Anti-Microbial Strap

Abstract

The invention discussed includes a durable antimicrobial strap made using a polymer material, including plastics or vinyl, or a combination thereof, which have been enhanced through the integration of antimicrobial material adapted to kill microbes. The antimicrobial strap may be used in applications including but not limited to gait belts, helmet harness, and seat belts in child safety seats where the strap controls the level of cross-contamination by killing unwanted microbes that contact the strap and thereby, prevents the spread of disease and infections. A belt such as a child safety restraint made by a method of applying heat to the belt strap ends to form loops between the ends and the belt is also presented.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part of co-pending and co-owned U.S. application Ser. No. 13/586,851 having a filing date of Aug. 15, 2012, which claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/575,087, entitled “Antimicrobial strap” filed Aug. 15, 2011, the disclosure of which is hereby incorporated herein by reference in its entirety.

FIELD OF INVENTION

The disclosed invention is a strap including antimicrobial properties designed to improve the ability to maintain an antimicrobial free or near antimicrobial free point of contact between hosts in contact with the strap, thereby slowing down or stopping the cycle of spreading pathogens or germs.

BACKGROUND

In everyday life humans and animals come in contact with inanimate objects. During this contact, microbes are exchanged between the host and the inanimate object. The conventional method for controlling the spread of microbes is to clean the major points of contact to disinfect the inanimate object after such a contact. When used, the conventional method for controlling the spread of microbes may be inhibited by human elements such as failure to see the need for cleaning, failure and inadequacies of policies and procedures, inappropriate methods for cleaning, and inadequate training of staff personnel responsible for cleaning, as well as a poor understanding of proper hygiene by those doing the cleaning. Furthermore, even if the inanimate object is cleaned appropriately, the cleaning does not protect against future transmission of pathogens or germs to the inanimate object in contact with or in close proximity to the inanimate object. Yet further, even when cleaned “properly”, there is oftentimes residual contamination left behind. This invention helps to increase the kill rate of undesirable microbial contaminates thereby reducing the number of contaminates on the products, and thereby reducing the spread of germs and saving lives.

A 2002 study by the Centers for Disease Control and Prevention estimates there were 4.5 hospital infections for every 100 patient admissions and nearly 100,000 deaths from hospital infections. More recent studies have indicated that the rate is increasing due to antibiotic resistance with the expansion in transmission of harmful, microbes including MRSA., VRE, Cdiff, HINE fungi, mold and the like. The high levels of infections are leading to evolving classes of precautions in hospital settings as evidenced by the use of vinyl gloves, introduction of antimicrobial agents into medical devices, emphasis on the impact and importance of thoroughly washing hands and the like.

Currently available methods for cleaning straps are often ineffective or not adhered too.

Antimicrobial coating for use with fibers, filaments, yarns, fabrics and textiles are disclosed in U.S. Pat. No. 7,754,625, antimicrobial catheters inserted into the bladder via the urethra, normally used once on a person and discarded, is disclosed in U.S. Pat. No. 7,354,605.

What is needed is an antimicrobial strap that provides a barrier to the growth of microbes and decreases the amount of cross contamination between hosts coming into contact with the strap.

SUMMARY OF THE INVENTION

An antimicrobial strap and method of forming is disclosed. The antimicrobial strap decreases the amount of cross-contamination between hosts in contact with the strap by attacking pathogens or germs at the transmission source or point of contact, and thereby continuously preventing against transmission of microbes. A belt is also formed from the antimicrobial strap wherein the polymeric non-porous substrate of the antimicrobial strap accommodates a heating process of forming junctions within the belt.

A belt formed in accordance with the present invention therefore contains: a first strap containing a first end and a second end; a second strap containing a third end and a fourth end; a first loop formed by a first fused junction of the first end and the first strap; a second loop formed by a second fused junction of the second end and the first strap; a third loop formed by a third fused junction of the third end and the second strap; a fourth loop formed by a fourth fused junction of the fourth end and the second strap; a first accessory slidably fixed to the second loop; a second accessory slidably fixed to the fourth loop; and a buckle joining the first end to the third end, thereby joining the first strap to the second strap. It will be appreciated that the first and second straps are preferably formed from a flexible non-porous substrate material containing an exposed surface, and an antimicrobial agent integrated within the exposed surface of the non-porous substrate. The belt may also contain at least one tri-glide member fixed within the first loop or another loop, relatively larger than the rest, for slidably adjusting the length of the belt. In sum, a belt formed in accordance with the present invention contains scaled junctions within the belt that prevent the entrapment of contaminates, wherein the method of fusing the belt material together forms these fused “sealed” junctions thereby inhibiting bacterial growth.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. IA illustrates cross-sectional view of an antimicrobial strap including a layer of antimicrobial material coated on an exposed surface of a flexible non-porous substrate formed from a polymer material using an adhesive binder that attaches both to the antimicrobial layer and the polymer material exposed surface of the antimicrobial strap in accordance with an embodiment of the invention.

