefore avoiding reservoir free cavities at the top or bottom of the finished pack. Consequently, the density of the VLAP once installed was 58 kg/m.sup.3. The tray filed with VLAP material was then inserted into a die to secure it during the heat sealing process.

[0139] A 250 mm strip of hydrophilic polypropylene spunbond internal localised mediating layer was placed flat, and in register with, the gel impregnated nonwoven VLPA layer within the tray unit. The perforated contact liquid delivery layer was held under tension (1.4 kg per 200 mm width), print over the tray located in the die with the gel impregnated VLAP in its internal cavity covered by the mediating layer. Heat sealer was then used to apply heat and pressure to the contact liquid delivery layer onto the tray sealing flanges (141 C. for 8 secs) to heat seal the underside of the elastic film to the upper surface of the tray unit flanges. The tray unit was allowed to cool before removing from the die to avoid distortion of the tray plastic while it is still hot and flexible.

[0140] The finished tray unit was then sandwiched between 2 layers of taut PET/Al foil/PE film (with PE facing in towards the unit). Heat and pressure are then applied just outside the perimeter of the unit to create a hermetic seal for the unit, therefore eliminating premature alcohol evaporation during storage.

[0141] For deployment the holster unit was securely attached by adhesive bonding to an upright contact surface of a door. The tray unit was removed from its packaging and placed into the holster unit with light pressure to lock the tray unit within the holster unit. During use the tray unit was found to deliver adequate and effective amounts of gel material to its contact surface during use and there was no significant pooling of gel material within the tray unit during its operation.

[0142] Throughout the description and claims of this specification, the words comprise and contain and variations of the words, for example comprising and comprises, means including but not limited to, and is not intended to (and does not) exclude other components, integers or steps.

[0143] Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. Features, integers, characteristics, compounds described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

[0144] All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.