Curable resin coated sheets having reduced tack

An orthopedic casting material comprising a nonwoven sheet of polyester impregnated with a pre-lubricated, isocyanate functional, polyurethane prepolymer resin:

• wherein a major surface of the material exhibits a kinetic coefficient of friction of less than about 1.2;
• wherein said nonwoven sheet of polyester comprises a pattern of fiber bundles and apertures between said fiber bundles, each said fiber bundle comprising a plurality of fibers having interstices therebetween, the average cross-sectional area of each said fiber bundle being from about 0.2 mm.sup.2 to about 1.2 mm.sup.2, said nonwoven polyester sheet having from about 10% to about 45% extensibility along its length when a 2 pound force is applied across a 1.5 inch section of said sheet;
• and
• wherein said pre-lubricated, isocyanate functional, polyurethane prepolymer resin is impregnated into the interstices between said fibers of said fiber bundles in sufficient quantity such that the resin represents from about 65% to about 90% by weight of the total weight of the orthopedic casting material and imparts sufficient strength to the material upon curing to be used as an orthopedic casting material, said apertures remaining substantially unoccluded such that upon curing a laminate comprising 6 layers of said material said laminate has a water vapor permeability of at least about 2000 mg H.sub.2 O vapor/m.sup.2 -hr when measured under an atmosphere of about 45% relative humidity and at a temperature of about 22.degree. C., thereby substantially avoiding skin maceration.

An orthopedic support material, comprising a nonwoven, stretchable fabric impregnated with a pre-lubricated curable resin:

• wherein a major surface of the material exhibits a kinetic coefficient of friction of less than about 1.2;
• wherein said nonwoven fabric comprises a pattern of fiber bundles and apertures between said fiber bundles, each said fiber bundle comprising a plurality of fibers having interstices therebetween, the weight of said nonwoven fabric being from about 1 ounce per square yard to about 2.5 ounces per square yard;
• and
• wherein said resin is impregnated into the interstices between said fibers of said fiber bundles so as to impart sufficient strength to the material while leaving the apertures between fiber bundles substantially unoccluded so as to permit sufficient water vapor permeability through the cured material.

An orthopedic support material, comprising a nonwoven, stretchable fabric impregnated with a pre-lubricated curable resin:

• wherein a major surface of the material exhibits a kinetic coefficient of friction of less than about 1.2;
• wherein said nonwoven fabric comprises a pattern of fiber bundles and apertures between said fiber bundles, each said fiber bundle comprising a plurality of fibers having interstices therebetween;
• wherein said resin is impregnated into the interstices between said fibers of said fiber bundles so as to impart sufficient strength to the material upon curing to be used as an orthopedic support material while leaving the apertures between fiber bundles substantially unoccluded so as to permit sufficient water vapor permeability through the cured material;
• and
• wherein upon curing laminate comprising 6 layers of said material said laminate has a passive water vapor permeability of at least about 2000 mg H.sub.2 O vapor/m.sup.2 -hr when measured under an atmosphere of about 45% relative humidity and at a temperature of about 22.degree. C.

An orthopedic support material, comprising a nonwoven, stretchable fabric impregnated with a pre-lubricated curable resin:

• wherein a major surface of the material exhibits a kinetic coefficient of friction of less than about 1.2;
• wherein said nonwoven fabric comprises a pattern of fiber bundles and apertures between said fiber bundles, each said fiber bundle comprising a plurality of fibers having interstices therebetween;
• wherein said resin is impregnated into the interstices between said fibers of said fiber bundles so as to impart sufficient strength to the material upon curing to be used as an orthopedic support material while leaving the apertures between fiber bundles substantially unoccluded so as to permit sufficient water vapor permeability through the cured material;
• and
• wherein upon curing a laminate comprising 6 layers of said material, with each layer having an area of about 4 in.sup.2, said laminate has an air permeability of from about 30 cm.sup.3 air/second to about 370 cm.sup.3 air/second when an air pressure differential of about 6.4 psi exists between two sides of the laminate.