FIG. 1B illustrates a cross sectional view of an antimicrobial polymer strap manufactured by use of an appropriate binder to form an Interpenetrating Polymer Network (IPN) that physically binds the antimicrobial agent in an antimicrobial layer to the polymer substrate's surface.

FIG. 2 illustrates a cross-sectional view of an antimicrobial step including antimicrobial agents that are mixed with polymer particles and coated on to an exposed surface of a polymer substrate material of the antimicrobial strap using a heated plasma spray mechanism to coat a polymer substrate material with an antimicrobial coating properties in accordance with an embodiment of the invention.

FIG. 3 illustrates a cross-sectional view of an antimicrobial strap including an antimicrobial polymer material that is formed from antimicrobial agents impregnated into the polymer material during the manufacturing process in accordance with an embodiment of the Invention including an enlarged view of an antimicrobial agent particle that is uniformly distributed within the polymer substrate material used in constructing the strap in accordance with an embodiment of the Invention.

FIG. 4A illustrates a cross-sectional view of an antimicrobial strap wherein an antimicrobial agent is diffused into an exposed polymer substrate material surface of the antimicrobial strap, wherein the diffusion is facilitated by a solvent in accordance with an embodiment of the invention.

FIG. 4B illustrates an antimicrobial polymer after diffusion of the antimicrobial agent into the polymer substrate material in accordance with an embodiment of the invention.

FIG. 5 illustrates a gait belt having antimicrobial properties in accordance with an embodiment of the invention.

FIG. 6 illustrates a roll of planar non-porous substrate material integrated with an antimicrobial agent, in accordance with an embodiment of the invention.

FIG. 7a illustrates a child safety restraint or belt in accordance with the present invention.

FIG. 7b is a side view of the child safety restraint or belt of FIG. 7a, in accordance with the present invention.

DRAWINGS

Reference Numerals

Antimicrobial Layer              10a 10b, 10c, 10e
Binder Layer                     20
Polymer Substrate material       30a, 30b, 30c, 30d, 30e
Plurality of Antimicrobial Agents 40a, 40b, 40c, 40d, 40e
Plurality of polymer particles   52
Powdered mixture                 54
polymer substrate material surface 32a, 32b, 32c, 32d, 32e
Antimicrobial strap              60a 60b, 60c, 60d, 60e
Gait Belt Buckle Receptacle      70
Gait Belt Buckle Prongs          71
A roll of antimicrobial material integrated into 72
a non-porous substrate material
Uniform planar sheet             74
Thermal Gun Assembly             80
Polymer and Antimicrobial Mixture Reservoir 82
Heating Mechanism and Nozzle     84
Atomized Spray                   86
Conveyor Mechanism               90
Solvent                          92

DETAILED DESCRIPTION OF THE INVENTION

In particular, the invention is directed to antimicrobial polymer straps formed from a combination of antimicrobial and flexible, non-porous substrate materials. The flexible, non-porous substrate materials may be formed from a polymer material that is be made with or treated with an antimicrobial agent.

A polymer material, as defined herein, includes, but is not limited to a polymer, a polymer composition, a polymer composite, or a polymer matrix wherein the polymer material includes plastic or vinyl, or a combination thereof. In an embodiment of the invention, the polymer material is formed from one or more types of polymers, including, but not limited to plastics or vinyl, or a combination of plastic and vinyl, and is manufactured to include a nonporous exposed surface that prevents contamination of the exposed surface after the exposed surface has been exposed to an unwanted microbial contaminate.

In an embodiment of the invention, the polymer material formed from suitable plastics may include any thermoplastic, as long as the thermoplastic processing temperature does not deactivate the active ingredient used. In an embodiment of the invention, a thermoplastic may include thermoplastic elastomers (TPE). TPEs are materials that include elastomeric phases physically incorporated therein by mixing the elastomeric phase into thermoplastically processed polymers or by incorporating the elastomeric phases into the polymers by chemical bonding.

