JPH07112480B2 - Method for producing wound dressing - Google Patents

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a method for producing contoured dressings and bandages, and more particularly to a method for substantially continuously in-line contouring hydrocolloid wound dressings. is there.

[0002]

BACKGROUND OF THE INVENTION A method of making wound dressings or bandages is described in Chen et al., US Pat. No. 3,339,546, issued Sep. 5, 1967; Samuelse.
n), U.S. Pat. No. 4,86, issued Sep. 19, 1989
7,748; and Applicant's U.S. Application No. 590,684, filed October 1, 1990. The Chen patent discusses a two-stage process that includes a roller mill stage and a flat press stage. The Samuelsen patent discusses flat pressing and / or die casting. Applicant's pending U.S. Pat. No. 590,684 refers to possible ways of making the disclosed wound dressings, but does not disclose details of the method.

There is a need to reduce cost, time, and energy to make wound dressings that use an adhesive layer that conforms to the skin. The methods disclosed by Chen U.S. Pat. No. 3,339,546 and Sam Elson U.S. Pat. No. 4,867,748 are energy intensive and require relatively long press cycles. As far as is known so far, the above-cited references do not disclose a substantially in-line substantially continuous production method for hydrocolloid wound dressings or bandages. The present invention provides an economical method for producing a very preferred type of wound dressing by performing various operations to produce a wound dressing in a substantially stepwise and continuous manner. To do. The method as taught in the present invention substantially reduces the energy requirements for producing wound dressings. The reduced energy requirements, combined with the increased production, can significantly reduce the production costs of this highly preferred wound dressing.

[0004]

The present invention is summarized, at least in part, for its purpose. One object of the present invention is to provide a hydrocolloid wound dressing or bandage,
It is intended to provide a method of manufacturing in a substantially continuous and stepwise manner. Another object of the present invention is to provide a method of manufacture that substantially reduces the energy and time requirements for selectively contouring hydrocolloid wound dressings or bandages. Yet another object of the present invention is to provide a substantially in-line process for producing a contoured adhesive wound dressing or bandage. Yet another object of the present invention is to provide a method of producing a contoured wound dressing or bandage at an effective cost. Yet another object of the present invention is to provide a method of making a contoured wound dressing or bandage with substantially no bubbles between its laminate layers.

In addition to the above summary, the following disclosure sets forth the present invention in order to provide a thorough understanding and aid of the present invention. But then even if you change its shape,
Or, even with further improvement and disguise, this disclosure is not intended to cover concepts of the new invention. For this reason, particular embodiments for contouring hydrocolloid wound dressings or bandages were selected. These particular embodiments have been selected for purposes of explanation and description, as shown in the accompanying drawings. In the following description, various details are identified by specific names for convenience. These names are intended to be substantially common in their application. Corresponding reference characters shall refer to similar parts throughout the several views. The drawings accompanying and forming part of this specification disclose details of how to outline the adhesive layer of a wound dressing. Although such details are for the purpose of illustration, the details may be changed without departing from the concept and principles of the invention. It is believed that the invention includes embodiments other than those shown.

[0006] With reference to embodiments Figure 1 for carrying out the present invention, 20 encapsulating material or bandage which is contoured as shown in those products typical of that produced by the method of the present invention. The encapsulant 20 has a thick absorbent layer 22 and a thin flange layer 24. FIG. 2 shows an enlarged sectional view of the wrapping material or bandage 20. This wrapping material 2
0 has a contoured adhesive layer 26, which has an adhesive retention layer 28 well adhered to the first major surface of the adhesive layer 26 and a protective release coating layer 32 is the second major surface. It is detachably attached to 34. FIG. 3 shows another aspect of the covering material 20. In this embodiment, the adhesive layer 26
Are completely covered with the adhesive holding layer 28. More specifically, the tip end portion 36 of the thin flange portion 24 is sufficiently protected by the adhesive holding layer 28.

