Manufacturing method for wound dressings
Inventors
Assignees
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Publication Number
US-9827146-B2
Publication Date
2017-11-28
Expiration Date
Abstract
A wound dressing having a thin barrier layer of soft, pliant adhesive material with a flexible cover layer extending along one side of the adhesive layer and a removable release sheet on the opposite side is disclosed. The adhesive material has a center and border surrounding the center such that the adhesive is contoured. A method for making the contoured dressing using a gear pump and a laminating roller having a predetermined softness and firmness is also disclosed.
Core Innovation
The invention relates to a contoured dressing formed with a center and a bordered edge in which a hydrocolloid-containing adhesive is laminated to a protective cover. The adhesive is deposited in a specified shape and predetermined thickness onto a flexible silicone release web and then laminated using a laminating roller to feather edges of the adhesive, forming a contoured dressing having a center and a bordered edge.
A method is provided for making a contoured dressing by discontinuously depositing an adhesive using a gear pump onto a flexible silicone release web removably supported on an upper surface of a lower table member or a lower horizontal platen member. The adhesive is laminated with a protective cover using a laminating roller with predetermined softness and firmness to feather the edges of the adhesive.
In-line continuous manufacturing is described in which the contoured dressing web is driven to a cutting station for individual cutting and packaging. The adhesive may include a physically cross-linked elastomer continuous phase with dispersed hydrocolloid, together with specified tackifiers and hydrogenated esters of rosin, and the protective cover is selected from specified materials.
Claims Coverage
The independent claims cover three method claims for forming or making a contoured dressing, centered on discontinuous gear-pump deposition of adhesive onto a flexible silicone release web, laminating with a laminating roller to feather adhesive edges, and forming a contoured dressing with a center and a bordered edge. Additional inventive features are specified in dependent claims.
Discontinuous gear pump deposition onto a flexible silicone release web
Discontinuously depositing an adhesive in a specified shape and predetermined thickness using a gear pump onto a flexible silicone release web that is removably supported on an upper surface of a lower table member or a lower horizontal platen member.
Laminating with a laminating roller to feather adhesive edges
Laminating the deposited adhesive with a protective cover using a laminating roller with a predetermined softness and firmness to feather edges of the adhesive.
Forming a contoured dressing with a center and a bordered edge
Forming a contoured dressing having a center and a bordered edge.
Roller firmness in a Shore A range
Employing a laminating roller having a firmness between 10 Shore A and 90 Shore A.
Adhesive formulation with physically cross-linked elastomer continuous phase and dispersed hydrocolloid
Using an adhesive in which a physically cross-linked elastomer forms a continuous phase with a dispersed hydrocolloid, and including a hydrocarbon tackifier and hydrogenated esters of rosin.
Protective cover selected from polyurethane, polyethylene, woven fabric, nonwoven fabric, or flexible polymeric foam
Selecting the protective cover from polyurethane, polyethylene, a woven fabric, a nonwoven fabric, or a flexible polymeric foam.
Adhesive deposition shape selected from round, oval, trapezoidal, or rectangular
Depositing the adhesive in a selected shape among round, oval, trapezoidal, or rectangular.
Adhesive including perforations
Depositing an adhesive that includes perforations.
Cutting and packaging a contoured dressing from protective cover and release web
Cutting and packaging a contoured dressing taken from a protective cover and a release web.
Across the independent claims, the core claim coverage is a method for making or forming a contoured dressing by discontinuous gear-pump deposition of adhesive in a specified shape and predetermined thickness onto a flexible silicone release web, followed by laminating with a laminating roller to feather adhesive edges, and forming a contoured dressing with a center and a bordered edge. Dependent claims further constrain roller firmness, protective cover materials, adhesive formulation components, deposition shapes, optional perforations, and downstream cutting and packaging.
Stated Advantages
Reduced energy and time by eliminating compression, die cutting, and roller molding steps used for shaping.
Avoidance of adhesive and web waste.
Reduced sticking of adhesive to the roller.
Improved cost and efficiency.
Documented Applications
In-line continuous manufacturing of contoured dressing webs, with driving to a cutting station for individual cutting and packaging.
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