Also, as defined here, an antimicrobial agent has antimicrobial properties to effectively kill or hinder the growth of microbes, which includes but is not limited to viruses, bacteria, mold, fungi, mildew, yeast, and spores, thereby decreasing the spread of pathogens or germs.

The antimicrobial agent integrates antimicrobial properties into the strap, thereby eliminating, or significantly lowering the rate at which infection via microbes spreads to hosts that come into contact with the strap. The concentration of the antimicrobial agent may be modulated to control the bacterial kill efficacy of the antibacterial strap.

The use of an antimicrobial agent in the antimicrobial strap hinders or inhibits the ability of microbes to develop and grow and thereby, decreases the amount of cross contamination between hosts coming into contact with inanimate objects having antimicrobial properties of the antimicrobial strap. Therefore, the antimicrobial strap fulfills a need to provide a level of barrier to the growth of microbes, to decrease the amount of cross contamination thereof, and to further decrease the spread of pathogens or germs.

The antimicrobial strap creates a new field in pathogen or germ control by attacking pathogens or germs at the transmission source or point of contact.

The strap helps eliminate the need for constant and methodical cleaning of the strap as the only procedure by which the spread of infection is controlled. With the use of appropriate antimicrobial agents integrated in the strap's construction, growth and spread, of both gram-positive and gram-negative bacteria on the surface of die antimicrobial strap is eliminated or substantially reduced.

The antimicrobial strap may be manufactured with a composition that allows cleaning of the strap with standard household and hospital cleaners or disinfectants without hampering the strap's antimicrobial properties or abilities to effectively hinder or inhibit growth of microbes.

The antimicrobial strap is manufactured with a non-porous polymer material on all external surfaces, thereby preventing contamination of the surfaces before and after the antimicrobial strap has been cleaned. Additionally, all the surfaces forming the antimicrobial strap including surfaces bounded by the strap's length L and width W, surfaces bounded by the strap's length L and thickness T, and the surfaces bounded by the strap's width W and thickness T are nonporous and therefore, free from contamination both before and after the surfaces have been cleaned.

In an embodiment of the invention, the antimicrobial agent used is an oxidizing agent that oxidizes microbes by attracting, trapping and then oxidizing negatively charged virus, bacteria, mold, fungi and spores and thereby effectively killing or hindering the growth of such bacteria, mold, fungi and spores. In an embodiment of the invention, the antimicrobial agent is an oxidizing agent such as, but not limited to the oxidizing agent sold under the trademark OxiTitan™, manufactured by EcoActive Surfaces, Inc., Pompano Beach, Fla. 33061-0338. The OxiTitan^nq oxidizing agent is a photo-catalyst mixture including zinc nano-particles in a matrix of non-crystalline titanium dioxide, wherein the positive charge of the mixture attracts, traps and then oxidizes the negatively charged virus, bacteria, mold, fungi and spores. Any oxidizing agent may be used that is suitable to oxidize microbes.

In an embodiment of the invention, the manufacturing of the antimicrobial polymer or polymer composition, including plastics or vinyl or a combination thereof, includes the antimicrobial agent bonded to the polymer or polymer composition. In an embodiment of the invention, the antimicrobial agent is a quaternary ammonium compound that chemically bonds to the polymeric substrate but does not leach or off-gas and does not lose effectiveness over time. In an embodiment of the invention, the antimicrobial agent may be, but is not limited to, a quarternary ammonium compound sold under the trademark. Biosafe(k) HM 4100, manufactured by BIOSAFE, Inc., Suite 400, 100 Technology Drive, Pittsburgh, Pa. 15219. Biosafe® HM 4100 is a polymeric powder that is environmentally sustainable silane-based cationic quarternary ammonium salt, that is easily compounded into plastics, and that is then mixed into coatings. The active ingredient in the HM 4100 technology forms a colorless, odorless, positively charged polymer that molecularly bonds to product substrates,—making the positively charged polymer material combined with the product substrate antibacterial and acts by puncturing and rupturing negatively charged bacteria cells.

Another method of integrating antimicrobial agents into the flexible, non-porous substrate material forming the antimicrobial strap includes use of ion exchange methods, such as is disclosed in U.S. Pat. No. 7,754,625, which is herein incorporated by reference, wherein non-antimicrobial ions are wholly or partially replaced by antimicrobial copper and silver ions.