Aspects of FIGS. 1, 2 and 3 FIGS. 1, 2 and 3 are presented to illustrate one type of encapsulant made by the method of the present invention. The present invention relates to the above-mentioned U.S. patent application No. 590,684 applied to the applicant.
It can be used to manufacture the dressing or bandage disclosed in US Pat.
The present invention can also be used to produce the encapsulant disclosed in US Pat. No. 4,867,748 (Samuelson).

Aspect of FIG . 4 In FIG . 4, one aspect of the invention is shown diagrammatically and diagrammatically. A continuous web of thin release material 40 is fed from a first feed roll (not shown). A continuous web of thin protective release coating 32 is fed from a second roll (not shown). The thin release web 40 and protective release coating 32 are fed to a calibration and contouring station 44 at a particular rate. The contouring station 44 includes a hydrocolloid adhesive layer 2
At least one of the major surfaces 30 or 34 of the six substantially continuous bands is contoured. Strip of the continuous of the hydrocolloid adhesive material layer 26 may be spread (Malleabl
e) has the property of being provided between the thin release web 40 and the thin protective release coating 32. A first laminate 46 including an adhesive layer 26 is sandwiched between a thin release web 40 and a thin protective release coating 32 and contoured by the co-rotating action of a first contouring roller 48 and a second contouring roller 50. It First contouring roller 48
Has a recessed shape 52 along its periphery. The recess 52 is substantially formed in the final shape of the encapsulant or bandage. The thin release web 40 is made of a material having a release coating on at least one side thereof. The thin release web 40 is a silicone release paper, the treated side of which preferably abuts the adhesive layer 26. The thin release web 40 is formed on the first major surface 30 of the adhesive layer 26.
Provides a means for the hydrocolloid adhesive to be contoured without transfer to the first contouring roller 48. This thin release web 40 also applies to the roller 5
The effects of 0 and 50 minimize friction when contoured. The contoured first laminate 46 is continuously transferred to the next stripping station 54. Here, the thin release web 40 is separated from the first laminate 46 and sent to a collector (not shown). A particular shaped separator plate 56 causes the thin release web 40 to be peeled from the adhesive layer 26 as desired, and the first of the adhesive layer 26 is removed.
Reveal the main surface of.

The adhesive layer 26 carried over the thin protective release coating 32 is then transferred to a laminating station where the adhesive retention layer 28 is combined with the adhesive layer 26 and the protective release coating 32. This adhesive holding layer 2
8 is water impermeable, but other suitable materials can be used. The first laminating roller 60 and the second laminating roller 62 cooperate to form a second second laminate 64. The second laminate 64 includes the adhesive layer 26 between the adhesive retaining layer 28 and the protective release coating 32 and is transferred to the next step in a substantially continuous manner. The first laminating roller 60 has an outer rubber layer 66, preferably silicone rubber or foam rubber, but other suitable dressings may be used. The outer rubber layer 66 can cover the adhesive 26 with the adhesive holding layer 28 without substantially changing the contour of the encapsulant 20. The second laminated body 64 has substantially no bubbles between layers. The first laminate 46 and the second laminate 64 are transferred to the cutting station 68. The 1st cutting roller 70 and the 2nd cutting roller 72 rotate at a predetermined speed, and cut the 2nd laminated body 64 into the individual encapsulating material 20. These individual covering materials 20 are transferred to the collecting section and the packaging section. The rollers of the laminating station 58 also serve as a means of transferring a continuous stack of encapsulant material to various operating stages. The cutting station 68, the laminating station 58 and the metrology and contouring station 44 rotate with respect to each other in a timed and synchronized relationship to provide the desired spacing and contour between the encapsulants. This timed relationship can be by mechanical, electromechanical, electronic or other suitable means. The individual stations are adjustable with respect to the gap between the pair of rollers relative to each other so as to provide the desired thickness of the wound dressing.

Aspect of FIG. 5 In FIG. 5, another aspect of manufacturing the dressing or bandage 20 is shown. In this embodiment, there is a metrology and contouring station 44, where the first stack 46 is contoured to the desired shape. Similar to Figure 4, this first
The laminate of 1 comprises a thin release layer 40 and an adhesive layer 26 sandwiched between a protective release coating 32. This first laminate 4
6 moves to the stripping station 54 in a substantially continuous manner, where the thin stripping web 40 is stripped from the first laminate 46 by the stripping plate 56. The resulting laminate exposes major surface 30 and travels to coalescing station 158 where rollers 160 coalesce adhesive retention layer 28 onto exposed major surface 30 of adhesive layer 26. The second stack 64 has the adhesive layer 26 sandwiched between the adhesive holding layer 28 and the release protective coating 32, and then moved to the air removal station 162. At the air removal station 162, there is a rotating brush 164 that presses the adhesive retaining layer 28 against the contoured adhesive layer 26. The action of the rotating brush 164 removes substantially all the air bubbles sealed between the adhesive layer 26 and the adhesive holding layer 28. This removal of air bubbles removes any dry spots in the adhesive layer. This second laminate is then transferred to and through the laminating station 58, where it is further pressurized to the adhesive layer 26.
The adhesive holding layer 28 is adhered to. From this point onward, the steps up to the collection of the individual encapsulants are substantially the same as described by FIG.

Embodiment of FIG . 6 In FIG. 5, yet another embodiment of making the wound dressing or bandage 20 is shown. In this embodiment, there is a means of delivering the hydrocolloid adhesive layer to the metering and contouring station 144 in a substantially continuous band. A protective release coating layer 32 is provided substantially continuously,
The first laminate 14 laminated to the adhesive layer 26
It becomes 6. The laminate 146 is selectively contoured by the co-rotating action of the first contouring roller 148 and the second contouring roller 50. The first contouring roller 148 is recessed to provide a number of forming pockets 152 on its surface. In the second aspect, the first contour forming roller 1
48 has a complete surface with a release coating on the pocket 152, such as silicone rubber or Teflon. This first contouring roller release coating reduces friction between roller 148 and adhesive layer 26 and prevents adhesive layer 26 from remaining on roller 148. The first laminate 146 is then transferred to the next laminating station 58 and cutting station 68. This first laminate 146
Can also be transported through coalescing station 158 and air removal station 162, if desired. Subsequent functions of the stations 58, 68, 158 and 162 are as described in FIGS. 4 and 5 above.

Embodiments of FIGS. 7 and 8 In FIG. 7, a cross-sectional view of adhesive layer 26 as it is transferred to a metrology and contouring station is shown. The strip has a uniform cross section of preset thickness and width. FIG. 8 illustrates another cross-sectional shape as the adhesive layer 126 is transferred to the metrology and contouring station 44. The band of adhesive layer 126 is extruded with ridges 128 on at least one of its major surfaces 30 or 34. These rows of ridges 128 run along the portion of the rollers 48 that form the two longitudinal thin flanges 24 of the encapsulant. Preliminary contouring as in FIG. 8 can substantially reduce the force required to undergo deformation as it passes through the metrology station and contouring station 44.

The above description has primarily described the encapsulating material contoured on one side. The method described above also applies to the production of encapsulating material contoured on both of its major surfaces. Of course, rollers 50, 62 and 72 need to be recessed to give the desired shape. It has been found that the method shown in FIG. 4 can produce an encapsulant having a thick absorbent portion 22 in the range 0.75 to 2.0 mm and a thin flange portion 24 in the range 0.10 to 0.30 mm. If an absorbent layer thicker than 2.0 mm is required, contouring of both major surfaces 30 and 34 is required. The rollers 48, 60 and 70 may have staggered patterns around their perimeters to reduce the contouring force required at any point on their circumferential surface. This pattern can be chosen as a design matter. The methods shown and described above can also be used to contour adhesive layers such as known hydrocolloids or other doughs. These methods can be used to form single or multiple rows of wound dressings. If there are constraints, it is just the length of the rollers and the capacity of the machine.