In several embodiments of the invention, any one or more of the following active ingredients having antimicrobial properties may be suitable to incorporate into the antimicrobial strap: ansamycin derivatives (rifamycin, rifapentin), and preferably any additional antimicrobial substances that have also been used for clinical purposes for what are known as difficult-to-treat infections. In another embodiment of the Invention, any one or more of an antimicrobially active group disclosed in U.S. Pat. No. 7,705,073, the disclosure of which is herein incorporated by reference in its entirety, may be suitable to incorporate into the antimicrobial strap including: lipophilic members of the amino glycosides group, of the cephalosporin group and beta-lactams based thereon, of chloramphenicol, lincosamides, macrolides, penicillin, quinolones, sulphonamides, tetracycline, except the combination tetracycline-minocyclin. Lipophilic antibiotics are preferably: benzathin, phenoxymethylpenicillin, chloramphenicol, chlortetracyclin, ciprofloxacin betaine, ciprofloxacin, clarithromycin, clindamycin palmitate hydrochloride, trimethoprim, erythromycin 2-acetate, and the corresponding stearate, erythromycin estolate, erythromycin ethyl succinate, erythromycin glutamate, erythromycin lactopropionate, erythromycin stearate, fusidinic acid, preferably free fusidinic acid, gramicidin, mupirocin, lipophilic members of the imidazole series, such as econazole, itraconazole, clotrimazole and others, pristinamycin, rifabutin, rifapentin, rifampicin, silver sulfadiazine.

Generally, the flexible, non-porous substrate material is enhanced with antimicrobial agents, in several embodiments of the invention, the antimicrobial agents are either bonded with or directly integrated into the flexible, non-porous substrate material forming the antimicrobial strap to enhance the kill efficacy of microbes.

In an embodiment of the invention, the flexible, non-porous substrate material is formed by a polymer substrate material, which in an embodiment of the invention, may be selected from a family of plastics or vinyl, or a combination thereof. In another embodiment of the invention, the polymer substrate material is formed as an. Interpenetrating Polymer Network (IPN) that includes two or more polymer networks, which are partially interlaced, though not covalently bonded to each other. Although not held together by chemical bonds, the polymer networks are entanglements and concatenations of polymer networks, which prevent separation of the IPN and add tensile strength to the IPN.

The antimicrobial polymer straps may be prepared in a number of different ways depending upon the specific polymer material substrate and the stage at which the antimicrobial agent is introduced to the polymer material.

In an embodiment of the invention, the antimicrobial strap includes: a polymer material including an exposed surface, and an antimicrobial agent, wherein the antimicrobial agent is integrated within the exposed surface of the antimicrobial strap.

Referring now to the figures. FIGS. 1A and 1B illustrate a cross-sectional view of an embodiment of the invention where an antimicrobial agent is bonded to an underlying exposed surface of a non-porous substrate material such as a polymer material used to form an antimicrobial strap.

In an embodiment of the invention shown in FIGS. 1A and 1B, the antimicrobial polymer strap includes the polymer substrate material 30a (FIG. 1A), 30b (FIG. 1B) laminated with one or more layers of antimicrobial agent to form a laminated coating, wherein the laminated coating is an integral part of the polymer or polymer composition manufacturing process. The coating does not significantly degrade over time and provides needed efficacy for preventing growth of microbes over exposed surfaces of the antimicrobial strap throughout the average lifespan of the apparatus with or within which the invention is used.

FIG. 1A illustrates a cross-sectional view of an antimicrobial strap 60a including an antimicrobial layer 10a formed from a plurality of antimicrobial agents 40a that is coated on the exposed polymer material substrate surface 32a with the addition of a layer of binder 20 that adheres to the both antimicrobial layer 10a and the polymer material substrate surface 32a.

The antimicrobial agent may be applied to the polymer substrate material by use of a laminate coating using an appropriate binder that physically binds the antimicrobial agents 40a to the surface 32a of the polymer substrate material.

The antimicrobial material is coated on exposed surfaces of the antimicrobial strap using an adhesive binder layer 20 that attaches both to the antimicrobial layer 10a and the polymer substrate material surface 32a of the antimicrobial strap 60a in accordance with an embodiment of the Invention. In the embodiment of the invention shown in FIG. 1A, the thickness of the laminate antimicrobial and binder layers are much less than the thickness of the flexible non-porous substrate layer 30a.

On another embodiment of the invention, the antimicrobial polymer strap is formed as an Interpenetrating Polymer Network (1PN) that includes two or more polymer networks, which are partially interlaced though not covalently bonded to each other. Although not held together by chemical bonds, the polymer networks are entanglements and concatenations of polymer networks, which prevent separation of the 1PN and add tensile strength to the 1PN.