The above description and drawings provide the basis for producing a contoured hydrocolloid adhesive encapsulant by the following steps: feeding a thin release web material substantially continuously; thin. The protective release coating is supplied substantially continuously; the hydrocolloid adhesive layer is supplied substantially continuously, the adhesive layer having the desired spreadability; the thin release web material and the thin release web material. The adhesive layer is releasably applied between the protective release coating and at the same time the adhesive layer is contoured at a metrology station and a contouring station; the thin release web is contoured at a delamination station. Peeled from the adhesive layer to expose the major surface of the contoured adhesive layer;
Adhering the adhesive holding layer substantially continuously; at the coalescing station, coalescing the adhesive holding layer with the exposed adhesive layer; at the bubble removal station, the adhesive layer and the adhesive holding layer Substantially eliminate all air bubbles between the: second laminate is pressed through the laminating station; at the cutting station, the laminate is cut into individual sized encapsulants; To collect.

[0015]

EFFECTS OF THE INVENTION Since the present invention is configured as described above, it is possible to continuously manufacture a wound dressing material at low cost and with little energy. Left, right, top, bottom, bottom, top, front,
Later, the terms inside, outside, etc. apply to the embodiments described and illustrated in relation to the figures. These terms are merely for explanatory purposes and do not necessarily apply where the invention is implemented. While these individual improvements have been described, the invention is not limited thereto and the scope of protection is the maximum acceptable from the prior art.

[Brief description of drawings]

FIG. 1 shows an isometric view of a wound dressing or bandage produced by the method of the present invention.

FIG. 2 depicts a partial cross-sectional view on an enlarged scale of one embodiment of a contoured adhesive layer made by the method of the present invention.

FIG. 3 is a partial cross-sectional view of another embodiment of a contoured adhesive layer produced by the method of the present invention on the same scale as FIG.

FIG. 4 shows an aspect of the invention in a one-part diagrammatic view and one-part layout diagram.

FIG. 5 shows another aspect of the invention in a one-part diagrammatic view and one-part layout diagram.

FIG. 6 shows a second alternative embodiment of the method according to the invention in a diagrammatic part and partial layout.

FIG. 7 is a partial cross-sectional view of the hydrocolloid adhesive layer prior to entering the first operating stage of the present invention.

FIG. 8 is a partial cross-sectional view of another embodiment of the hydrocolloid adhesive layer prior to entering the first operating stage of the present invention.

[Explanation of symbols]

 20 Encapsulating Material 22 Absorbing Layer 24 Flange Layer 26 Adhesive Material Layer 28 Adhesive Holding Layer 32 Protective Release Coating Layer

Claims (14)