In another embodiment of the invention shown in FIG. 1B, the antimicrobial polymer strap 60b may be manufactured by use of an appropriate binder to form an 1PN that physically binds the antimicrobial agent 40b in an antimicrobial layer 10b to the polymer substrate's surface 32b.

In an embodiment of the invention, an antimicrobial coating, such as, but not limited to the variety of antimicrobial coatings sold under the trademark of Aglonc for example, manufactured by the Sciessent company, headquartered in 60 Audubon Road, Wakefield, Mass. 01880, that use silver ions as primary active antimicrobial ingredient may be used on a polymer substrate material surface to inhibit the growth of microbes.

In another embodiment of the invention, an antimicrobial strap including antimicrobial agents that are mixed with polymer particles and coated on to an exposed polymer substrate material of the antimicrobial strap in accordance with an embodiment of the invention.

In another embodiment of the invention, the antimicrobial agent may be applied to the polymer material strap by use of a polymer- or resin-based coating applied to the exposed surfaces of the polymer substrate material.

In another embodiment of the invention, the antimicrobial layer includes a polymer particle material that adheres to the strap surface of the polymer substrate material being coated and an active antimicrobial agent which is chemically or ionically bonded to the particle polymer material, wherein the polymer particle material has a glass transition temperature that is lower than the melting point of the antimicrobial agent, thus enabling the polymer particle material to melt and bond to the antimicrobial agent before the antimicrobial agent begins to melt.

In an embodiment of the invention shown in. FIG. 2, the polymer particle material used is in a powder form with an average particle size of about 20 microns to about 80 microns. In another embodiment of the invention, nano-particle size polymers 52 may be used with average particle size of 25 nanometers to about 40 nanometers. The antimicrobial agents 40c added to the polymer particle material are in a powder form, wherein the average particle size of the antimicrobial agent 40c is comparable to the size of the polymer particles 52 to provide a uniform distribution of polymer particles and antimicrobial agents throughout the antimicrobial layer 10c coated onto the polymer substrate material 30c.

In an embodiment of the invention, the polymer particle material used may be a polymide including various types of nylon such as nylon 11 or nylon 12, or a powder coating resin that exhibits increased adhesion to the polymer substrate material's exposed surfaces of the antimicrobial strap. In an embodiment of the invention, the blended mixture of the polymer particle material and the antimicrobial agent, which includes 0.001% to 20% by weight of the antimicrobial agent, is heated above the glass temperature of the polymer particle material, but below the melting temperature of the antimicrobial agent. In another embodiment of the Invention, the heated blended polymer particle material and the antimicrobial agent-polymer mixture is sprayed on the polymer substrate material to form the antimicrobial layer of the antimicrobial strap.

In an embodiment of the invention as shown in FIG. 2 a high velocity impact fusion plasma spray gun is used, such as one disclosed in U.S. Pat. No. 5,285,967, which is incorporated herein by reference, to spray-coat the exposed surfaces of the polymer substrate material 30c with the molten mixture of melted polymer powder and antimicrobial agent.

FIG. 2 illustrates an embodiment of the invention wherein a heated plasma spray mechanism is used to coat a polymer substrate material 30e with an antimicrobial layer coating 40c. In an embodiment of the Invention, a polymer substrate material 30c is mounted on a conveyor mechanism 90. The plasma spray gun 80 includes a reservoir 82 that contains a powdered mixture 54 of matrix polymer 52 and antimicrobial agents 40c for use in generating the antimicrobial layer 10c. The spray gun 84 includes a heating mechanism to melt the mixture 54. The molten mixture is atomized into an atomized spray 86 using a high pressure spray gas included within the spray gun 80. The speed of conveyor mechanism, the pressure of the spray gas, consistency of the powder, and the melting temperature are controlled to obtain a uniform antimicrobial coating 10c.

The antimicrobial layer 10c is coated on the polymer material surface 30c and bonds to the polymer material surface. Antimicrobial coating 10c includes a matrix polymer- or resin-based coating that adheres to the underlying polymer material surface 30c wherein active antimicrobial agents 40c have been added. The antimicrobial coating is applied to the exposed polymer material surface 30c as shown in the FIG. 2.

In another embodiment of the Invention shown in FIG. 3, an antimicrobial strap 60d includes a polymer substrate material 30d that is formed from antimicrobial agents 40d impregnated into the polymer substrate material 30d during the manufacturing process in accordance with an embodiment of the invention.