[Claims] 1. A method of making an individualized wound dressing having a contoured and skin-adhesive adhesive layer, the method comprising the steps of: (a) a thin release web material; Substantially continuously feeding; (b) feeding a thin protective release coating layer substantially continuously; (c) feeding a strip of adhesive material substantially continuously; The strip has a predetermined thickness and malleability; (d) a strip of the adhesive material is releasably attached between the thin release web material and the protective release coating layer while at the same time providing the adhesive. A first laminate of material material and a thin release web material and a protective release coating is combined and transported through a metrology and contouring station and contoured into a predetermined shape; (e) the first laminate is then Transfer to the delamination station of Peeling the thin release web from the contoured adhesive material exposes the major surface of the contoured adhesive material; (f) providing a substantially continuous adhesive material retaining layer. (G) combining the adhesive material retaining layer with the contoured adhesive material layer and applying the adhesive material retaining layer to sufficiently cover the exposed major surface of the adhesive layer; Two laminates, while passing the second laminate through a laminating station and pressurizing it; and (h) transferring the second laminate to a cutting station for a predetermined time relationship to cut and predetermined. Of individual, contoured encapsulants. 2. The method of claim 1, wherein the step of transferring the second laminate to the laminating station further comprises removing all air bubbles in the second laminate at the laminating station. 3. A method of making an individual wound dressing having a contoured skin-adhesive layer of adhesive, the method comprising the steps of: (a) a thin release web material. Substantially continuously feeding; (b) feeding a thin protective release coating layer substantially continuously; (c) feeding a strip of adhesive material substantially continuously; The strip has a predetermined thickness and malleability; (d) a strip of the adhesive material is releasably attached between the thin release web material and the protective release coating layer while at the same time providing the adhesive. A first laminate of material material and a thin release web material and a protective release coating is combined and transported through a metrology and contouring station and contoured into a predetermined shape; (e) the first laminate is then Transfer to the delamination station of Peeling the thin release web from the contoured adhesive material exposes the major surface of the contoured adhesive material; (f) providing a substantially continuous adhesive material retaining layer. (G) at a coalescing station, coalescing the adhesive material retaining layer with the contoured adhesive material layer such that the adhesive material retaining layer sufficiently covers the exposed major surface of the adhesive layer. (H) passing the second laminate through an air bubble removal station to remove all of the air bubbles in the second laminate; (i) transferring the second laminate through the laminating station to remove the second air bubble. Pressing the laminate; and (J) transferring the second laminate to the cutting station for a predetermined time relationship to cut into predetermined, individual, contoured encapsulants. 4. A method of making an individual wound dressing having a contoured skin-adhesive layer, the method comprising the steps of: (a) a thin protective release coating. (B) supplying a strip of adhesive material substantially continuously, the strip of adhesive material having a predetermined thickness and malleability; (c) ) A strip of the adhesive material is releasably attached to the protective release coating layer while at the same time incorporating the adhesive material and protective release coating through a metering and contouring station to form the first laminate into a predetermined shape (D) supplying the adhesive material holding layer substantially continuously; (e) combining the adhesive material holding layer with the contoured adhesive material layer to form the adhesive. Applying a material retaining layer to sufficiently cover the exposed major surface of the adhesive layer Forming a second laminate, while passing the second laminate through a laminating station and pressing it; and (f) transferring the second laminate to the cutting station for a predetermined time relationship for cutting, A predetermined, individual, contoured encapsulant. 5. The steps of providing a continuous strip of adhesive material further comprises the following steps:
Or the method according to 4, mixing a specific formulation of a skin-friendly, moisture-activated adhesive; and shaping the formulation into a continuous strip. 6. The step of selectively shaping a band of an adhesive layer comprises forming a plurality of rows of ridges on at least one of a first major surface and a second major surface of the adhesive layer. ,
The method according to claim 5. 7. The method of claim 5, wherein the mixing further comprises formulating a hydrocolloid adhesive material. 8. The method of claim 6, wherein the mixing further comprises formulating a hydrocolloid adhesive material. 9. The method of claim 1, 3 or 4, further comprising collecting individual encapsulants after cutting. 10. Transporting the first laminate through a metering or contouring station selectively rotates the first contouring roller and the second contouring roller; and the first roller and the first contouring roller. 5. A method according to claim 1, 3 or 4, including at least one of the two rollers having a peripheral contour with a particular contour. 11. The measuring or contouring station,
5. A method according to claim 1, 3 or 4, comprising operating the laminating station and the cutting station in a specific synchronized time relationship. 12. Transferring said second laminate through a laminating station selectively rotating a first laminating roller and a second laminating roller; and said first laminating roller and 11. The method of claim 10 including providing at least one of the second laminating rollers with a selectively elastic peripheral surface. 13. Transporting the second laminate through a cutting station further comprises selectively rotating the first cutting roller and the second cutting roller; and the first cutting roller and the second cutting roller. 13. The method of claim 12 including providing at least one of said cutting rollers with a selectively contoured peripheral cutting surface. 14. The method of claim 3, wherein the step of removing bubbles comprises rotating at least one rotating brush.