FIG. 3 shows the antimicrobial agent 40d incorporated directly into the composition of the polymer substrate material when the polymer substrate material is manufactured. The incorporation of the antimicrobial agent into the polymer substrate material may 1 be through a diffusion process.

In an embodiment of the invention illustrated in FIG. 3, the polymer substrate material 30d used to form the antimicrobial strap 60d is manufactured with material that includes antimicrobial agents 40d. In an embodiment of the invention, the antimicrobial agents included in the composition of the polymer material layer are microscopic in nature.

FIG. 3 further shows an enlarged in view of an antimicrobial agent particle 40d that is uniformly distributed within the material 30d used in constructing the strap in accordance with an embodiment of the invention.

Manufacturing of antimicrobial plastics compositions may be achieved via the use of thermoplastic processing wherein any of the variety of active ingredients with antimicrobial properties are used.

As shown in FIGS. 4A-4B the antimicrobial polymer may be manufactured by applying an antimicrobial, layer 10c of the antimicrobial agent 40e to the polymer's exposed surfaces 32e by use of an appropriate solution or solvent 92 that effects an infusion or impregnation of the antimicrobial agent 40e into the surface 32e of the polymer substrate material 30e or polymer composition.

FIG. 4 illustrates the cross-sectional view of another embodiment of the invention of an antimicrobial strap wherein the antimicrobial agents 40e are diffused into an exposed polymer substrate material surface 32e of the antimicrobial strap 60e, wherein diffusion of the antimicrobial layer 10e is facilitated by the use of an appropriate chemical solvent 92 including water that fosters the flow of antimicrobial particles into the underlying polymer substrate material's exposed surface 32e. In an embodiment of the invention, the chemical solvent 92 fosters the formation of a chemical or ionic bond of the antimicrobial agent 40e with the underlying polymer material exposed surface 32c.

The antimicrobial polymer composition forming the antimicrobial strap 60a, 60b, 60c, 60d, 60e may be reinforced by reinforcement materials such as polyester or equivalent webbing adhered or attached to the strap in any manner suitable that does not inhibit the antimicrobial properties of the strap and that increases the strap's strength.

The antimicrobial strap 60a, 60b, 60c, 60d, 60e described has many uses and may be adapted to serve as shopping cart straps, helmet straps, stretcher straps, gait belts, purse straps, seat belts, crossing guard straps, belts for CT and MRI scanning, as functional barriers at airports, banks, and anywhere where such barriers against microbes are needed. The strap provides a nonporous antimicrobial material used to form straps, strapping, belts, belting and the like. In an embodiment of the invention as shown in FIG. 5, the antimicrobial strap is used in the formation of belts wherein the antimicrobial belts may or may not have accessory attachments for adjusting the belt's length.

Furthermore, additional components or accessories may be added to the antimicrobial strap, such as the detachable buckles when disclosed invention is used as shopping cart straps, helmet straps, stretcher straps, gait belts, purse straps, seat belts, crossing guard straps, belts for CT and MRI scanning, as functional barriers at airports, banks, and anywhere where such microbial barriers are needed. FIG. 5 illustrates a perspective view of gait belt having antimicrobial properties in accordance with an embodiment of the invention.

FIG. 5 illustrates the use of the antimicrobial strap having antimicrobial properties disclosed in construction of a gait belt of the type used in the medical profession for patient care. A first end of antimicrobial strap 60 is attached to the buckle receptacle 70 and an opposing second end of the antimicrobial strap 60 is attached to a buckle prong 71 wherein the buckle prong 71 and the buckle receptacle 70 are complementary components of a buckle assembly.

In an embodiment of the invention shown in FIG. 6, the strap may be formed from a uniform planar sheet 74 of antimicrobial non-porous polymer material manufactured as a roll 72 of antimicrobial polymer formed by any of the methods disclosed herein and cut to a desired dimension, in an embodiment of the invention, the manufactured roll of antimicrobial polymer may include, but is not limited to the following dimensions of: thickness of 0.05 to 0.25 inches, width of 0.25 to 128 inches, and length of 72 yards.

The roll 72 of antimicrobial polymer material (sheet 74) may be prepared using any of the plurality of methods disclosed herein suitable to incorporate the antimicrobial properties required to inhibit microbial growth. The methods used in manufacturing the antimicrobial roll are determined by the specific substrate properties of the polymer material being used to form the antimicrobial strap, the type of antimicrobial agent used to form the strap, and the particular manufacturing stage of the antimicrobial polymer wherein the antimicrobial agent is introduced. Further, the belt may be formed by cutting out the antimicrobial strap from a roll of antimicrobial stock.

The antimicrobial and flexible non-porous substrate materials forming the strap 60a, 60b, 60c, 60d, 60e (as shown in FIGS. 1A, I B, 3, 4B) may have width and length dimensions that are determined by the intended use of the strap. In an embodiment of the invention, a thickness of the strap 60 is much smaller than the width.

In yet another aspect of the invention a cleanable child safety restraint (CSR) or child safety belt is formed from a polymer material as described herein. It will be appreciated that other belts may be formed in the same way as the CSR, and therefore the description provided should not be limited to just a child safety belt for example. The polymer may be selected from but is not limited to, a polymer, a polymer composition, a polymer composite, a polymer matrix wherein the polymer material includes a plastic or vinyl, or a combination thereof. The polymer material may or may not be “reinforced”. The term “reinforced” indicates that the vinyl strap has an internal mesh or webbing (made out of polyester, nylon, cotton etc.) molded into the vinyl, or that the internal mesh or webbing is coated with vinyl. It gives the vinyl its strength, extra flexibility and durability. For example only, Value Vinyls (301 E. Trinity Blvd. Grand Prairie, Tex. 7505), Herculite (17318 Aberdeen Road York, Pa. 1740) and TMK5350 Campbells Run Road, Pittsburgh, Pa.) manufacture exemplary reinforced vinyl materials that are typically sold in rolls. The polymer may or may not have antimicrobial properties. As shown in FIGS. 7A and 7B, a child seat belt 110 is described as follows, wherein the child seat belt contains a first polymeric strap 112a coupled with a second polymeric strap 112d. The first vinyl or polymeric strap 112a contains a first end 112b and a second end 112c. The second vinyl or polymeric strap 112d contains a third end 112e and a fourth end 112f. A buckle 114 is fixed proximate to the first end 112c and the third end 112c for coupling the first strap 112a with the second strap 112d. As shown in FIG. 7B, each end of the straps may be looped respectively. Accordingly, end 112 b Is manufactured with a loop 116b and end 112c with a loop 116c. In the same way, end 112e is manufactured with a loop 116e and end 112f with a loop 116f. In accordance with the present invention, each loop is formed by a melt process, or plastic welding process thereby obviating the need to sew the respective ends about the buckle 114, for example.

A first attachment accessory 118a is contained and flexibly or loosely fixed within loop 116b so that the attachment accessory 118a is retained within the loop 116b while yet being slidably received within the loop 116b. A second attachment accessory 118b is contained and flexibly or loosely fixed within loop 116f so that the attachment accessory 118b is retained within the loop 116f while yet being slidably received within the loop 116f. The attachment accessories 118a and 118b may be any useful appliance depending on the application of the belt. For example, the attachment accessories might be hooks or clamps that are received on a shopping cart or on a high chair for locking the belt into place.

A male receptacle 114a of buckle 114 may be contained within the loop 116c formed and defined at the end 112c for connecting ends 112c and 112e. A female receptacle 114b of buckle 114 may be contained within the loop 116e, formed and defined at the end 112e, for connecting ends 112c and 112e. It will be appreciated that the male receptacle 114a when snap-locked or otherwise fixed to female receptacle 114b forms a closed union of the two buckle components, thereby securing strap 112a to strap 112d. At least one tri-glide member 120 is provided in the belt 110, and may be contained within loop 116e to slidably engage the loop 116e for adjusting the length of the combined assembly 110, or the combined lengths of straps 112a and 112d. As shown in FIG. B, and although not thereby limited, loop 116e is relatively larger than the other loops described herein, whereby loop 116e may by operation of the adjustable tri-glide 120, be increased or decreased in circumference to accommodate a desire to decrease or increase the length of the belt 110, respectively. Other options and embodiments of the child safety restraint or child safety belt 110 are contemplated. For example, both of loops 112c and 112e could be relatively larger for operable containment of the buckle components 114a and 114e, respectively, and also for operable containment of the adjustable tri-glide 120 and a second adjustable tri-glide 122 (not shown) within the loops 112c and 112c, respectively. Other changes could be altering the length of the belt by modifying the lengths of the straps 112a and 112d, or, by providing various attachment accessories 118a and 118b, whereby the accessories 118a and 118b could be the same type of attachment device, or perhaps could be different attachment devices depending on the particular application for the belt 110.

In yet another aspect of the child safety restraint (CSR) or child safety bell, or any other belt such as a gait belt, each loop may be formed by a melt method, by a weld method, or by heating the ends to a point where one of the respective ends 112b, 112c, 112e, and 112f may be joined to an intermediate point on the respective strap 112a or 112b, as appropriate. By joining or fusing the particular end to the particular strap, such as joining end 112c to strap 112a for example, the loop 118c may be formed without the need to sew the loops as is done in standard gait belts or other belts. Upon heat welding or heat application to the respective ends and the contact points on the respective straps, fusion or junction points 124b, 124c, 124e, and 124f are formed to fix the ends to the stems. As such, any belt may be formed in the present method whereby sewing junctions are therein eliminated to correspondingly eliminate areas of microbial proliferation. By eliminating cloth or other porous substrates as constituents of the belt, whatever type it may be, bacterial infections such as those caused by MRSA, e-coli, and so forth are at least substantially mitigated if not altogether eliminated. Accordingly, the present invention includes a method of manufacturing belts such as a child safety belt and so forth. A product formed by the aforementioned process, such as a child safety belt is also contemplated as an aspect of the present invention.

While several aspects have been presented in the foregoing detailed description, it should be understood that a vast number of variations exist and these aspects are merely an example, and it is not intended to limit the scope, applicability or configuration of the invention in any way. Rather, the foregoing detailed description provides those of ordinary skill in the art with a convenient guide for implementing a desired aspect of the invention and various changes can be made in the function and arrangements of the embodiments of the invention without departing from the spirit and scope of the appended claims.

Claims

1. A belt comprising:

a first strap containing a first end and a second end;

a second strap containing a third end and a fourth end;

a buckle joining said first end to said third end, and thereby joining said first strap to said second strap;

a first accessory slidably fixed to said second end; and

a second accessory slidably fixed to said, fourth end;

wherein said first and second straps are formed from a flexible non-porous substrate material containing an exposed surface, and an antimicrobial agent integrated within the exposed surface of the non-porous substrate.

2. The belt of claim 1 further comprising:

a first loop formed from a fused junction formed between said first end and said belt; and

a tri-glide member slidably contained within said first loop for adjusting the length of said belt.

3. The belt of claim 1 wherein said buckle comprises a male receptacle fixed to said first end, and a female receptacle fixed to said third end and releasably fixed to said male receptacle.

4. A belt comprising:

a first strap containing a first end and a second end;

a second strap containing a third end and a fourth end;

a first loop formed by a first fused junction of said first end and said first strap;

a second loop formed by a second fused junction of said second end and said first strap;

a third loop formed by a third fused junction of said third end and said second strap;

a fourth loop formed by a fourth fused junction of said fourth end and said second strap;

a first accessory slidably fixed to said second loop;

a second accessory slidably fixed to said fourth loop; and

a buckle joining said first end to said third end, thereby joining said first strap to said second strap,

wherein said first and second straps are formed from a flexible non-porous substrate material containing an exposed surface, and an antimicrobial agent integrated within the exposed surface of the non-porous substrate.

5. The belt of claim 4 further comprising:

a tri-glide member slidably contained within said first loop for adjusting the length of said belt.

6. The belt of claim 4 wherein said buckle comprises a male receptacle fixed to said first end, and a female receptacle fixed to said third end and releasably fixed to said male receptacle.

7. A belt formed by a method comprising the steps of:

providing a flexible non-porous substrate material containing an exposed surface with an antimicrobial agent integrated within the exposed surface of the non-porous substrate

providing a first strap containing a first end and a second end, the strap formed from the flexible non-porous substrate material;

providing a second strap containing a third end and a fourth end, the strap formed from the flexible non-porous substrate material;

heating said first end and forming a first loop at a first junction of said first end and said first strap;

heating said second end and forming a second loop at a second junction of said second end and said first strap;

heating said third end and forming a third loop at a third junction of said third end and said second strap; and

heating said fourth end and forming a fourth loop at a fourth junction of said fourth end and said second strap.

8. A product formed by the method of claim 7, the method further comprising the steps of:

fixing a first attachment accessory within the second loop;

fixing a second attachment accessory within the fourth loop;

fixing a male buckle receptacle within the third loop;

and fixing a female buckle receptacle within the fourth loop for attachment to said male buckle receptacle.